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Use of computers in manufacturing processes
Use of computers in manufacturing processes
Computers are the foundation of all computerised machining, they are much more efficient and accurate compared to manual machining. They simulate the process that they would need to take for that specific machine (additive or subtractive) and follow that procedure to get the outcome that was determined by the program.
Additive manufacturing
Additive manufacturing
Additive manufacturing machines such as 3D printers have a CPU that converts G-code into movements. To make G-code manufacturers input a 3d model into the 3d printers software (or alternatives). CAM software controls all the details about the model and can be changed by the manufacturer to suit their needs, some of the parameters that can be changed include: fill percentage, use of supports or the size of the model. Fill percentage is very important for structural integrity and the CAM software uses the percentage that the manufacturer feeds into it to calculate the best structure for the interior of the object. The computer does these calculations to find where the tool has to move then automaticly converts this information into G-code which the language that most 3D printers (and some other manufacturing tools) use. The 3d printer monitors is temperature to maintane a constant temperature to melt the filliment while its . Its near impossible to use additive manufacturing without the use of a computer, it makes things possible that could not physically be made with high accuracy like the machine does it. Using computer aided machines makes the dimensions of a part much more precise.
Automated G-code, 1000s of lines long with careful geometry, feed calculations, temperature monitoring
Subtractive manufacturing
Subtractive manufacturing
Although subtractive manufacturing can be done manually, using machines is much faster and more accurate. The CAM software can calculate the tool path and simulate what the machine will do to make sure there aren't collisions, when the computer predicts that nothing will go wrong it will navigate the tool bit to cut away material into the desired shape with very high accuracy. This gives the manufacturer much more freedom in there designs with the use of 5 axis arms that the machine can quickly navigate with CNC. Using computer processes means each part will be much more uniform and precise compared to workers because computers don't have human error
When machining numerous parts or complicated geometry, doing this using computing allows for far greater production rates due to the machine not needing breaks, more uniformity, and accurately and consistently following complex toolpaths at higher speeds than what is possible manually.
Computer numerical control (CNC)
Computer numerical control (CNC)
Computer numerical code
6 axis machine
CNC is a string of code that is used to control certain aspects of a machine, a lot of CAD software can calculate the movements needed for a
3, 4, 5 axis arm - Machines don't have as much range of motion that humans have so they have to simulate joints by moving and rotating the arm and bay to access all parts of a part. The more axis's a machine has the more options the manufacturer has to machine a part, this could mean it can be run in one go instead of multiple runs where the manufacturer has to manually turn the part. A 3 axis machine can move in the XYZ directions. A 4 axis machine can mace in the XYZ directions in addition to rotating in the X axis. A 5 axis machine can do what a 4 axis machine can do but it can also rotate in the Y axis.
Milling machine - these machines remove material using rotating cutters, the computer controls the arm of the machine to cut away materials in places that where set up by the manufacturer. The user has the option to simulate the tooling process on the computer to make sure the mill is the right tool for that job.
Turning machine - This type of machine spins the material around at high speeds and cuts away at it with a linear cutter, this is used to make a cylindrical shape or other forms that resemble a cylinder. originally these machines where controlled by workers but with CNC the machines can follow the program to get results much more accurate and refined than a human could.
Machining centres - this machines is much more advanced than basic machines as they can perform a variety of machining processes. The tool head is automatically chosen from the tool magazine to make the machine work without the manufacturer making the decision to change the tool.
Welding fabrication machines - This is a machine designed to weld material together. Where normal welding would need a very skilled craftsman for accurate jobs the machine can follow a set process to more reliably and accurately weld the material in the designated way. It ensures that the weld will be evenly distributed across the materials.
All of these machines can be simulated in the CAD/CAM design space allowing the manufacturer to chose what machine could make the product most efficiently and if any machine would have any problems and couldn't make the product. CNC programs the machines to follow tool paths at a speed that can be controlled by the manufacturer meaning the machines output of parts and precision can be controlled easily. These machines are fully automated to follow tool paths and store the data they collect when machining.
