Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions

How is the operation of a stepper motor different from the operation of conventional DC or AC motors?
What is a solenoid?
Briefly describe the three phases of the analog-to-digital conversion process?
What is the resolution of an analog-to-digital converter?
Briefly describe the two steps in the digital-to-analog conversion process?
What is the difference between a contact input interface and a contact output interface?
What is the difference between an analog sensor and a discrete sensor?
What is the difference between an active sensor and a passive sensor?
What is the transfer function of a sensor?
What is an actuator?
Nearly all actuators can be classified into one of three categories, according to type of drive power. Name the three categories.
In a DC motor, what is a commutator?
What are the two important disadvantages of DC electric motors that make the AC motor relatively attractive?
During calibration, an Iron/Constantan thermocouple is zeroed (set to emit a zero voltage) at 0(C. At 750(C, it emits a voltage of 38.8 mV. A linear output/input relationship exists between 0(C and 750(C. Determine (a) The transfer function of the thermocouple and (b) The temperature corresponding
A stepper motor has a step angle = 7.5(. (a) How many pulses are required for the motor to rotate through five complete revolutions? (b) What pulse frequency is required for the motor to rotate at a speed of 200 rev/min?
The shaft of a stepper motor is directly connected to a lead screw that drives a worktable in an x-y positioning system. The motor has a step angle = 5(. The pitch of the lead screw is 6 mm, which means that the worktable moves in the direction of the lead screw axis by a distance of 6 mm for each
A single-acting hydraulic cylinder with spring return has an inside diameter of 88 mm. Its application is to push pallets off of a conveyor into a storage area. The hydraulic power source can generate up to 3.2 MPa of pressure at a flow rate of 175,000 mm3/sec to drive the piston. Determine (a) The
A double-acting hydraulic cylinder has an inside diameter = 75 mm. The piston rod has a diameter = 14 mm. The hydraulic power source can generate up to 5.0 MPa of pressure at a flow rate of 200,000 mm3/sec to drive the piston. (a) What are the maximum possible velocity of the piston and the maximum
A double-acting hydraulic cylinder is used to actuate a linear joint of an industrial robot. The inside diameter of the cylinder is 3.5 in. The piston rod has a diameter of 0.5 in. The hydraulic power source can generate up to 500 lb/in2 of pressure at a flow rate of 1200 in3/min to drive the
A continuous voltage signal is to be converted into its digital counterpart using an analog-to-digital converter. The maximum voltage range is (30 V. The ADC has a 12-bit capacity. Determine(a) Number of quantization levels,
A voltage signal with a range of zero to 115 V. is to be converted by means of an ADC. Determine the minimum number of bits required to obtain a quantization error of(a) (5 V maximum,(b) (1 V maximum,(c) (0.1 V maximum.
A digital-to-analog converter uses a reference voltage of 120 V dc and has eight binary digit precision. In one of the sampling instants, the data contained in the binary register = 01010101. If a zero-order hold is used to generate the output signal, determine the voltage level of that signal.
A DAC uses a reference voltage of 80 V and has 6-bit precision. In four successive sampling periods, each 1 second long, the binary data contained in the output register were 100000, 011111, 011101, and 011010. Determine the equation for the voltage as a function of time between sampling instants 3
In the previous problem, suppose that a second order hold were to be used to generate the output signal. The equation for the second-order hold is the following: E(t) = E0 + (t + (t2 , where E0 = starting voltage at the beginning of the time interval. (a) For the binary data given in the previous
A digital tachometer is used to determine the surface speed of a rotating work piece in surface ft/min. Tachometers are designed to read rotational speed in rev/min, but in this case the shaft of the tachometer is directly coupled to a wheel whose outside rim is made of rubber. When the wheel rim
A digital flow meter operates by emitting a pulse for each unit volume of fluid flowing through it. The particular flow meter of interest here has a unit volume of 57.9 cm3 per pulse. In a certain process control application, the flow meter emitted 6489 pulses during a period of 3.6 min.
