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

What is the difference between repeatability and accuracy in a robotic manipulator?
What are the five joint types used in robotic arms and wrists?
Name the five common body-and-arm configurations identified in the text.
What is a playback robot with point-to-point control?
What is an end effector?
In a machine loading and unloading application, what is the advantage of a dual gripper over a single gripper?
Robotic sensors are classified as internal and external. What is the distinction?
Using the notation scheme for defining manipulator configurations (Section 8.1.2), draw diagrams (similar to Figure 8.1) of the following robots: (a) TRT, (b) VVR, (c) VROT.
The arc-on time is a measure of efficiency in an arc welding operation. As indicated in our discussion of arc welding in Section 8.5.2, typical arc-on times in manual welding range between 20% and 30%. Suppose that a certain welding operation is currently performed using a welder and a fitter.
The linear joint (type L) of a certain industrial robot is actuated by a piston mechanism. The length of the joint when fully retracted is 600 mm and when fully extended is 1000 mm. If the robot's controller has an 8bit storage capacity, determine the control resolution for this robot.
In the previous problem, the mechanical errors associated with the linear joint form a normal distribution in the direction of the joint actuation with standard deviation = 0.08 mm. Determine
Using the notation scheme for defining manipulator configurations, draw diagrams of the following robots: (a) TRL, (b) OLO, (c) LVL.
The revolving joint (type V) of an industrial robot has a range of 240( rotation. The mechanical errors in the joint and the input/output links can be described by a normal distribution with its mean at any given addressable point, and a standard deviation of 0.25(. Determine the number of storage
A cylindrical robot has a T-type wrist axis that can be rotated a total of 5 rotations (each rotation is a full 360(). It is desired to be able to position the wrist with a control resolution of 0.5( between adjacent addressable points. Determine the number of bits required in the binary register
One axis of an RRL robot is a linear slide with a total range of 950 mm. The robot's control memory has an 10bit capacity. It is assumed that the mechanical errors associated with the arm are normally distributed with a mean at the given taught point and an isotropic standard deviation of 0.10 mm.
A TLR robot has a rotational joint (type R) whose output link is connected to the wrist assembly. Considering the design of this joint only, the output link is 600 mm long, and the total range of rotation of the joint is 40(. The spatial resolution of this joint is expressed as a linear measure at
Using the notation scheme for defining manipulator configurations, draw diagrams (similar to Figure 8.1) of the following robots: (a) TRT:R, (b) TVR:TR, (c) RR:T.
Describe the differences in orientation capabilities and work volumes for a :TR and a :RT wrist assembly. Use sketches as needed.
A robot performs a loading and unloading operation for a machine tool. The work cycle consists of the following sequence of activities:The activities are performed sequentially as listed. Every 30 work parts, the cutting tools in the machine must be changed. This irregular cycle takes 3.0 minutes
In the previous problem, suppose that a double gripper is used instead of a single gripper as indicated in that problem. The activities in the cycle would be changed as follows:Steps 1, 4, and 5 are performed simultaneously with the automatic machining cycle. Steps 2 and 3 must be performed
Since the robot's portion of the work cycle requires much less time than the machine tool in Problem 8.6, the possibility of installing a cell with two machines is being considered. The robot would load and unload both machines from the same incoming and outgoing conveyors. The machines would be
Determine the hourly production rate for a two-machine cell as in Problem 8.8, only the robot is equipped with a double gripper as in Problem 8.7. Assume the activity times from Problem 8.7 apply here.
Briefly define the two categories of discrete process control?
What are the advantages of using a PLC rather than conventional relays, timers, counters, and other hard-wired control components?
What are the five basic components of a PLC?
The typical operating cycle of the PLC, called a scan, consists of three parts: (1) input scan, (2) program scan, and (3) output scan. Briefly describe what is accomplished in each part.
Name the five PLC programming methods identified in the International Standard for Programmable Controllers (IEC 1131-3).