Sources
Sources
https://boruimc.com/3-axis-vs-5-axis-cnc-machines/
https://www.3erp.com/blog/milling-machine/
Robotics
Robotics
Robotics is a sector of science and engineering dedicated to the design, creation and use of robots. robots are a substitute for human, they work at a much greater efficiency and accuracy and it means humans don't have to do the very dangerous work. This is a video of a production line where robot arms are using high power spot welders at a much faster rate than workers could. Although the cost to start up a robotic production line is exedingly high, in the long run the amount of money saved from not having to hire workers make it more profitable in the long run.
Another advantage of using robots over workers is that they dont feel fatigue when working non stop, workers will have to take brakes regularly when working on a mass prodcution line but robots could would 24hr a day without slowing down or losing accuracy. Robots that run on the same code everytime will rpoduce results the exact same, this level of precision can not be seen with workers - it is very rare that two products will be the exact same when made by workers. In addition, robots can lift alot more so can carry heavier machines, this gives the manufacturers alot more freedom and movement with tools that would normally be stationary.
System control
System control
Programable logic controllers (PLC) are used to control systems with little to no manual interference and are generally fine tuned for there specific application. PLC's are made up of modules, some of these are: the input modules that are the physical connectors between the plc and the outside world, the CPU hold the program that decides what outputs are required by applying rules the signals, the output model provides the signal the the device that it controls
Electrical system - Electrical control systems are wires that connect machines together to control the distribution of electricity. They are used in production lines
Hydraulic system - hydraulic systems use liquid to create pressure in a system to control switches. As liquid can be compressed it can produce a much higher load than pneumatic systems
Pneumatic system - similar to hydraulic this system uses pressure to turn switches except it uses gas instead of liquid, it is better for lighter loads because gas is compressible so cant produce as high a load.
Using these systems to lift things is a lot safer than getting workers to move heavy loads because there is always the risk of dropping it or injuring someone.
PLC automatically control data input and output allowing computer systems to make decisions and make predictions on production rate, and monitor resources.
Using PLCs has many advantages: the connection between inputs and outputs are digital and not lots of physical wires making it compact, they are easy to reprogram, faults are easier to find and fix in a PLC, you can use the same program in multiple PLC units, they are much smaller than relay banks.
Computer aided process planning planning (CAPP)
Computer aided process planning planning (CAPP)
CAPP is the use of computer programs and software to create and map out a plan to manufacture a given part, it can assist manufacturers make the plan or completely automate the process. This improve productivity, accuracy and the consistency of plans; it also means that the process planner doesn't need to take as much time from each plan
First the manufacturer inputs the design from the CAD software and any rules that the CAPP software should conform the the CAPP software determines what manufacturing operations need to be used on the materials then plans the sequence that the part will be manufactured. It will output the plan along with the estimate of how long the process will take to run the part.
Some other sectors of CAPP are:
Production planning - The software creates a detailed process plan and keep track of this information to use as a reference to create a forecast of future demand so the manufacturer can create the predicted needed supply and not waste any parts by producing too much.
Resource management - The system could keep track of material usage and stock levels so it can automatically order more of the needed material before the stock runs out. This optimisation ensure the process will be running constantly to produce the maximum output. Workers and machines are also monitored and managed to ensure all resources are used to there full potential.
Data and Database management
Data and Database management
The computer can aid with data analysis tracking the quality and quantity of product to create a dashboard for engineers to easily find areas in the company that can be improved upon to increase profit.
Automated ordering system - This system works when consumers order electronically. The system is directly links the online store to the production line and feeds it data about orders, this means the production line knows exactly what has been ordered and can produce only the items that are needed. Much like just in time production, this means a very small amount of product is wasted saving the company materials and therefore money. The system also keeps data on the amount of stock for each material so when something starts to run out it can order more before that happens ensuring they don't by more materials than needed meaning that they profit more.
