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Summary
Summary
Divided into four parts, Programmable Automation focuses on programmable automation technologies used in industry. Comprehensive yet concise, this unique textbook provides a solid foundation of analytical techniques to justify automation and the knowledge and instruction of how to program computer numerical controlled (CNC) equipment, industrial robots and programmable logic controllers (PLC). Through a very practical approach, readers will learn specific programming languages related to each technology including G code and ladder logic. And it is sure to be found useful by electrical, industrial, mechanical and/or manufacturing engineering technology undergraduate students, in addition to anyone in industry interested in learning about programmable automation and developing the corresponding programming skills. Each chapter begins with an overview of chapter material with emphasis on desired outcomes and concludes with a summary, questions, and problems where appropriate. Presents explicit skills and methodologies to aid in the programming process. Features a good use of examples with numerous illustrations. Uses computer simulation and actual lab equipment extensively in learning activities.
Author Notes
Dan Kandray is a registered professional engineer in the State of Ohio and currently is Assistant Professor at The University of Akron, teaching in the Manufacturing and Mechanical Engineering Technology programs. He has a B. S. in Mechanical Engineering from Youngstown State University and M. S. in Technology from Kent State University. Professor Kandray has long provided consulting services to industry, including machine, part, and tooling design. He has over 20 years experience as a Mechanical Engineer, much of this time in the rubber and plastics industry. The products he has designed range from submarine machinery to helicopter bearings to complete automated machines.
Table of Contents
| Preface | p. xiii |
| Chapter 1 Introduction to Programmable Automation | p. 1 |
| 1.2 The Manufacturing Process | p. 2 |
| 1.3 Automation | p. 11 |
| 1.4 Manufacturing Performance Measures | p. 20 |
| 1.5 Benefits of Automation | p. 22 |
| 1.6 Automation Strategies | p. 24 |
| 1.7 Summary | p. 26 |
| 1.8 Key Words | p. 28 |
| 1.9 Review Questions | p. 28 |
| 1.10 Bibliography | p. 29 |
| Chapter 2 Automation Justification and Productivity Concepts | p. 31 |
| 2.1 Automation Justification and Productivity | p. 32 |
| 2.2 Productivity Calculations | p. 32 |
| 2.3 Process Outputs and Mathematical Concepts for Quantifying Production | p. 35 |
| 2.4 Process Inputs and Manufacturing Costs | p. 48 |
| 2.5 Comparing Alternatives with Productivity Calculations | p. 53 |
| 2.6 The Impact of Production Volume on Alternatives | p. 62 |
| 2.7 Productivity and the USA Principle | p. 67 |
| 2.8 Summary | p. 68 |
| 2.9 Key Words | p. 70 |
| 2.10 Review Questions | p. 70 |
| 2.11 Bibliography | p. 73 |
| Chapter 3 Introduction to Computer Numerical Control (CNC) | p. 75 |
| 3.1 Introduction to CNC Technology | p. 76 |
| 3.2 CNC System Components | p. 82 |
| 3.3 Coordinate Systems and Reference Points | p. 96 |
| 3.4 The Ten Steps of CNC Programming | p. 105 |
| 3.5 Advantages and Disadvantages of CNC Technology | p. 107 |
| 3.6 When to Use CNC Technology | p. 109 |
| 3.7 Summary | p. 110 |
| 3.8 Key Words | p. 112 |
| 3.9 Review Questions | p. 112 |
| 3.10 Bibliography | p. 114 |
| Chapter 4 CNC Programming | p. 115 |
| 4.1 Overview of CNC Programming | p. 116 |
| 4.2 Program Code | p. 120 |
| 4.3 Cutting Parameters | p. 162 |
| 4.4 Program Organization | p. 166 |
| 4.5 Programming Process | p. 169 |
| 4.6 Turning Programs | p. 176 |
| 4.7 Summary | p. 182 |
| 4.8 Key Words | p. 183 |
| 4.9 Review Questions | p. 184 |
| 4.10 Bibliography | p. 188 |
| Chapter 5 CNC Simulation Software | p. 191 |
| 5.1 Overview of CNC Simulation Software | p. 192 |
| 5.2 Installation and Setup of CncSimulator® | p. 195 |
| 5.3 User Interface | p. 201 |
| 5.4 Simulation Examples | p. 219 |
| 5.5 Summary | p. 249 |
| 5.6 Key Words | p. 250 |
| 5.7 Review Questions | p. 251 |
| 5.8 Bibliography | p. 255 |
| Chapter 6 Introduction to Robotics Technology | p. 257 |
| 6.1 Industrial Robotics | p. 258 |
| 6.2 Robot Hardware | p. 261 |
| 6.3 Robot Applications | p. 280 |
| 6.4 Robot Safety | p. 283 |
| 6.6 Robot Selection Considerations | p. 287 |
| 6.7 Summary | p. 288 |
| 6.8 Key Words | p. 290 |
| 6.9 Review Questions | p. 291 |
| 6.10 Bibliography | p. 292 |
| Chapter 7 Robot Programming | p. 293 |
| 7.1 Robot Programming Concepts | p. 294 |
| 7.2 Programming Methods | p. 295 |
| 7.3 Robot Programming Languages | p. 301 |
| 7.4 Robot Program Development, Organization, and Structure | p. 304 |
| 7.5 Writing Robot Program of Instructions | p. 335 |
| 7.6 Robot Simulation | p. 343 |
| 7.7 Robot Program Simulation Example | p. 366 |
| 7.8 Summary | p. 371 |
| 7.9 Key Words | p. 372 |
| 7.10 Review Questions | p. 372 |
| 7.11 Bibliography | p. 373 |
| Chapter 8 Introduction to Programmable Logic Controllers (PLCs) | p. 375 |
| 8.1 Programmable Logic Control Overview | p. 376 |
| 8.2 Industrial Process Control | p. 378 |
| 8.3 PLC Terminology | p. 385 |
| 8.4 PLC Hardware Components | p. 387 |
| 8.5 PLC Applications | p. 389 |
| 8.6 Sensors and Actuators | p. 390 |
| 8.7 Implementing Automation with PLCs | p. 408 |
| 8.8 Summary | p. 413 |
| 8.9 Key Words | p. 416 |
| 8.10 Review Questions | p. 416 |
| 8.11 Bibliography | p. 417 |
| Chapter 9 Programming PLCs | p. 419 |
| 9.1 Programming Concepts | p. 420 |
| 9.2 Ladder Logic Terminology | p. 428 |
| 9.3 Typical PLC Instruction Set | p. 431 |
| 9.4 PLC Programming Process | p. 441 |
| 9.5 PLC Program Simulation | p. 452 |
| 9.6 PLC Programming Example | p. 470 |
| 9.7 Summary | p. 483 |
| 9.8 Key Words | p. 485 |
| 9.9 Review Questions | p. 486 |
| 9.10 Bibliography | p. 487 |
| Chapter 10 Automated Workstations and Work Cells | p. 489 |
| 10.1 Automated Workstations and Work Cells | p. 490 |
| 10.2 Workstation and Work Cell Components | p. 493 |
| 10.3 Automated Workstation and Work Cell Examples | p. 501 |
| 10.4 Summary | p. 506 |
| 10.5 Keywords | p. 506 |
| 10.6 Review Questions | p. 506 |
| 10.7 Bibliography | p. 507 |
| Index | p. 507 |