A tool-chip thermocouple is used to measure the cutting temperature in a turning operation. The two dissimilar metals in a tool-chip thermocouple are the tool material and the work piece metal. During the turning operation, the chip from the work metal forms a junction with the rake face of the
A DC servomotor is used to actuate one of the axes of an x-y positioned. The motor has a torque constant of 8.75 in-lb/A and a voltage constant of 10 V/(1000 rev/min). The armature resistance is 2.0 ohms. At a given moment, the positioned table is not moving and a voltage of 20 V is applied to the
A DC servomotor has a torque constant = 0.088 N-m/A and a voltage constant = 0.12 V/(rad/sec). The armature resistance is 2.3 ohms. A terminal voltage of 30 V is used to operate the motor. Determine(a) The starting torque generated by the motor just as the voltage is applied,(b) The maximum speed
In the previous problem, what is the power delivered by the motor at the operating point in units of (a) Watts and (b) Horsepower? Previous problem A DC servomotor has a torque constant = 0.088 N-m/A and a voltage constant = 0.12 V/(rad/sec). The armature resistance is 2.3 ohms. A terminal voltage
A voltage of 24 V is applied to a DC servomotor whose torque constant = 0.115 N-m/A and voltage constant = 0.097 V/(rad/sec). Armature resistance = 1.9 ohms. The motor is directly coupled to a blower shaft for an industrial process. (a) What is the stall torque of the motor? (b) Determine the
The step angle of a certain stepper motor = 1.8(. The application of interest is to rotate the motor shaft through 10 complete revolutions at an angular velocity of 20 rad/sec. Determine (a) The required number of pulses and (b) The pulse frequency to achieve the specified rotation.
What is numerical control?
What is a machining center?
Name four of the six part characteristics that are most suited to the application of numerical control listed in the text.
Although NC technology is most closely associated with machine tool applications, it has been applied to other processes also. Name three of the six examples listed in the text.
What are four advantages of numerical control when properly applied in machine tool operations?
What are three disadvantages of implementing NC technology?
Briefly describe the differences between the two basic types of positioning control systems used in NC?
What is an optical encoder, and how does it work?
With reference to precision in an NC positioning system, what is control resolution?
What is the difference between manual part programming and computer-assisted part programming?
What are the three basic components of an NC system?
What is post processing in computer-assisted part programming?
What are some of the advantages of CAD/CAM-based NC part programming compared to computer-assisted part programming?
What is the right-hand rule in NC and where is it used?
What is the difference between point-to-point and continuous path control in a motion control system?
What is linear interpolation, and why is it important in NC?
What is the difference between absolute positioning and incremental positioning?
Name five of the ten features and capabilities of a modern CNC machine control unit listed in the text.
What is distributed numerical control (DNC)?
A machinable grade of aluminum is to be milled on an NC machine with a 20 mm diameter four-tooth end milling cutter. Cutting speed = 120 m/min and feed = 0.008 mm/tooth. Convert these values to rev/min and mm/rev, respectively.
A component insertion machine takes 2.0 sec to put a component into a printed circuit (PC) board, once the board has been positioned under the insertion head. The xy table that positions the PC board uses a stepper motor directly linked to a lead screw for each axis. The lead screw has a pitch =
The two axes of an xy positioning table are each driven by a stepping motor connected to a Leadscrew with a 4:1 gear reduction. The number of step angles on each stepping motor is 200. Each Leadscrew has a pitch = 5.0 mm and provides an axis range = 400.0 mm. There are 16 bits in each binary
A dc servomotor is used to drive one of the table axes of an NC milling machine. The motor is coupled directly to the lead screw for the axis, and the lead screw pitch = 5 mm. The optical encoder attached to the lead screw emits 500 pulses per revolution of the lead screw. The motor rotates at a
In Problem 7.3, the axis corresponding to the feed rate uses a dc servomotor as the drive unit and an optical encoder as the feedback sensing device. The motor is geared to the lead screw with a 10:1 reduction (10 turns of the motor for each turn of the lead screw). If the lead screw pitch = 5 mm,
The worktable of an NC machine is driven by a closed-loop positioning system which consists of a servomotor, Leadscrew, and optical encoder. The lead screw pitch = 4 mm and is coupled directly to the motor shaft (gear ratio = 1:1). The optical encoder generates 225 pulses per Leadscrew revolution.
