2022 question paper

Automation in Manufacturing

18 questions

1. Q1(a). Define automation.20222m

   Module 1: Introduction

   Define automation.

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   Automation is the technology by which manufacturing processes are performed with minimum or no direct human intervention using control systems, computers, sensors, machines and other automatic equipment.

2. Q1(b). Which type of control system is suitable in applications like food industry, petro-chemical and industries involving robots?20222m

   Module 2: Flexible Automation

   Which type of control system is suitable in applications like food industry, petro-chemical and industries involving robots?

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   A closed-loop (feedback) control system is suitable. It is commonly used where accurate automatic control and feedback are required, such as robotic and process-control applications in food and petro-chemical industries.

3. Q1(c). Which G-code gives point-to-point movement?20222m

   Module 4: Computer Aided Manufacturing

   Which G-code gives point-to-point movement?

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   The G-code for point-to-point (rapid positioning) movement is G00 (G0).

4. Q1(d). Name the basic geometric building block provided in a CAD/CAM package.20222m

   Module 3: Computer Aided Design

   Name the basic geometric building block provided in a CAD/CAM package.

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   The basic geometric building blocks (primitives) in a CAD/CAM package include points, lines, arcs/circles and other basic curves/surfaces. A commonly cited basic building block is the geometric primitive.

5. Q1(e). How can the speed and position in CNC be controlled?20222m

   Module 4: Computer Aided Manufacturing

   How can the speed and position in CNC be controlled?

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   In CNC, speed is controlled mainly by the spindle drive/controller, while position is controlled by the feed-drive/servo system using feedback from position sensors such as encoders or resolvers.

6. Q1(f). What effect does overloading have on fluid power and electrical systems?20222m

   Module 5: Low Cost Automation

   What effect does overloading have on fluid power and electrical systems?

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   Overloading causes the pressure/force in fluid-power systems to rise beyond the safe limit, so relief or overload valves operate to protect components. In electrical systems, excessive load causes excessive current, leading to heating, voltage drop and possible tripping of protective devices or damage to components.

7. Q1(g). Can we simulate transportation, manufacturing and health system?20222m

   Module 6: Introduction to Modeling and Simulation

   Can we simulate transportation, manufacturing and health system?

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   Yes. Transportation, manufacturing and health-care systems can be simulated using mathematical/computer models. Simulation helps study system behaviour, test alternatives and predict performance without experimenting directly on the real system.

8. Q1(h). Why are designs periodically modified?20222m

   Module 3: Computer Aided Design

   Why are designs periodically modified?

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   Designs are periodically modified to improve performance, quality, reliability and manufacturability, reduce cost and material usage, incorporate new technology or customer requirements, and correct problems found during use or manufacturing.

9. Q1(i). Which technique is used for solution of nonlinear programming?20222m

   Module 6: Introduction to Modeling and Simulation

   Which technique is used for solution of nonlinear programming?

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   Nonlinear programming can be solved using iterative numerical optimization techniques, such as the gradient (steepest-descent) method, Newton's method, or sequential quadratic programming (SQP). The appropriate method depends on the objective function and constraints.

10. Q1(j). Name any two of the available softwares used in computer-aided design (CAD).20222m

    Module 3: Computer Aided Design

    Name any two of the available softwares used in computer-aided design (CAD).

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    Two examples of CAD software are AutoCAD and CATIA. Other examples include SolidWorks, Creo and Siemens NX.

12. Q2(a). Why is automation necessary in manufacturing field? Write its advantages and disadvantages.202214m

    Module 1: Introduction

    Why is automation necessary in manufacturing field? Write its advantages and disadvantages.

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    Need for automation in manufacturing

    Automation is needed to increase productivity, maintain consistent quality, reduce manufacturing time and cost, improve worker safety, and manufacture complex products accurately. It is especially useful for repetitive, hazardous and high-volume operations.

    Advantages

    1. Higher production rate and productivity.
    2. Better and more consistent product quality.
    3. Reduced manufacturing time and labour cost per unit.
    4. Improved dimensional accuracy and repeatability.
    5. Better utilization of machines and materials.
    6. Improved safety by removing workers from hazardous operations.
    7. Reduced human error and fatigue.
    8. Enables manufacture of complex products and integration with CAD/CAM.