What are three of the reasons and factors that explain why personal computers are being used with greater and greater frequency for industrial control applications?
Name the two basic approaches used in PC-based control systems.
What is Boolean algebra? What was its original purpose?
What is the difference between a delay-off timer and a delay-on timer?
What is the difference between an up counter and a down counter?
What is a ladder logic diagram?
What is a programmable logic controller?
Write the Boolean logic expression for the pushbutton switch of Example 9.2 using the following symbols: X1 = START, X2 = STOP, Y1 = MOTOR, and Y2 = POWERTOMOTOR.
In the fluid filling operation of Example 9.6, suppose a sensor (e.g., a submerged float switch) is used to determine whether the contents of the tank have been evacuated, rather than rely on timer T2 to empty the tank. (a) Construct the ladder logic diagram for this revised system. (b) Write the
In the manual operation of a sheet metal stamping press, a two button safety interlock system is often used to prevent the operator from inadvertently actuating the press while his hand is in the die. Both buttons must be depressed to actuate the stamping cycle. In this system, one press button is
An emergency stop system is to be designed for a certain automatic production machine. A single "start" button is used to turn on the power to the machine at the beginning of the day. In addition, there are three "stop" buttons located at different locations around the machine, any one of which can
An industrial robot performs a machine loading and unloading operation. A PLC is used as the robot cell controller. The cell operates as follows: (1) a human worker places a work part into a nest, (2) the robot reaches over and picks up the part and places it into an induction heating coil, (3) a
A PLC is used to control the sequence in an automatic drilling operation. A human operator loads and clamps a raw work part into a fixture on the drill press table and presses a start button to initiate the automatic cycle. The drill spindle turns on, feeds down into the part to a certain depth
An industrial furnace is to be controlled as follows: The contacts of a bimetallic strip inside the furnace close if the temperature falls below the set point and open when the temperature is above the set point. The contacts regulate a control relay which turns on and off the heating elements of
Construct the ladder logic diagram for the robot interlock system in Example 9.1.
In the circuit, suppose photo detectors were used to determine whether the lamp worked. If the lamp does not light when both switches are closed, the photo detector causes a buzzer to sound. Construct the ladder logic diagram for this system.
Construct the ladder logic diagrams for (a) The NAND gate and (b) The NOR gate.
Construct the ladder logic diagrams for the following Boolean logic equations: (a) Y = (X1 + X2)(X3, (b) Y = (X1 + X2)((X3 + X4), and (c) Y = (X1(X2) + X3.
Write the low level language statements for the lamp and photo detector system in Problem 9.4.
Write the low level language statements for the fluid filling operation in Example 9.6.
Write the low level language statements for the four parts of Problem 9.5.
Provide a definition of material handling.
What features distinguish self-guided vehicles from conventional AGVs?
What is forward sensing in AGVS terminology?
What are some of the differences between rail-guided vehicles and automated guided vehicles?
What is a conveyor?
What is the difference between a hoist and a crane?
How does material handling fit within the scope of logistics?
Name the four major categories of material handling equipment.
What is the unit load principle?
What are the five categories of material transport equipment commonly used to move parts and materials inside a facility?
What is an automated guided vehicle system (AGVS)?
Name three categories of automated guided vehicles.
