Faculty of Engineering School of Mechanical And

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FACULTY OF ENGINEERING SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING

MANF3510

COMPUTER APPLICATIONS IN MANUFACTURING

SESSION 2, 2009

Contents Course staff Course details Course aims Student learning outcomes Teaching strategies Assessment Academic honesty and plagiarism Course schedule Resources for students Course evaluation and development Administrative Matters Additional Information

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Course staff Dr. Erik van Voorthuysen, Course Convenor Room: ME M3; Ph: 9385 4147 Email: [email protected] A/Prof Jun Wang Room MME 207; Ph: 9385 5784 Email: [email protected] Mr. Seetha Mahadevan Room: ME M2; Ph: 9385 4109 Email: [email protected]

Matters relating to course administration should be directed to Dr Erik van Voorthuysen.

Course details The course is organized in two parts, Part A: Process Technology, which deals with technical and programming aspects of automation and control, and Part B: Flexible Manufacturing, which deals with strategic and organizational aspects and higher level technologies aimed at Computer integrated Manufacturing. This course involves four (4) contact hours per week of face-to-face lectures and tutorials. In addition, the course will also incorporate non-contact time in the form of assignments and laboratory work. MANF3510 carries 6 UOC.

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Each class will consist of a 1-2 hrs lecture followed by a tutorial work or assignments related to the material covered in the lecture. Details for the formal part of the course are as follows:

4hrs/week, Session 2 Part A: Flexible Manufacturing Monday 1200 – 1400 OMB 144A Part B: Process Technology Thursday 1500 - 1700 OMB 150

Course aims Key factors for success in modern manufacturing include quality, productivity, efficiency, flexibility, customer satisfaction and control over cost and logistics. Depending on the characteristics of the product and its market, an appropriate manufacturing system and key enabling technologies (such as automation) need to be selected. Part A of this course deals with common manufacturing processes and technologies, the control of these processes as well as materials handling and robotics. It includes the function and programming of programmable logic controllers (PLCs) as well as an introduction to the architecture, capabilities and programming of common micro-controllers such as the PIC series (specifically the PICAXE40X). Part B of this course deals with higher level enabling technologies, cellular manufacturing, flexible manufacturing, CAD/CAM, CAPP, CIM as well as strategic issues such as cost justification and competitive advantage. This course includes a substantial amount of laboratory work.

Part A: Process Technology The course covers the basic technology and elements used to design computerised and automated manufacturing systems. It deals with the principles of numerically controlled machine tools and their elements, from basic machines to the level of sophisticated turning and machining centers. It then covers in more detail, assisted by tutorial work, the procedure of CNC programming, industrial robots and their programming and programmable logic controllers (PLC). Topics include: Function and control of CNC machine tools Sensors and actuators in automated systems Manufacturing system performance and productivity Programming of CNC machine tools and PLCs Design and classification of industrial robots Programmable logic controllers

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Part B: Flexible Manufacturing Part B of the course builds on the knowledge of the basic elements of computerized manufacture, covered in Part A. Part B incorporates and integrates this fundamental knowledge into the design of computerised production strategies and systems. Part B will introduce some new material on process technology including CNC theory, machine vision and accuracy. However, the main focus is to present the tools, analyses and frameworks for selecting and designing computerised and automated production systems. Part B explains the fundamentals of Group Technology, as well as the technical and organizational aspects of Flexible Manufacturing Cells and Systems. Most production strategies and systems are computer enabled. Here we refer to a wide range of applications, including but not limited to the design function (both product and process), manufacturing management, product planning, quality control and machine / process control. The successful integration of a majority of these applications may be termed Computer Integrated Manufacturing or CIM. The final part covers the principles of Computer Aided Manufacture, including process planning, CAD/CAM and Computer Integrated Manufacture. The following are specific course objectives To give students a comprehensive overview of the field of computerized manufacturing and automation, including its terminology as well as major classes of technology, hardware and applications. To enable students to incorporate and integrate the fundamental knowledge of computerised manufacture into the design of computerised production strategies and systems. To enable students to understand and use the appropriate techniques and analyses for the selection, design and evaluation of computerised and automated production systems.

Student learning outcomes On completion of the course it is expected that the student will be able to: Understand and describe the essential building blocks of factory automation, including machine tools, materials handling, control, actuation and sensing devices. Distinguish between different levels of automation and the evolution of machine tools and robotics. Understand and analyse control strategies for automation technology such as CNC machine tools. Analyse the costs and benefits associated with introducing factory automation. Understand and describe the performance of automated devices, such as machine tools, in terms of cycle time, duty cycle, productivity, accuracy and repeatability.