    Disadvantages

    1. High initial investment and installation cost.
    2. Skilled personnel are required for programming, operation and maintenance.
    3. Maintenance and troubleshooting can be complex.
    4. Automation may be uneconomical for low-volume or frequently changing production.
    5. Failure of an automated system can interrupt a large part of production.
    6. Workers may require retraining and some conventional jobs may be reduced.

    Conclusion: Automation is most economical when its productivity, quality and safety benefits justify the initial investment and operating complexity.

13. Q3(a). What is PLC? Explain the working of PLC.202214m

    Module 4: Computer Aided Manufacturing

    What is PLC? Explain the working of PLC.

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    PLC

    A Programmable Logic Controller (PLC) is a rugged industrial digital controller used to monitor inputs, execute a stored control program, and operate outputs for controlling machines and manufacturing processes.

    Working of PLC

    The basic operation is a continuous scan cycle:

    1. Input scan: The PLC reads the status of sensors, switches and other input devices and stores their states in memory.
    2. Program execution: The CPU executes the user program, typically written in ladder logic or another IEC 61131-3 language, using the stored input states.
    3. Output update: Based on the program result, the PLC updates output devices such as motors, solenoid valves, relays and actuators.
    4. Communication/diagnostics: The PLC performs communication and diagnostic tasks as configured.
    5. The cycle repeats continuously, allowing the controller to respond to changes in the process.

    Block flow: Input devices → Input module → CPU + Program/Memory → Output module → Actuators/process.

    Advantages

    PLCs are reliable, fast, programmable, easy to modify, suitable for harsh industrial environments, and require less wiring than conventional relay control systems.

14. Q4(a). Classify CNC machines. Explain which one is suitable for small-scale industries and why.202214m

    Module 4: Computer Aided Manufacturing

    Classify CNC machines. Explain which one is suitable for small-scale industries and why.

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    Classification of CNC machines

    CNC machines may be classified in several ways:

    1. According to motion control:

    • Point-to-point (PTP): Tool moves between programmed positions; machining is generally performed at the destination.
    • Straight-cut: Controlled motion is along one or more coordinate axes to produce straight cuts.
    • Contouring/continuous-path: Two or more axes are coordinated simultaneously to machine a continuous profile.

    2. According to number of axes: 2-axis, 2.5-axis, 3-axis, 4-axis, 5-axis and higher-axis machines.

    3. According to machine tool: CNC lathe/turning centre, CNC milling machine/machining centre, CNC drilling machine, CNC grinding machine, etc.

    Suitability for small-scale industries

    For small-scale industries, a 2-axis CNC turning centre/CNC lathe is often suitable when the products are mainly rotational components. It provides good accuracy, repeatability and productivity with comparatively lower investment and simpler operation than multi-axis systems. For prismatic components, a 3-axis CNC milling machine is the corresponding economical choice.

    Thus, the appropriate CNC machine depends on the type of component and production requirement; for simple turned parts, a 2-axis CNC lathe is generally the economical choice.

15. Q5(a). Discuss the CIM wheel with neat sketch. Briefly discuss various elements of CIM.202214m

    Module 1: Introduction

    Discuss the CIM wheel with neat sketch. Briefly discuss various elements of CIM.

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    CIM wheel

    The CIM (Computer Integrated Manufacturing) wheel represents the integration of the major computer-based functions involved in manufacturing. At its centre is the manufacturing information/database and communication system, while engineering, planning, production and business functions are interconnected around it.

    A simplified representation is:

    Marketing & Sales → Product Design/CAD → Process Planning/CAPP → Production Planning → Scheduling → CNC/Manufacturing → Material Handling & Storage → Inspection/Quality → Feedback

    All these functions exchange information through a common computer and communication infrastructure.

    Major elements of CIM

    1. CAD: Computer-aided product design and engineering analysis.
    2. CAPP: Computer-aided process planning and generation of manufacturing instructions.
    3. CAM/CNC: Computer-based control and execution of manufacturing operations.
    4. Production planning and control: Planning, scheduling, inventory and shop-floor control.
    5. Material handling and storage: Automated movement and storage of parts/materials.
    6. Robotics/automation: Automatic handling, assembly and processing.
    7. Inspection and quality control: Computer-assisted measurement and quality monitoring.
    8. Database and communication: Central/shared manufacturing data and communication networks.
    9. Business functions: Order processing, purchasing, costing and other enterprise activities.