A NC machine tool table is powered by a servomotor, lead screw, and optical encoder. The lead screw has a pitch = 5.0 mm and is connected to the motor shaft with a gear ratio of 16:1 (16 turns of the motor for each turn of the lead screw). The optical encoder is connected directly to the lead screw
Solve the previous problem assuming the optical encoder is directly coupled to the motor shaft rather than to the lead screw. Previous problem A NC machine tool table is powered by a servomotor, lead screw, and optical encoder. The lead screw has a pitch = 5.0 mm and is connected to the motor
A lead screw coupled directly to a dc servomotor is used to drive one of the table axes of an NC milling machine. The lead screw has 2.5 threads/cm. The optical encoder attached to the lead screw emits 100 pulses/rev of the lead screw. The motor rotates at a maximum speed of 800 rev/min. Determine:
Solve the previous problem only the servomotor is connected to the lead screw through a gear box whose reduction ratio = 10:1 (10 revolutions of the motor for each revolution of the lead screw). Previous problemA lead screw coupled directly to a dc servomotor is used to drive one of the table axes
A milling operation is performed on a NC machining center. Total travel distance = 300 mm in a direction parallel to one of the axes of the worktable. Cutting speed = 1.25 m/s and chip load = 0.05 mm. The end milling cutter has four teeth and its diameter = 20.0 mm. The axis uses a dc servomotor
A cast iron work piece is to be face milled on an NC machine using cemented carbide inserts. The cutter has 16 teeth and is 120 mm in diameter. Cutting speed = 200 m/min and feed = 0.005 mm/tooth. Convert these values to rev/min and mm/rev, respectively.
A dc servomotor drives the x-axis of a NC milling machine table. The motor is coupled directly to the table lead screw, whose pitch = 6.25 mm. An optical encoder is connected to the lead screw. The optical encoder emits 125 pulses per revolution. To execute a certain programmed instruction, the
A two-axis NC system used to control a machine tool table uses a bit storage capacity of 16 bits in its control memory for each axis. The range of the x-axis is 600 mm and the range of the y-axis is 500 mm. The mechanical accuracy of the machine table can be represented by a Normal distribution
Stepping motors are used to drive the two axes of an insertion machine used for electronic assembly. A printed circuit board is mounted on the table which must be positioned accurately for reliable insertion of components into the board. Range of each axis = 700 mm. The lead screw used to drive
Referring back to Problem 7.8, the mechanical inaccuracies in the open loop positioning system can be described by a normal distribution whose standard deviation = 0.005 mm. The range of the worktable axis is 500 mm, and there are 12 bits in the binary register used by the digital controller to
The positioning table for a component insertion machine uses a stepping motor and lead screw mechanism. The design specifications require a table speed of 0.4 m/s and an accuracy = 0.02 mm. The pitch of the lead screw = 5.0 mm, and the gear ratio = 2:1 (2 turns of the motor for each turn of the
The two axes of an xy positioning table are each driven by a stepping motor connected to a lead screw with a 10:1 gear reduction. The number of step angles on each stepping motor is 20. Each lead screw has a pitch = 4.5 mm and provides an axis range = 300 mm. There are 16 bits in each binary
Write the part program to drill the holes in the part shown in Figure P7.26. The part is 12.0 mm thick. Cutting speed = 100 m/min and feed = 0.06 mm/rev. Use the lower left corner of the part as the origin in the x-y axis system. Write the part program in the word address format using absolute
The part is to be drilled on a turret-type drill press. The part is 15.0 mm thick. There are three drill sizes to be used: 8 mm, 10 mm, and 12 mm. These drills are to be specified in the part program by tool turret positions T01, T02, and T03. All tooling is high speed steel. Cutting speed = 75
The outline of the part in the previous problem is to be profile milled using a 30 mm diameter end mill with four teeth. The part is 15 mm thick. Cutting speed = 150 mm/min and feed = 0.085 mm/tooth. Use the lower left corner of the part as the origin in the x-y axis system. Two of the holes in the
The outline of the part in Figure P7.29 is to be profile milled, using a 20 mm diameter end mill with two teeth. The part is 10 mm thick. Cutting speed = 125 mm/min and feed = 0.10 mm/tooth. Use the lower left corner of the part as the origin in the x-y axis system. The two holes in the part have
An end milling operation is performed on an NC machining center. The total length of travel is 625 mm along a straight line path to cut a particular work piece. Cutting speed = 2.0 m/s and chip load (feed/tooth) = 0.075 mm. The end milling cutter has two teeth and its diameter = 15.0 mm. Determine
Write the APT geometry statements to define the hole positions of the part. Use the lower left corner of the part as the origin in the x-y axis system.
Write the complete APT part program to perform the drilling operations for the part drawing in Figure P7.26. Cutting speed = 0.4 m/s, feed = 0.10 mm/rev., and table travel speed between holes = 500 mm/min. Postprocessor call statement is MACHIN/DRILL, 04.
