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PLTW CIM Finals

Terms in this set (170)

AGV
Automated Guided Vehicle. A computer-controlled system that uses pallets and other interface equipment to transport work pieces to NC machine tools and other equipment in a flexible manufacturing system.
ASRS
Automated Storage/Retrieval System. A system that moves material either vertically or horizontally between a storage compartment and a transfer station or within a process.
Automation
The use of technology to ease human labor or extend the mental or physical capabilities of humans.
CAD
Computer Aided Design. The use of computers in converting the initial idea for a product into a detailed engineering design.
CAM
Computer Aided Manufacturing. The use of computers in converting engineering designs into finished products.
CIM
Computer Integrated Manufacturing. A company-wide management philosophy for planning, integration, and implementation of automation.
CNC
Computer Numerical Control. A numerical control method in which one computer is linked with one machine tool to perform NC functions.
Dependent Variable
A variable whose value depends on the value of another variable.
FMS
Flexible Manufacturing System. A flexible group of CNC machine tools that are highly automated and integrated capable of producing a family of parts.
Independent Variable
The controlling factor between variables, on which the value of the other variable depends.
JIT
Just in Time. A system that eliminates work-in-process (WIP) inventory by scheduling arrival of parts and assemblies for an operation at the time they are needed and not before.
Kaizen
The continuous improvement that involves all participants.
Lean Manufacturing
The systematic elimination of waste.
Manufacturing
A series of interrelated activities and operations that involve product design and the planning, producing, materials control, quality assurance, management, and marketing of that product.
PLC
Programmable Logic Controller. A solid-state control system that has a user-programmable memory to store instructions.
Robotics
The science and technology of robots, their design, manufacture, and application.
Six Sigma
A highly structured methodology that incorporates techniques and tools for eliminating defects and variability from a process. To achieve Six Sigma, a process must not produce more than 3.4 defects per million opportunities.
WIP
Work-in-Process. Materials or parts that are actually being processed into final products.
Engineering notebook
• An engineering notebook is a book in which an engineer will formally document, in chronological order, all of his/her work that is associated with a specific design project.
• An engineering notebook is recognized as a legal document that is used in patent activities to...
• All work is in pen.
• Date each entry
• Inserted items are permanently attached
• Glue is preferred
• No loose leaf items
• Sign your name so that it extends across both the notebook page and the inserted document.
• Markers that bleed through the paper are not used.
• Pages are sequentially numbered in ink on the top outside edge.
• Notebooks are bound.
• Entries begin at the top of the page, working left-to-right and top-to-bottom
• Do not leave blank space. If there is extra space, draw an X or a line across it and sign
• If you make a mistake, draw a line through it, enter the correct information, and initial the change.
• Never erase or remove anything.
Automatic Storage and Retrieval System (ASRS)
Moves material vertically or horizontally between storage compartment and transfer station or within a process
Automated Guided Vehicles (AGV)
Computer-controlled system using pallets to transport workpieces to NC machine tools and other equipment in a flexible manufacturing system
Artificial Intelligence (AI)
Machines learn from experience; Knowledge used to problem solve
Computer Integrated Manufacturing (CIM)
Company-wide management philosophy for planning, integration, and implementation of automation. CIM was promoted by machine tool manufacturers in the 1980s and the Society for Manufacturing Engineers. CIM uses computers to coordinate all aspects of manufacturing, including engineering, planning, machine processes, financial issues, and marketing.
Manufacturing Enterprise Wheel
1. Customer-centered
2. People and teamwork
3. Shared knowledge
4. Key processes
5. Resources and responsibilities
6. Infrastructure
What is Kaizen?
Japanese word for "improvement";Based on continuous improvement by everyone
Flexible Manufacturing Systems (FMS)
Adapts efficiently to changing need; Possibly increase productivity by 50%
What is Six Sigma?
based on statistical analysis to maximize production and minimize defects;Indicates measure of quality for near perfection;Produces fewer than 3.4 defects per million opportunities;Identifies and corrects causes of defects; Utilizes the five "whys" to uncover root cause
Just In Time Manufacturing (JIT)
Objective is to eliminate waste; Capable of producing mixed products; Utilizes cross-trained workers
Toyota Production System (TPS)
Applied to automotive manufacturing; Competes with mass production; Employs lean production strategy
Rapid Prototyping
Prototype made directly from a computer model; Several technologies (Stereolithography ;3D Printing; Selective Laser Sintering;Fused Deposition Modeling)
Workcell
Manufacturing resources arranged into a group
Work Envelope
Range of motion of a robot or machine; Degrees of freedom are individual movements
What are the perspectives presented in the enterprise wheel?