A flexible manufacturing system is being planned. It has a ladder layout as pictured in Figure P10.1 and uses a rail guided vehicle system to move parts between stations in the layout. All work parts are loaded into the system at station 1, moved to one of three processing stations (2, 3, or 4),
An automated guided vehicle system is being proposed to deliver parts between 40 workstations in a factory. Loads must be moved from each station about once every hour; thus, the delivery rate = 40 loads per hour. Average travel distance loaded is estimated to be 250 ft and travel distance empty is
An automated guided vehicle system is being planned for a warehouse complex. The AGVS will be a driverless train system, and each train will consist of the towing vehicle plus four carts. Speed of the trains will be 160 ft/min. Only the pulled carts carry loads. The average loaded travel distance
The from-to Chart in the table below indicates the number of loads moved per 8hour day (above the slash) and the distances in ft (below the slash) between departments in a particular factory. Fork lift trucks are used to transport materials between departments. They move at an average speed = 275
A warehouse consists of five aisles of racks (racks on both sides of each aisle) and a loading dock. The rack system is four levels high. Forklift trucks are used to transport loads between the loading dock and the storage compartments of the rack system in each aisle. The trucks move at an average
Suppose the warehouse in the preceding problem were organized according to a class-based dedicated storage strategy based on activity level of the pallet loads in storage, so that aisles 1 and 2 accounted for 70% of the deliveries (class A) and aisles 3, 4, and 5 accounted for the remaining 30%
Major appliances are assembled on a production line at the rate of 55 per hour. The products are moved along the line on work pallets (one product per pallet). At the final workstation the finished products are removed from the pallets. The pallets are then removed from the line and delivered back
For the production line in the previous problem, assume that a single AGV train consisting of a tractor and multiple trailers are used to make deliveries rather than separate vehicles. Time required to load a pallet onto a trailer = 15 sec; and the time to release a loaded train and move an empty
An AGVS will be implemented to deliver loads between four workstations: A, B, C, and D. The hourly flow rates (loads/hr) and distances (m) within the system are given in the table below (travel loaded denoted by "L" and travel empty denoted by "E"). Load and unload times are each 0.45 min, and
An overhead trolley conveyor is configured as a continuous closed loop. The delivery loop has a length of 120 m and the return loop = 80 m. All parts loaded at the load station are unloaded at the unload station. Each hook on the conveyor can hold one part and the hooks are separated by 4 m.
A 300 ft long roller conveyor, which operates at a velocity = 80 ft/min, is used to move pallets between load and unload stations. Each pallet carries 12 parts. Cycle time to load a pallet is 15 sec and one worker at the load station is able to load pallets at the rate of 4 per min. It takes 12 sec
In Example 10.2 in the text, suppose that the vehicles operate according to the following scheduling rules: (1) vehicles delivering raw work parts from station 1 to stations 2, 3, and 4 must return empty to station 5; and (2) vehicles picking up finished parts at stations 2, 3, and 4 for delivery
A roller conveyor moves tote pans in one direction at 150 ft/min between a load station and an unload station, a distance of 200 ft. With one worker, the time to load parts into a tote pan at the load station is 3 sec per part. Each tote pan holds 8 parts. In addition, it takes 9 sec to load a tote
A closed loop overhead conveyor must be designed to deliver parts from one load station to one unload station. The specified flow rate of parts that must be delivered between the two stations is 300 parts per hour. The conveyor has carriers spaced at a center-to-center distance that is to be
Consider the previous problem, only the carriers are larger and capable of holding up to four parts (np = 1, 2, 3, or 4). The loading time TL = 9 + 3np, where TL is in seconds. With other parameters defined as in the previous problem, determine which of the four values of np are feasible. For those
A recirculation conveyor has a total length of 700 ft and a speed of 90 ft/min. Spacing of part carriers = 14 ft. Each carrier can hold one part. Automatic machines load and unload the conveyor at the load and unload stations. Time to load a part is 0.10 min and unloads time is the same. To satisfy
A recalculating conveyor has a total length of 200 m and a speed of 50 m/min. Spacing of part carriers = 5 m. Each carrier holds two parts. Time needed to load a part carrier = 0.15 min. Unloading time is the same. The required loading and unloading rates are 6 parts per min. evaluate the conveyor
