1、CompanyLOGOAdvanced Manufacturing Technology(AMT)Huzhou Teachers CollegePREFACE Manufacturing Manufacturing(from Latin,making by hand)is the use of tools and labor to make things for use or sale.The term may refer to a range of human activity,from handicraft to high tech,but is most commonly applied
2、 to industrial production,in which raw materials are transformed into finished goods on a large scale.technology Technology is the process by which humans modify nature to meet their needs and wants.Advanced manufacturing technology AMT involves new manufacturing techniques and machines combined wit
3、h the application of information technology,micro-electronics and organizational practices within the manufacturing process.Advanced manufacturing technology is a modern method of production incorporating highly automated and sophisticated computerized design and operational systems.AMT aims at manu
4、facturing high quality products at low cost within the shortest delivery time.Advanced manufacturing technology is typically reflected by the achievements in high precision and sophisticated automation manufacturing operations.hardware technologies of AMTsAMTs“soft”technologies of AMTsSame examples
5、The hardware technologies have found wide acceptance in discrete manufacturing and in resource and processing sectors.Computer numeric controls have been applied to systems for machining,forming,cutting and moulding.The accuracy,speed and control of robots have improved significantly and,as a result
6、,they are used extensively in welding,painting,material handling and an enormous number of unique assembly applications.Vision systems provide,in real time,monitoring for precision machining and high-speed printing and remote handling of mining equipment used thousands of metres underground.Computer
7、-aided design(CAD)and rapid prototyping have substantially shortened the development time for new products.Computer-integrated manufacturing(CIM)is applied in machine shops for tool building,the production of engines and body assemblies for passenger cars,the manufacture of airplane landing gear and
8、 the production of hypodermic needles for the medical devices sector.CIMS是英语是英语 Computer Integrated Manufacturing System是计算机集成制造系统。它是随着是计算机集成制造系统。它是随着计算机辅助设计与制造的发展而产生的。计算机辅助设计与制造的发展而产生的。它是在信息技术、自动化技术与制造的基它是在信息技术、自动化技术与制造的基础上，通过计算机技术把分散在产品设计础上，通过计算机技术把分散在产品设计制造过程中各种孤立的自动化子系统有机制造过程中各种孤立的自动化子系统有机地集成起来，
9、形成适用于多品种、小批量地集成起来，形成适用于多品种、小批量生产，实现整体效益的集成化和智能化制生产，实现整体效益的集成化和智能化制造系统。集成化反映了自动化的广度，造系统。集成化反映了自动化的广度，智智能化则体现了自动化的深度，它不仅涉及能化则体现了自动化的深度，它不仅涉及物资流控制的传统体力劳动自动化，还包物资流控制的传统体力劳动自动化，还包括信息流控制的脑力劳动的自动化。括信息流控制的脑力劳动的自动化。Complementary to the hardware technologies of AMTs is a wide range of soft manufacturing proce
10、ss technologies.Just-in-time(JIT)manufacturing,total quality management(TQM)and supply chain management are but a few of the many soft AMTs adopted by manufactures and processors globally.The nature of competition in manufacturing has changed.High-quality and highly customized goods are demanded.The
11、re is a premium for being the first to market with a product.This has created a demand for hard and soft technologies that help shorten design and production cycles.Free trade has increased the breadth of geographical competition,making it easy for foreign manufacturers to enter the Chinese market a
12、nd for Chinese firms to enter foreign markets.The source of this competition varies,some of it from low-wage areas and some of it from very technologically sophisticated countries.Manufacturing practices and processes have come under increased pressure from global competition.Demands for improved cu
13、stomer service,breadth of product line,improved quality,quick response and a much shortened time-to-market for new product introduction cannot be ignored by firms.In the face of these intense pressures,manufacturers around the world are moving away from mass production manufacturing processes.They a
14、re turning to greater flexibility and speed in manufacturing practices.These practices have become the foundation for Best in Class manufacturers and processors.Manufacturing has been influenced by trade liberalization,global competition,market fragmentation,technological innovation and the demands