Customer-centered, People and teamwork, Shared knowledge, Key processes, Resources and responsibilities, and Infrastructure
Why is the customer the center of the enterprise wheel?
Shows where the focus should be and that the end results should contribute something of value to the customer
What three elements immediately contribute to the customer's value?
People and Teamwork in Organization (P-T-O)
What material is the most valuable today?
Information is the dominant material today
What are the three process categories of the enterprise wheel?
1) Product/process definition: How
2) Manufacturing: Planning reality
3) Customer Support: Meeting customer needs
In the past manufacturing was regionally focused. Where does the geographical boundary stop? How does that impact the decisions made in manufacturing?
Geographical boundary does not exist in global economy.
Decisions now must account for global competition for goods and services. Decisions also must consider global sources of raw goods and labor.
What are some examples of a manufacturing input?
Capital, knowledge, materials
What external factors should a manufacturer consider?
1) Global competition
2) Raw materials, energy, transportation, research institutions, workforce, etc.
What major changes have manufacturers taken to make resource transformation more efficient?
World-class manufacturers organize, integrate, and invest their resources to achieve new levels of customer satisfaction.
Closed Loop
A system that uses feedback from the output to control the input.
Control System
A system in which one or more outputs are forced to change in a desired manner as time progresses. A control system is a device or set of devices that are coordinated to execute a planned set of actions.
Decision Block
The diamond-shaped block used for YES/NO questions. These blocks have two outputs: 1 (for yes) and 2 (for no).
Flow Chart
A graphical representation of the progress of a system for the definition, analysis, or solution of a data-processing or manufacturing problem.
Flow Lines
The connecting line or arrow between symbols on a flow chart.
Input/Output Block
A function that makes information available for processing or that records processed information.
Interface
The connection between the computer and the control system.
Iterative
Process flow that may repeat or skip steps until some condition is satisfied.
Open Loop
A control system that has no means for comparing the output with input for control purposes. An open-loop system often requires human intervention.
Potentiometer
A variable resistor.
Process Block
Part of a flowchart that tells the program what action to take.
Pseudocode
Describe task in short phrases as simple tasks without concern for syntax
Schematic
A diagram that uses special symbols in place of actual pictures. In a wiring schematic, for example, a squiggly line is used to represent a resistor.
Sequential
Occurring in regular succession without gaps.
Simulation
A representation of a situation or problem with a similar but simpler model or a more easily manipulated model in order to determine experimental results.
Open Loop Control System
- Sprinkler System
• No direct connection between the output of the system and the conditions can be controlled
• Can not compensate for unexpected forces
Closed Loop Control System
- Refrigerator Light Sensor
• Provides the system with operation feedback
• Can compensate for conditional changes
- Thermostat
• Heating or cooling equipment is actuated based on temperature sensed
Motor Speed
affected by battery power
If battery is fully charged, then motors move quickly.
If battery is low, then motors move slowly.
Device or robot will not move consistently as the battery power drains.
Servos
Rotates between 0 and 120 degrees
Motor is set to a "power value"
Servo is set to a "position value"
-127 = 0 degrees, 0 = 60 degrees, 127 = 120 degrees, etc.
Potentiometer
Analog sensor
Measures rotation of a shaft between 0 and ~265 degrees
Cortex returns values 0 - ~4095
Optical Shaft Encoder
- Inner shaft spins as the encoder measures angle of revolution
- The distance which a robot moves can be controlled by monitoring the angle at which the wheels attached to the shaft encoder spin
Ultrasonic Range Finder
- Digital sensor returns distance values between 0 and 255 inches or the equivalent centimeters or millimeters
- Ultrasonic Range Finder detects objects in a "cone" field of view
- Sensor detects object distance from the center of the sensor
- Sensor distance calculations based on sound waves
- Objects that may not be detectable include soft objects that absorb sound, sharp objects that deflect sound, etc.
Digital sensor
Pressed or Released (1 = Pressed and 0 = Released)
Caution : Bouncing may occur when sensor is pressed or released; Value may bounce between 0 and 1 very briefly and quickly ; Very brief wait can be inserted to reduce bouncing effect
BEHAVIOR BASED PROGRAMMING
• A behavior is anything your robot does
- Example: Turn on a single motor or servo
• Complex behaviors are broken down into simple behaviors, which are broken down into basic behaviors
Three main types of behavior
- Complex behavior
- Simple behavior
- Basic behavior
Complex behavior
Robot performs a complex task
Example: automate fan control
Simple behavior
Robot performs a simple task
Example: fan stops when sensor is activated
Basic behavior
Single command to a robot
Example: start a motor
PSEUDOCODE
• Break down behaviors into individual actions
• Do not be concerned about syntax or which commands will be used with ROBOTC
• Simply describe them in short phrases
• Example
- Turn a motor on for three seconds
- Follow a line until it runs into a wall
Fixed Costs
A periodic cost that remains (more or less) unchanged irrespective of the output level or sales revenue of a firm. Includes rent, lighting, and heating.