There is a plan to install a continuous loop conveyor system with a total length of 1000 ft and a speed of 50 ft/min. The conveyor will have carriers that are separated by 25 ft. Each carrier will be capable of holding one part. A load station and an unload station are to be located 500 ft apart
In Example 10.2 in the text, suppose that the vehicles operate according to the following scheduling rule in order to minimize the distances the vehicles travel empty: vehicles delivering raw work parts from station 1 to stations 2, 3, and 4 must pick up finished parts at these respective stations
A planned fleet of forklift trucks has an average travel distance per delivery = 500 ft loaded and an average empty travel distance = 350 ft. The fleet must make a total of 60 deliveries per hour. Load and unload times are each 0.5 min and the speed of the vehicles = 300 ft/min. The traffic factor
An automated guided vehicle system has an average travel distance per delivery = 200 m and an average empty travel distance = 150 m. Load and unload times are each 24 s and the speed of the AGV = 1 m/s. Traffic factor = 0.9. How many vehicles are needed to satisfy a delivery requirement of 30
Four forklift trucks are used to deliver pallet loads of parts between work cells in a factory. Average travel distance loaded is 350 ft and the travel distance empty is estimated to be the same. The trucks are driven at an average speed of 3 miles/hr when loaded and 4 miles/hr when empty. Terminal
An AGVS has an average loaded travel distance per delivery = 400 ft. The average empty travel distance is not known. Required number of deliveries per hour = 60. Load and unload times are each 0.6 min and the AGV speed = 125 ft/min. Anticipated traffic factor = 0.85 and availability = 0.95. Develop
A rail-guided vehicle system is being planned as part of an assembly cell. The system consists of two parallel lines, as in Figure P10.8. In operation, a base part is loaded at station 1 and delivered to either station 2 or 4, where components are added to the base part. The RGV then goes to either
An AGVS will be used to satisfy material flows indicated in the from-to Chart in the table below, which shows deliveries per hour between stations (above the slash) and distances in meters between stations (below the slash). Moves indicated by "L" are trips in which the vehicle is loaded, while "E"
Materials stored in manufacturing include a variety of types. Name six of the ten categories.
Identify the three application areas of automated storage/retrieval systems.
What are the four basic components of nearly all automated storage/retrieval systems?
Name and briefly describe four of the six measures used to assess the performance of a storage system?
Briefly describe the two basic storage location strategies.
What is a class-based dedicated storage strategy?
Name the four traditional (non-automated) methods for storing materials.
What are some of the objectives and reasons behind company decisions to automate their storage operations? Name six of the ten objectives and reasons listed in Table 11.3.
What are the differences between the two basic types of automated storage systems?
Each aisle of a six-aisle Automated Storage/Retrieval System is to contain 50 storage compartments in the length direction and 8 compartments in the vertical direction. All storage compartments will be the same size to accommodate standard size pallets of dimensions: x = 36 in and y = 48 in. The
An automated storage/retrieval system for work-in-process has five aisles. The storage racks in each aisle are 10 m high and 50 m long. The S/R machine for each aisle travels at a horizontal speed of 2.0 m/s and a vertical speed of 0.4 m/s. Pick and deposit time = 15 s. Assume that the number of
The length of one aisle in an AS/RS is 100 m and its height is 20 m. Horizontal travel speed is 4.0 m/s. The vertical speed is specified so that the storage system is "square in time," which means that L/vy = H/vz. The pick-and-deposit time is 12 s. Determine the expected throughput rate
An automated storage/retrieval system has four aisles. The storage racks in each aisle are 40 ft high and 200 ft long. The S/R machine for each aisle travels at a horizontal speed of 400 ft/min and a vertical speed of 60 ft/min. If the pick and deposit time = 0.3 min, determine the throughput rate
An AS/RS with one aisle is 300 ft long and 60 ft high. The S/R machine has a maximum speed of 300 ft/min in the horizontal direction. It accelerates from zero to 300 ft/min in a distance of 15 ft. On approaching its target position (where the S/R machine will transfer a load onto or off of its
An AS/RS with four aisles is 80 m long and 18 m high. The S/R machine has a maximum speed of 1.6 m/s in the horizontal direction. It accelerates from zero to 1.6 m/s in a distance of 2.0 m. On approaching its target position (where the S/R machine will transfer a load onto or off of its platform),

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

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