Write the APT geometry statements to define the hole positions of the part. Use the lower left corner of the part as the origin in the x-y axis system. Discuss.
Write the APT part program to perform the drilling operations for the part. Use the TURRET command to call the different drills required. Cutting speed = 0.4 m/s, feed = 0.10 mm/rev., and table travel speed between holes = 500 mm/min. Postprocessor call statement is MACHIN/TURDRL, 02.
Write the APT geometry statements to define the outline of the part. Use the lower left corner of the part as the origin in the x-y axis system.
Write the complete APT part program to profile mill the outside edges of the part. The part is 15 mm thick. Tooling = 30 mm diameter end mill with four teeth, cutting speed = 150 mm/min, and feed = 0.085 mm/tooth. Use the lower left corner of the part as the origin in the x-y axis system. Two of
Write the APT geometry statements to define the part geometry. Use the lower left corner of the part as the origin in the x-y axis system.
Write the complete APT part program to perform the profile milling operation for the part drawing in Figure P7.29. Tooling = 20 mm diameter end mill with two teeth, cutting speed = 125 mm/min, and feed = 0.10 mm/tooth. The part is 10 mm thick. Use the lower left corner of the part as the origin in
Write the APT geometry statements to define the outline of the cam.
The outline of the cam in Figure P7.38 is to be machined in an end milling operation, using a 12.5 mm diameter end mill with two teeth. The part is 7.5 mm thick. Write the complete APT program for this job, using a feed rate = 80 mm/min and a spindle speed = 500 rev/min. Postprocessor call
A turning operation is to be performed on an NC lathe. Cutting speed = 2.5 m/s, feed = 0.2 mm/rev, and depth = 4.0 mm. Work piece diameter = 100 mm and its length = 400 mm. Determine(a) Rotational speed of the work bar,(b) Feed rate,(c) Metal removal rate, and(d) Time to travel from one end of the
The part outline is to be profile milled in several passes from a rectangular slab (outline of slab shown in dashed lines), using a 25 mm diameter end mill with four teeth. The initial passes are to remove no more than 5 mm of material from the periphery of the part, and the final pass should
The top surface of a large cast iron plate is to be face-milled. The area to be machined is 400 mm wide and 700 mm long. The insert-type face-milling cutter has eight teeth and is 100 mm in diameter. Define the origin of the axis system at the lower left corner of the part with the long side
Write the APT geometry statements to define the part geometry.
The part is to be milled, using a 20 mm diameter end mill with four teeth. Write the APT geometry and motion statements for this job. Assume that preliminary passes have been completed so that only the final pass ("to size") is to be completed in this program. Cutting speed = 500 rev./min, and feed
A numerical control drill press drills four 10.0 mm diameter holes at four locations on a flat aluminum plate in a production work cycle. Although the plate is only 12 mm thick, the drill must travel a full 20 mm vertically at each whole location to allow for clearance above the plate and
Two stepping motors are used in an open loop system to drive the lead screws for xy positioning. The range of each axis is 250 mm. The shafts of the motors are connected directly to the lead screws. The pitch of each lead screw is 3.0 mm, and the number of step angles on the stepping motor is
One axis of an NC positioning system is driven by a stepping motor. The motor is connected to a lead screw whose pitch is 4.0 mm, and the lead screw drives the table. Control resolution for the table is specified as 0.015 mm. Determine(a) The number of step angles required to achieve the specified
The worktable in an NC positioning system is driven by a lead screw with a 4 mm pitch. The lead screw is powered by a stepping motor which has 250 step angles. The worktable is programmed to move a distance of 100 mm from its present position at a travel speed of 300 mm/min.(a) How many pulses are
A stepping motor with 200 step angles is coupled to a lead screw through a gear reduction of 5:1 (5 rotations of the motor for each rotation of the lead screw). The lead screw has 2.4 threads/cm. The worktable driven by the lead screw must move a distance = 25.0 cm at a feed rate = 75 cm/min.
What is an industrial robot?
What are four of the six general characteristics of industrial work situations that tend to promote the substitution of robots for human workers?
What are the three categories of robot industrial applications, as identified in the text?
What is a palletizing operation?
What is the difference between powered lead through and manual lead through in robot programming?
What is control resolution in a robot positioning system?

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Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions

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