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Manufacturing Processes for Engineering Materials, 4th ed.Kalpakjian Schmid

Prentice Hall, 2003

CHAPTER 15

Computer-Integrated

Manufacturing

Systems

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Computer-

IntegratedManufacturing

System

FIGURE 15.1 Aschematic illustration of acomputer-integrated

manufacturing system.Source: U. Rembold etal., Computer-Integrated

Manufacturing andEngineering, Addison-

Wesley, 1993.

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Modeling for CAD

FIGURE 15.2 Various types of modeling for CAD.

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Types of Splines

FIGURE 15.3 Types of splines. (a) A Bezier curve passes through the first and last controlpoint and generates a curve from the other points. Changing a control point modifies theentire curve. (b) A B-spline is constructed piecewise, so that changing a vertex affects thecurve only in the vicinity of the changed control point. (c) Third-order piecewise Beziercurve constructed through two adjacent control points, with two other control pointsdefining the curve slope at the end points. A third-order piecewise Bezier curve iscontinuous, but its slope may be discontinuous.

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Boundary Representation of Solids

FIGURE 15.4 (a) Boundary representation of solids, showing the enclosing surfaces and

the generated solid model. (b) A solid model represented as compositions of solidprimitives. (c) Three representations of the same part be CAD. Source: P. Ranky.

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Parametric Design

FIGURE 15.5 An example of parametric design. Dimensions of part features can be easily

modified to quickly obtain an updated solid model.

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Octree Representation of a Solid Object

FIGURE 15.6 The octree representation of a solid object. Any volume can be broken downinto octants, which are then identified as solid, void, or partially filled. Shown is two-dimensional, or quadtree, version, for representation of shapes in a plane.

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Skeleton Data Structure for Solid Objects

FIGURE 15.7 (a) Illustration of the skeleton data structure for solid objects. The skeleton isthe dashed line in the objects interior. (b) A skeleton model used for kinematic analysis of aclamp. Source: S. D. Lockhart and C. M. Johnson,Engineering Design Communication,

Prentice Hall, 2000, p. 299.

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Simple Routing Sheet

FIGURE 15.8 An example of asimple routing sheet. These

operation sheets may include

additional information on

materials, tooling, estimated

time for each operation,processing parameters (such as

cutting speeds and feeds), and

other details. The routing sheet

travels with the part from

operation to operation. Thecurrent trend is to store all

relevant data in computers and

to affix to the part a bar code

that serves as a key into the

database of parts information.

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Robotic Welding Station

FIGURE 15.9 Simulation ofa robotic welding station. A

collision has been detected

that production engineers

can rectify before building

the assembly line, therebyreducing development time

and cost. Source: Mechanical

Engineering, March 2001.

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Grouping of Parts

FIGURE 15.10 Groupingparts according to theirgeometric similarities.

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Machine Tools in a

Traditional Plant

FIGURE 15.11 Functional layout of

machine tools in a traditional plant.

Arrows indicate the flow of materialsand parts in various stages of

completion. (b) Group-technology

(cellular) layout. Legend: L= lathe; M=

milling machine; D= drilling machine;

G= Grinding machine; A= assembly.Source: M. P. Groover.

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Decision-Tree Classification

FIGURE 15.12 Decision-tree classification for a sheet-metal bracket. Source: G. W. Millar.

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Classification and Coding System

FIGURE 15.13

A classification

and coding

system using the

Opitz system,consisting of five

digits and a

supplementary

code of four

digits.

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Multiclass Code for a Machined Part

FIGURE 15.14 Typical MultiClass code for a machined part. Source: Organization for

Industrial research.

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System for Rotational Components

FIGURE 15.15 The structure

of a KK-3 system for

rotational components. Source:

Japan Society for the

Promotion of MachineIndustry.

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Flexible Manufacturing Cell

FIGURE 15.16Schematic view

of a flexible

manufacturing

cell, showing two

machine tools,and automated art

inspection

system, and a

central robot

serving thesemachines.

Source: P. K.

Wright.

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Flexible Manufacturing System

FIGURE 15.17 Ageneral view of aflexiblemanufacturingsystem, showingseveral machinetools and anautomated guidedvehicle. Source:Courtesy ofCincinnati

Milacron, Inc.

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Comparison of Transfer Lines and Flexible

Manufacturing SystemsCharacteristic Transfer line FMS

Types of parts made Generally few InfiniteLot size > 100 150Part changing time 1/2 to 8 hr 1 minTool change Manual AutomaticAdaptive control Difficult AvailableInventory High LowProduction during breakdown None PartialEfficiency 6070% 85%

J ustification for capital expenditure Simple Difficult

TABLE 15.1 Comparison of the characteristics of transfer lines and flexible manufacturing

systems.

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Topology for a Local Area Network

FIGURE 15.18 Three basic types of topology for a local area network (LAN). (a) the startopology is suitable for situations that are not subject to frequent configuration changes. Allmessages pass through a central station. Telephone systems in office buildings usually have thistype of topology. (b) In the ring topology, all individual user station are connected in a continuousring. The message is forwarded from one station to the next until it reaches its assigned destination.Although the wiring is relatively simple, the failure of one station shuts down the entire network.

(c) In the bus topology, all stations have independent access to the bus. This system is reliable andis easier than the other two to service. Because its arrangement is similar to the layout of themachines in the factory, its installation is relatively easy, and it can be rearranged when themachines are rearranged.

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Reference Model for Open Communication

FIGURE 15.19 The ISO/OSI reference model for open communication. Source: U.Rembold et al., Computer Integrated Manufacturing and Engineering, Addison-Wesley,

1993.

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Expert System Structure

FIGURE 15.20 The basic structure ofan expert system. The knowledge base

consists of knowledge rules (general

information about the problem) and

inference rules (the way conclusions are

reached). The results may becommunicated to the user through the

natural-language interface. Source: K.

W. Goff, Mechanical Engineering,

October 1985.

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Vision Guided Robot

FIGURE 15.21 Expert system as applied to an industrial robot guided by machine vision.

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Solid Model of an Engine Compartment

FIGURE 15.22 Every vehiclecomponent, from body panels

to knobs on the instrument

panel, has a solid model

associated with it. Source:

Ford Motor Company.

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Instrument-Panel Concept

FIGURE 15.23 A clay sculptor working on an instrument-panel concept. Source: Ford

Motor Company.

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Flange and Fillet

FIGURE 15.24 First flange and fillet.

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