15、of more sophisticated consumers,in response to these pressures,manufacturers are incorporating more flexibility and technology in their production practices.These features have become a trade-mark of world-class corporations.AMTs are a key enabler for firms attempting to meet world-class performance
16、 targets.Manufacturing technology has developed for many years.Over these years,it has gone through many changes and progressed the following stages:1.Befor 1770:craftspeople with anvil（铁砧）and hammer（锤、榔头）.A blacksmith(铁匠)working iron with a hammer and anvilA lathe（车床）from 1911 showing component par
17、ts.2.1770:construction of simple production machines and mechanization（机械化）started.3.At the turn of 20th century:fixed automatic mechanisms and transfer lines for mass production come along.3.At the turn of 20th century:fixed automatic mechanisms and transfer lines for mass production come along.191
18、3 Ford Model T assembly line4.Next:machining tools with sample automatic control.5.1952:the introduction of numerical control(NC)opened a new era in automation.6.Next:computerized numerical control(CNC)for machine tools.plug board controller 7.1961:industrial robots were developed with CNC system.8.
19、Present:a fully automatic factory with FMS（Flexible Manufacture System，一组数控机床和其他自动化的工艺设备，由计算机信息控制系统和物料自动储运系统有机结合的整体），CAD/CAM techniques.异源的Chapter 1 Computers in Manufacturing Computers are being given an increasingly important role in manufacturing systems.A computers ability to receive and handle
20、large amounts of data,coupled with their fast processing time,makes a system approach indispensable.Computer application in manufacturing production controls the physical process and is typically referred to as computer-aided manufacturing(CAM).It is built on the foundation of such systems as CNC,AC
21、,robotics,automated guided vehicle system(AGVS),automated storage/retrieval system(AS/RS),and flexible manufacturing system(FMS).Many interrelated manufacturing activities are grouped together to form a special application system that may be referred to as a production and control system(PACS).A PAC
22、S is defined as a subsystem in a global manufacturing environment.It may be a single subsystem,or it may be a complex set of subsystems.An illustration of PACS working in a global manufacturing system is shown in Fig.1.2.Fig.1.2 Interaction of PACS in a Manufacturing System For PACS to meet their de
23、signed functional requirements,they should be designed to function independently of other PACS.Also,PACS should be able to work collectively with other PACS in a total integrated manufacturing environment.Each PACS in the total system can have an effect on the other PACS in the total system,and a sy
24、stems planning approach must be taken for the following reasons:To prevent duplication of effortTo enable vital information to pass efficiently through the systemTo allow each PACS to know its relation to the others and how it affects the othersTo make the whole manufacturing system function more ef
25、ficiently and productively Computers are by far the most powerful single approach used in integrating and manipulating the series of interrelated manufacturing PACS and activities.The advances in technical production have brought about a computer technology and manufacturing technology that has enha
26、nced manufacturing technology development.This marriage is the basis for computer-aided production and control systems(CAPACS),which are computer-driven CAPACS.Thus,CAPACS have increased the roles of smart machines in production and control functions.The ways in which production operations are conce
27、ptualized,formulized,discharged,and performed are being changed by CAPACS.Typical CAPACS in manufacturing are as follows:Fig.1.3 gives an overview of CAPACS working from an integrated data base system.Fig.1.3 overview of CAPACS The application of CAPACS to the manufacturing process enables the total
28、 system to increase productivity,reduce waste,and produce things it would not otherwise be able to make.As a result,new technologies,demands for products of higher quality and lower production costs,and the needs for improved technology in a competitive society have caused extensive use of CAPACS.1.