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List and describe the major classes of industrial robots and their applications and performance characteristics. Design and write practical low-level programs for machine tools (G-code) and programmable logic controllers (ladder programming). Understand essential kinematic and dynamic considerations in the design and selection of robots. Understand the functions, internal operation and applications of programmable logic controllers (PLC). Use advanced and high-level computer aided design technology (CATIA) to design a product part and to automatically generate CNC manufacturing code. Gain valuable experience by manufacturing two designs on the School’s Colchester Tornado lathe and Deckel 5-axis machine respectively. Understand the manufacturing strategies of group technology and cellular manufacturing.

Student-centered and self-directed learning (expectations of the students) In addition to the course contact hours and assignment work, it is expected that the student will put in, on average, an additional 4 hours per week of his/her own time (including stuvac and exams). This time should be spent in revising the lecture material and further reading, completing tutorial questions, completing the assignment and revising and learning for the examinations.

Teaching strategies The subject will be presented in the form of lectures, tutorials and assignments, including laboratory work. Lecture notes and tutorial problems will be available the week prior to each lecture on WebCT. Suggested approaches to learning in the course
• • • • • •

Be present and attentive at all lectures, tutorials and practical work. Careful reading, discussion and understanding of the material presented in lectures. Additional reading on and about the material presented in lectures to broaden the knowledge base. Paying attention throughout the tutorials, and asking questions when anything is not understood. Conscientiously working through the set assignments. Learning of the lecture material in preparation for examinations.

Assessment The students are assessed by way of assignments, quizzes, tutorial submissions and examinations. Examinations and quizzes involve both calculations and descriptive material.

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Part A: Process Technology Mid-session test Assignment 1 Assignment 2 Assignment 3 End of session test Part B: Flexible Manufacturing Assignment Mid-session test Class Assessment End of session test 30% 20% 10% 40% 20% 15% 15% 10% 40%

The assessments are based to allow students to obtain an understanding of the material being presented. The mid-session test will gauge the understanding of early fundamentals of the course, while the assignments will allow the students to apply these concepts in a practical sense. The end of session examination to determine the level of understanding the student has achieved in the total course. The end of session examination will cover all material taught in both parts of the course, from week 1-13 inclusive. A standard specification is available from the School office to aid presentation of your assignments (in all courses). All submissions should have a standard School cover sheet. All submissions are expected to be neat and clearly set out. Late submissions will not be accepted unless prior dispensation has been given; i.e. see your lecturer before the due date to avoid penalty.

Academic honesty and plagiarism What is Plagiarism? Plagiarism is the presentation of the thoughts or work of another as one’s own.* Examples include:


• • •

direct duplication of the thoughts or work of another, including by copying material, ideas or concepts from a book, article, report or other written document (whether published or unpublished), composition, artwork, design, drawing, circuitry, computer program or software, web site, Internet, other electronic resource, or another person’s assignment without appropriate acknowledgement; paraphrasing another person’s work with very minor changes keeping the meaning, form and/or progression of ideas of the original; piecing together sections of the work of others into a new whole; presenting an assessment item as independent work when it has been produced in whole or part in collusion with other people, for example, another student or a tutor; and

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claiming credit for a proportion a work contributed to a group assessment item that is greater than that actually contributed.†

For the purposes of this policy, submitting an assessment item that has already been submitted for academic credit elsewhere may be considered plagiarism. Knowingly permitting your work to be copied by another student may also be considered to be plagiarism. Note that an assessment item produced in oral, not written, form, or involving live presentation, may similarly contain plagiarised material. The inclusion of the thoughts or work of another with attribution appropriate to the academic discipline does not amount to plagiarism. The Learning Centre website is main repository for resources for staff and students on plagiarism and academic honesty. These resources can be located via: www.lc.unsw.edu.au/plagiarism The Learning Centre also provides substantial educational written materials, workshops, and tutorials to aid students, for example, in:
• • •

correct referencing practices; paraphrasing, summarising, essay writing, and time management; appropriate use of, and attribution for, a range of materials including text, images, formulae and concepts.

Individual assistance is available on request from The Learning Centre. Students are also reminded that careful time management is an important part of study and one of the identified causes of plagiarism is poor time management. Students should allow sufficient time for research, drafting, and the proper referencing of sources in preparing all assessment items. * Based on that proposed to the University of Newcastle by the St James Ethics Centre.
University of Newcastle † Adapted with kind permission from the University of Melbourne. Used with kind permission from the