    Benefit: CIM reduces information delays and manual data transfer, improves coordination and enables integrated, flexible and efficient manufacturing.

16. Q6(a). Explain the concept of flexible manufacturing system.202214m

    Module 2: Flexible Automation

    Explain the concept of flexible manufacturing system.

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    Flexible Manufacturing System (FMS)

    A Flexible Manufacturing System is an integrated, computer-controlled manufacturing system consisting of several automated machine tools/workstations connected by an automated material-handling and storage system and coordinated by a central control system.

    Main elements

    1. CNC machine tools/machining centres for processing parts.
    2. Automated material-handling system such as conveyors, AGVs or robots.
    3. Automated storage system for workpieces/tools.
    4. Central computer/control system for scheduling, routing and monitoring.
    5. Tooling and fixture systems that allow quick changeover.
    6. Inspection/measurement systems for quality control.

    Characteristics

    • Can manufacture a family of different parts.
    • Automatic routing and scheduling.
    • Quick changeover with little setup time.
    • Computer-based monitoring and control.
    • High utilization and repeatability.

    Advantages

    FMS combines much of the productivity of dedicated automation with the flexibility needed for product variety. It reduces setup time, work-in-process and material-handling effort while improving utilization and quality.

    Limitation: Initial investment, programming, maintenance and system integration costs are relatively high.

17. Q7(a). Explain the following commands in geometric modelling: (a) Scaling, (b) Mirror, (c) Rotation.202214m

    Module 3: Computer Aided Design

    Explain the following commands in geometric modelling: (a) Scaling, (b) Mirror, (c) Rotation.

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    Geometric modelling commands

    (a) Scaling: Scaling changes the size of a geometric model. For scale factors $S_x,S_y,S_z$ along the three coordinate axes,
    $$x'=S_xx,\qquad y'=S_yy,\qquad z'=S_zz.$$
    If all scale factors are equal, uniform scaling is obtained; otherwise the model is stretched differently along different axes.

    (b) Mirror: Mirroring produces a reflected copy of the geometry about a specified mirror plane/axis. For example, reflection about the $YZ$ plane gives
    $$x'=-x,\qquad y'=y,\qquad z'=z.$$
    It is useful for creating symmetric features and opposite-hand components.

    (c) Rotation: Rotation turns the model through a specified angle about an axis. For rotation through angle $\theta$ about the $Z$-axis,
    $$x'=x\cos\theta-y\sin\theta,$$
    $$y'=x\sin\theta+y\cos\theta,$$
    $$z'=z.$$
    Rotation is used to position geometry and create circular or repeated features.

18. Q8(a). Explain system modelling. Write differences between continuous and discrete event.202214m

    Module 6: Introduction to Modeling and Simulation

    Explain system modelling. Write differences between continuous and discrete event.

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    System modelling

    System modelling is the process of developing a mathematical, logical or computer representation of a real system so that its structure, behaviour and interactions can be studied. A model contains the important entities, variables, relationships, inputs and outputs of the actual system.

    Continuous vs. discrete-event systems

    Continuous system	Discrete-event system
    State variables change continuously with time.	State changes occur at specific points/events.
    Usually represented using differential/algebraic equations.	Usually represented using event logic, state transitions and queues.
    Time advances continuously.	System state changes when an event occurs.
    Example: temperature variation, fluid level, motor speed.	Example: arrival/departure of jobs, machine failure/repair, production-line queues.

    In short: Continuous simulation tracks continuously varying quantities, whereas discrete-event simulation tracks changes caused by individual events.

19. Q9(a). Write a CNC program using appropriate G and M code to turn the component shown in the figure. [IMAGE REQUIRED — add the original component/profile figure here.] Raw material: MS 32 \times 50 mm, cutting speed V=40 m/min and feed =0.1. Assume suitable data for depth of cut. The figure specifies the component dimensions and profile.202214m

    Module 4: Computer Aided Manufacturing

    Write a CNC program using appropriate G and M code to turn the component shown in the figure. [IMAGE REQUIRED — add the original component/profile figure here.] Raw material: MS $32 \times 50$ mm, cutting speed $V=40$ m/min and feed $=0.1$. Assume suitable data for depth of cut. The figure specifies the component dimensions and profile.

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