Non-Value Added (NVA)
Typically generates a zero or negative return on the investment of resources and usually can be eliminated without impairing a process.
Overhead
The general, fixed cost of running a business, such as rent, lighting, and heating expenses, which cannot be charged or attributed to a specific product or part of the work operation.
Profit
The monetary surplus left to a producer or employer after deducting wages, rent, cost of raw materials, etc.
Raw Materials
Basic substance in its natural, modified, or semi-processed state, used as an input to a production process for subsequent modification or transformation into a finished good.
Value-Added
The difference between the price at which goods are sold and the cost of the materials used to make them.
Variable Cost
Periodic cost that varies, more or less, in step with the output or the sales revenue of a firm. Such costs include raw material, energy usage, labor (wages), distribution costs, etc.
Two Types of Cost
1. Fixed
2. Variable
Fixed
Unchanging
- Rent, heat, light, etc
Variable
Changes with production rate
- Labor, raw material, energy, etc.
Factors Affecting Costs
- Material goods
- Labor rate (wage)
- Time (urgency)
- Shipping
Value-added tasks
can be defined as the difference between the price at which goods are sold and the cost of the materials used to make them; they are easily quantifiable.
Non-Value-added tasks
does not contribute to that for which the customer pays; while they can usually be eliminated without impairing a process, some of the "non-value" added tasks are necessary and should be performed to make sure they don't slow-down production.
Competent
Properly or sufficiently qualified; capable or efficient.
Defective
Imperfect in form or function.
Design Flaws
An imperfection in an object or machine.
Durability
The quality of equipment or goods of continuing to be useful after an extended period of time and usage.
Economics
Dealing with production, distribution, and consumption of products or wealth.
Ethics
The standards for ethical or moral behavior of a particular group. In our case it will be the Engineering Code of Ethics.
Functionality
The ability of a product to do the job for which it was intended.
Morality
Rules relating to principles of right and wrong in behavior.
Purpose
What one intends to do or bring about.
Quality Control
The process of making sure that products or services meet consistently high standards.
Design process
A systematic problem-solving strategy, with criteria and constraints, used to develop many possible solutions to solve or satisfy human needs or wants and to narrow down the possible solutions to one final choice.
Define the Problem
• Identify a problem
• Validate the problem
• Who says it is a problem?
• Needs and wants
• Prior solutions
• Justify the problem
• Is the problem worth solving?
• Create design requirements (specifications)
• Criteria and constraints
• Design Brief: A written plan that identifies a problem to be solved, its criteria, and its constraints.
• Used to encourage thinking of all aspects of a problem before attempting a solution.
Design Brief
A written plan that identifies a problem to be solved, its criteria, and its constraints.
Generate Concepts
• Research
• Brainstorm possible solutions
• Consider additional design goals
• Apply STEM principles
• Select an approach
• Decision Matrix A tool used to compare design solutions against one another, using specific criteria.
Decision Matrix
A tool used to compare design solutions against one another, using specific criteria.
Develop a Solution
• Create detailed design solution
• Justify the solution path
• Technical Drawings: Drawings that provide technical information necessary to produce a product. (material, size, shape assembly, if necessary)
Technical Drawings
Drawings that provide technical information necessary to produce a product. (material, size, shape assembly, if necessary)
Construct and Test a Prototype
• Plan prototype testing
• Performance; Usability; Durability
• Test prototype ;collect test data; analyze test data
• Test Report
Evaluate the Solution
• Evaluate solution effectiveness
• Reflect on design
• Recommend improvements
• Optimize/Redesign the solution
• [Return to prior design process steps, if necessary]
• Revise design documents
• Project Recommendations
Present the Solution
• Document the project Project Portfolio
• Communicate the project Formal Presentation
The Design Process Steps
1. Define the Problem
2. Generate Concepts
3. Develop a Solution
4. Construct and Test a Prototype
5. Evaluate the Solution
6. Present the Solution
Factors of Design
• Economy
• Safety
• Functionality
• Ethics
Economy
• Manufacturers of some copiers have changed from metal parts to plastic parts because they are cheaper.