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Course Schedule Week
1 23/7 27/7 2 30/7 3/8 3 6/8 10/8 4 13/8 17/8 5 20/8 24/8 6 27/8 31/8 7 3/9 5-12/9 14/9 8 17/9 21/9 9 24/9 10 5/10 8/10 12/10 11 15/10 19/10 12 22/10 13 26/10 29/10 Programmable Logic Controllers 2 Assignment (student presentations) Lecture: Computer Integrated Manufacturing Programmable Logic Controllers 3 Revision Tutorials and Course Summary (EVV) (JW) (EVV) (JW) (EVV) Industrial Robotics 4 (thesis conference) Assignment (student presentations) Programmable Logic Controllers 1 Assignment (student presentations) (EVV) (JW) (EVV) (JW) Industrial Robotics 3 CAPP, FMS Costing Analysis (EVV) (JW) Industrial Robotics 2 Mid-session Break Automatic Inspection Systems (JW) (EVV) Industrial Robotics 1 Mid-session test, review of test questions (EVV) (JW) Turning and Machining Centers Flexible Manufacturing Systems 2 (SM, EVV) (JW) CNC Programming – Milling (Assign 2) Flexible Manufacturing Systems 1 (SM, EVV) (JW) CNC Programming – Turning (Assign 1) Group Technology, Flexible Manufacturing Cells (SM, EVV) (JW) NC Part Programming, CATIA Lab Group Technology (EVV) (JW) Control of Machine Tools & NC tools Computer controls – CNC, DNC, AC (EVV) (JW)

Date
20/7

Topic
Introduction to Automation & CIM (JW)

EVV = Dr Erik van Voorthuysen, JW = A/Prof Jun Wang, SM = Mr Seetha Mahadevan

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Resources for students Lecture notes will be available on WebCT.

Textbooks:
1. M.P. Groover, "Automation, Production Systems, and Computer-Integrated Manufacturing", Second Edition, Prentice Hall International 2001. Alternative but out of print: M.P. Groover and E.W. Zimmers, "CAD/CAM: Computer-Aided Design and Manufacturing", Prentice-Hall International, 1984.

REFERENCE BOOKS: 1. Y Koren, “Computer Control of Manufacturing Systems”, McGraw-Hill 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. JD Otter, “Programmable Logic Controllers: Operation, Interfacing and Programming”, Prentice-Hall CH Chang and MA Melkanoff, “NC Machine Programming and Software Design”, Prentice-Hall JJ Childs, “Principles of Numerical Control”, International Press GM Mair, “Industrial Robotics”, Prentice Hall, 1988 T.C. Chang, R.A. Wysk, HP Wang, "Computer-Aided Manufacturing", Prentice-Hall International, 1998 A.W. Scheer, "CIM: computer integrated manufacturing : towards the factory of the future ", Springer-Verlag, 1994 (also 1991). A.L. Foston, C.L. Smith, T. Au, Manufacturing" Prentice-Hall, 1991. "Fundamentals of Computer-Integrated

D. Kochan, "CAM, Developments in Computer-Integrated Manufacturing", SpringerVerlag, 1986. T.C. Chang, R.A. Wysk, "An Introduction to Automated Process Planning Systems", Prentice-Hall, 1985. W.W. Luggen, "Flexible Manufacturing Cells and Systems" Prentice-Hall, 1991. R.A. Maleki, "Flexible Manufacturing Systems: the technology and management", Prentice-Hall, 1991. M.P. Groover, "Automation, Production Manufacturing", Prentice-Hall, 1987. Systems, and Computer Integrated

Students seeking resources can also obtain assistance from the UNSW Library. One starting point for assistance is: info.library.unsw.edu.au/web/services/services.html Course evaluation and development Continuing student feedback on the course is important in terms of continuous improvement. Feedback is gathered through the formal Course and Teaching Evaluation and Improvement (CATEI) Process (usually towards the end of the course) as well as through informal processes during the course. You are welcome to submit suggestions, benefits and concerns throughout the delivery of the course. Page 9 of 10

Administrative Matters


Information about each of the following matters is presented in a handout available from the School office or the School of Mechanical and Manufacturing Engineering Website:- www.mech.unsw.edu.au. It is essential that you obtain a copy, read it carefully and become familiar with the information, as it applies to this course and to each of the other courses in which you are enrolled. Expectations of students (including attendance at lectures and tutorials/laboratory classes/seminars; and computer use, for example, in the use of email and online discussion forums) Academic honesty (including misconduct, plagiarism) Procedures for submission of assignments Examination procedures and advice concerning illness or misadventure Student support services Occupational health & safety (refer to www.hr.unsw.edu.au/ohswc/ohs/ohs_home.html )

Additional Information
Students who have a disability that requires some adjustment in their teaching or learning environment are encouraged to discuss their study needs with the course convenor prior to, or at the commencement of, their course, or with the Equity Officer (Disability) in the EADU 9385 4734. Issues to be discussed may include access to materials, signers or note-takers, the provision of services and additional exam and assessment arrangements. Early notification is essential to enable any necessary adjustments to be made. (Also refer to www.studentequity.unsw.edu.au/content/default.cfm?ss=0 and www.secretariat.unsw.edu.au/acboardcom/minutes/coe/disabilityguidelines.pdf)

Dr Erik Jan van Voorthuysen July 2009

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