Production and supplier management - A feature of data management grants the ability to organise and plan autonomously. Using computers to monitor quality is much faster; it can quickly check parts to make sure they fit tolerances accurately and reliably. It can determine what resources are needed and schedule activities to meet demand. It works to do lean manufacturing, which is a practice to minimize waste, improve efficiency, and enhance productivity.
Supplier management involves identifying and selecting suppliers that are good quality and cost effective and negotiate these prices for more favourable terms and conditions to ensure mutual benefit. It monitors these supplies to ensure there performance is consistent with things such as on time delivery, quality, and responsiveness. Finally, it helps build strong relationship with suppliers by collaborating on improvements.
Effectively managing both production and supply can improve company efficiency and decreasing the overall cost of production making this essential for making profit.
Sources: https://www.youtube.com/watch?v=uOtdWHMKhnw
Advantages of using computers in manufacturing
Advantages of using computers in manufacturing
Computers have made a vast difference in workflow in all aspects of engineering. From design to manufacturing most aspects have improved in efficiency, quality, and reliability. Manufacturing industries implements computers into the majority of production lines to automate the machines meaning less workers have to do manual labour making manufacturers lives much less physically straining so they can focus on bettering production and coming up with new ideas.
Using computers in manufacturing provides many benefits that greatly increase production speed and operating efficiency. Advanced computers can use previous data to use and compare to the current system to find places that can be streamlined to reduce waste and optimise resource utilisation. AI could also help with process planning, it uses old records of production plans to generate a new one using what worked well in the records. Production speed has increased drastically since computers have been used in manufacturing, machines controlled by computers can do manual labour without much manual input giving manufacturers the option to focus on other (possible more important) things. With a computer controlling the tool they work much faster and to higher degrees of accuracy massively speeding up the production of parts. By combining tools quality checking machines and computers quality checking becomes automated, this means parts produced in mass can still be quality checked to ensure everything is up to standard.
Using computers to come up with production methods gives the user much more options for tools that would not be usable by hand, tools such as 3D printers where never seen before computers because It would take too much time and accuracy to make layers so perfect. This gives designers much more flexibility when designing because things like hollow parts where not possible before - AI can be used to generate a structure for the part with maximum material and weight efficiency using generative design, the manufacturer sets parameters such as loads and the safety factor and the computer will generate the rest. This is useful for industries like the automotive industry where every bit of weight is essential.
Connecting a machine to a system with computers would mean that standard parts could be uploaded onto the machine to produce that part and keep it up to the standards previously set. Process plans can be reused to produce similar process plans, to speed up the process, or old processes could be run again with the exact same tolerances and standards without any further work. This cuts down the length of the design cycle by reusing and recycling old plans and also allows the making of standard parts. It also allows for quick changes of unforeseen mistakes. Its always probable that there are mistakes and computers help keep the time fixing them to a minimum, this can be seen with tools like the timeline in Fusion 360 that lets the user make changes to old features - it automatically updates all drawing that and other files that are effected by the changes to save even more time.
Computers help manufacturers analyse there model and run simulations on a model to find out the tool path, this tool path is then converted to a language the machine understands and the machine carries out the instructions. This integration of CAD and CAM makes computers much more efficient than any team of workers, it also frees up people to do other tasks while the simulation runs.
Using software on computers means that less skilled workers can still do work using the computer for assistance. Finding highly skilled workers is very hard and costly to the company so hiring less skilled workers and apprentices would cut down overall cost and increase profit, it could also help produce the company's own skilled employees and make engineering and manufacturing more accessible and beginner friendly.
Using computers would mean all the movements, amount of parts produced, and other things like the amount of energy used could be logged and stored as data so the company has accurate records for later use. I used a software called power bi on a computer to make a dashboard for Ford. This dashboard shows data collected by the computers and makes it easy to read and show other people such as investors. It also grants the ability to easily asses what parts are produced the most or use the most money so changes can be made to improve the business.
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