• When a product uses a part multiple times, it is cheaper if the parts are all the same size. For example, when constructing furniture, using the same size screw for all connections is cheaper than using varying sizes.
• A worker with experience and education may provide better quality work, but may also have a higher salary. In addition, automation can reduce the amount of laborers needed to manufacture a product.
Safety
• Fast-food restaurants offer toys in their meals for children. They must also offer an alternative to very young children (under the age of three) due to the small parts that could become choke hazards.
• Environment appropriateness includes water resistance, electrical compatibility, interference of other obstacles, etc. For example, the cup holders in a car should be placed an appropriate distance from the radio so that they do not interfere with the radio's operation. A clock that claims to be pool-side implies that it may be weather-proof when in fact it may only be weather-resistant.
Functionality
life span,durability
• The toy will work - about three times. Then the inexpensive parts begin to show wear and tear. The seal on the canister breaks, the air tube pops out, or the rocket holder breaks off. However, the cost was less than a dollar, and the toy would last for a birthday party.
Ethics (Factor)
Environmentally friendly and safe; Honest; Competent; Supportive
Mass properties
Volume
Surface Area
Density
Mass
Volume
How much raw material must be purchased?
Surface Area
How much might it cost to coat/paint the product?
Density
How strong is the material and what machines are needed to process it?
Mass
Weight determines how much it will cost to transport the material.
CHOOSING MATERIALS
• Strength
• Durability
• Cost
• Availability
• Environmental impact
• Finishing costs
• Shipping and transport
3D Printing
1) Rapid prototyping processes use systems that are low cost, small in size, fast, easy to use, and often suitable for an office environment. 2) Collective term for all rapid prototyping activities.
ABS
Acrylonitrile Butadiene Styrene. A thermoplastic with rubber added for high toughness.
Additive Process
Fabrication of a part by adding material.
Assembling
The process of putting a product together out of separate parts.
Build Time
Length of time for the physical construction of a rapid prototype, excluding preparation and post-processing time. Also known as run time.
Casting
The process in which a solid material is made into a liquid, poured into a mold, and allowed to harden in the shape of the mold.
Ceramics
Any of various hard, brittle, heat-resistant, and corrosion-resistant materials made by shaping and then firing a nonmetallic mineral, such as clay, at a high temperature.
Concept Model
Physical model intended primarily for design review and not meant to be sufficiently accurate or durable for full functional or physical testing.
Conditioning Process
Process in which the properties of a material are changed using mechanical, thermal, or chemical means.
Die Casting
Similar to permanent mold casting except that the metal is injected into the mold under high pressure.
Electrical Discharge Machining (EDM)
A process by which an electrode spark is used to erode small amounts of material from a work piece.
Electrochemical Machining (ECM)
A process in which a stream of electrolyte (typically salt water) is pumped at high pressure through a gap between the positively charged work and the negatively charged tool (electrode).
Exhaustible Resources
Resources of which there are a limited supply.
Finishing Process
Machining a surface to size with a fine feed produced in a lathe, milling machine, or grinder.
Forging
A process by which metal is heated and shaped by plastic deformation by suitably applying compressive force.
Fused Deposit Modelling
Rapid prototyping process in which a filament of wax or polymer is extruded onto the existing part surface from a workhead to complete each new layer.
Forming Process
A process that changes the size and shape of a material by a combination of force and a shaped form.
Grinding
An operation that removes material by rotating an abrasive wheel or belt against the work.
Industrial Material
Material that has been changed from raw material so that it is ready to be used in manufacturing. Also referred to as standard stock.
Injection Molding
A process during which plastic is heated in a machine and forced into a cavity by a screw or ram. The material solidifies and is then ejected.
Laminated Object Manufacturing (LOM)
Rapid prototyping process in which sheet stock is cut and bonded into a stack.
Metals
Any of a category of electropositive elements that usually have a shiny surface, are generally good conductors of heat and electricity, and can be melted or fused, hammered into thin sheets, or drawn into wires.
Molding
A manufacturing process in which the industrial material is made into a liquid. The liquid is then introduced (poured or forced) into a prepared mold of proper design.
Plastics
Materials that undergo a permanent change in shape or size when subjected to a particular amount of stress.
Photopolymer
Liquid resin material that utilizes light (visible or ultra-violet) as a catalyst to initiate polymerization, in which the material cross-links and solidifies. This technique is used by various rapid prototyping technologies.
Post Processing
A common practice that includes clean up and finishing procedures on models after they are removed from the rapid prototyping machine. It may also include mechanical or chemical removal of support structures, powder removal, and surface finishing.
Primary Processing
The first step in manufacturing where raw materials are processed into a usable form for further manufacture.
Prototype
A full-scale working model used to test a design concept by making actual observations and necessary adjustments.
Rapid Prototyping (RP)
Computer-controlled additive fabrication. Commonly used synonyms for RP are three-dimensional printing, additive fabrication, freeform fabrication, solid freeform fabrication, and stereolithography. Note that most of these synonyms are imprecise.
What are Raw Materials?
Basic substance in its natural, modified, or semi-processed state, used as an input to a production process for subsequent modification or transformation into a finished good.
Renewable Resources
Biological materials that can be replaced.
Sand Casting
A process of pressing moist sand around a pattern to make a mold. The pattern is removed, leaving a cavity in the sand. The cavity is the mold that will be filled with liquid metal. The result will be a casting that is identical in shape to the original pattern.
Separating
A process that removes excess material to change the size, shape, or surface.
Selective Laser Sintering (SLSL)
A rapid prototyping process that used a moving laser beam to sinter heat-fusible powders one layer at a time.
Stereolithography (SLA)
A rapid prototyping process that fabricates a part layer-wise by hardening a photopolymer with a guided laser beam.
Subtractive Process
Processes that remove material to change the size, shape, or surface of a part. There are two groups of separating processes: machining and shearing.
Vacuum Forming
Process to heat a thermoplastic sheet until it softens and then force the hot and pliable material against the contours of a mold using vacuum pressure.
Water Jet Cutting
A process that uses a high speed jet of water emitted from a nozzle under high pressure (10,000-60,000 psi or greater). The advantage of water jet cutting is that it does not create a burr and it is a low temperature process.
Prototype
• A full-scale working model used to test and improve a design concept by making actual observations and necessary adjustments
• Prototypes can be produced by hand or machine
• Hand-made prototypes come in many forms
What is Rapid Prototyping?
• Computer-controlled additive fabrication.
• Family of fabrication methods to make engineering prototypes in minimum possible time based on a CAD model of the item
• The software takes a model and slices it into thin sections. Similar to a CT scan of the brain; The software creates one slice at a time, like stacking a deck of playing cards.
3d printing
• Rapid prototyping process that builds a part by ejecting adhesive bonding material onto successive layers of powders.
• Note that this term is often used to describe all rapid prototyping processes.
FUSED DEPOSITION MODELING (FDM)
• Rapid prototyping process in which a filament of wax or polymer is extruded onto the existing part surface from a workhead to complete each new layer.
STEREOLITHOGRAPHY
• A rapid prototyping process that fabricates a part layer-wise by hardening a photopolymer with a guided laser beam
SELECTIVE LASER SINTERING
• A rapid prototyping process that used a moving laser beam to sinter heat-fusible powders one layer at a time.
LAMINATED OBJECT MANUFACTURING
• Rapid prototyping process in which sheet stock is cut and bonded into a stack.
Manufacturing Processes
• Primary Processing
• Secondary Processing
What is Primary Processing?
- Raw materials to industrial materials/standard stock
• Trees processed into lumber
• Ore- processed into metal bar stock
- Raw materials are renewable( biological- trees, cotton, animal products) or exhaustible (can't be replaced - metal ore, natural gas, coal)
What is Secondary Processing?
- Create final products from primary product
• Lumber processed into furniture
• Metal bar into - metal step ladder
- Processes include: casting , molding, separating/joining, conditioning, assembling & finishing
Input
Put into a system in order to receive outputs and achieve goals - People, natural resources, capital, finance, knowledge, energy
Process
Where the actual work is done - Transformation processes; management processes.
Transformation Processes
Deal directly with inputs. Use resources to create desired outputs
Management Processes
Used to ensure the effective use of resources. All actions ensure that the transformation acts are efficient andappropriate.
Output
Desired Outputs - May be manufactured products or constructed structures. Other outputs include scrap, pollution, noise, fumes, etc.
Feedback
A system that can use its own information to control itself. If measured output is not what is expected, corrective actions are implemented.
Example: Thermostat - When the temperature is high enough in a room, the thermostat controls the heating and cooling systems in order to maintain the desired results.
MATERIAL PROPERTIES
Mechanical (compression, tension, etc.)
Physical (size, density, etc.)
Thermal (melting and freezing point, etc.)
Chemical (the ability to resist chemical change, such as corrosion)
Electrical/magnetic (conductivity, resistivity, permeability)
Optical (opacity and color)
Acoustical (absorb, transmit, and reflect sound
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