29、1.1 Automation Concepts Automation may be defined as a system that is relatively self-operating.KUKA Industrial robots engaged in vehicle underbody assembly Automation or industrial automation or numerical control is the use of control systems such as computers to control industrial machinery and pr
30、ocesses,reducing the need for human intervention.Such a system includes complex mechanical and electronic devices and computer-based system that take the place of observation,effort,and decision by a human operator.It is a system that exhibits properties of human beings by following predetermined op
31、erations or responding to encoded instructions.1.1.2 Computer Process Control Process control involves the control of variables in a manufacturing process,where one or many combination of materials and equipment produces or modifies a product to make it more useful and hence more valuable.Industrial
32、 processes are procedures involving chemical or mechanical steps to aid in the manufacture of an item or items,usually carried out on a very large scale.In process control systems,the computer serves as the control mechanism that automatically controls continuous operations.Two kinds of control syst
33、ems are the open loop and the closed loop.Open loop systemControlsystemClosed loop system In an open-loop control system,the computer does not itself automate the process.That is,there is no self-correction.The process remains under the direct control of human operators,who read from various sources
34、 of information such as instruments,set calibrated dials for process regulation,and change the controlling medium.Closed-loop control systems use computers to automate the process.The computer is directly in charge of the process.It adjusts all controls from the information provided by sensing devic
35、es in the system to keep the process to the desired specifications,a technique that uses a feedback mechanism.Feedback is the action of measuring the difference between the actual result and the desired result and using that difference to drive the actual result toward the desired result.The term fe
36、edback comes from a measured sample of the output of the process(production)function that becomes the input of the control function.That is,the out put of the control function,meeting special designed requirements is the input to the control system.Thus,the signal begins at the output of the control
37、led production function and ends at the input to the production.Management information systems are designed to aid in the performance of management functions.When required,information systems are used to aid management in the decision-making functions of the enterprise,its goal being to get the corr
38、ect information to the appropriate manager at the right time.1.1.3 Management Information Systems(MIS)SALESDATAUNITPRODUCT COSTPRODUCTCHANGE DATAEXPENSEDATAMISMISReportsMIS FILESMANAGERSMISManagement Information System(MIS)is a subset of the overall internal controls of a business covering the appli
39、cation of people,documents,technologies,and procedures by management accountants to solving business problems such as costing a product,service or a business-wide strategy.Management Information Systems(MIS)Engineering is the discipline and profession of applying technical knowledge and utilizing na
40、tural laws and physical resources in order to design and implement materials,structures,machines,devices,systems,and processes that realize a desired objective and meet specified criteria.1.1.4 Engineering Computers are used extensively in most engineering functions.Typical engineering functions usi
41、ng CAPACS are:design,process planning,analysis and optimization,synthesis,evaluation and documentation,simulation,modeling,and quality control planning.Using CAPACS in engineering increases the productivity of engineers and improves the quality of designs.For example,the application of computers to
42、an engineering design process is performed by a CAD system.Engineers can design and thoroughly test concepts quickly and simply from one workstation.1.Production Applications of computers to the production process encompass such functions as computer monitoring,supervisory computer control,direct di
43、gital control(DDC),material handling,and product fabrication,assembly and test/inspection operations.The integration of more computers into the production process increases automation on the factory floor.A computer automated system concept is shown in Fig.1.4.Each function in manufacturing has its
44、own area controller under the control of a host computer in order to share information with other operations.Fig.1.4 2.Computer-aided Engineering and Production Computer-aided engineering(often referred to as CAE)is the use of information technology for supporting engineers in tasks such as analysis
45、,simulation,design,manufacture,planning,diagnosis and repair.CAE areas covered include:Stress analysis on components and assemblies using FEA(Finite Element Analysis);Thermal and fluid flow analysis,Computational fluid dynamics(CFD);Kinematics;Mechanical event simulation(MES).Analysis tools for proc
46、ess simulation for operations such as casting,molding,and die press forming.Optimization of the product or process.The production cycle(CAD/CAM cycle)has four distinct phases in the manufacturing of a product.DefinitionTranslationConstructionSupportCADCAD/CAMCAMIntegrated computer-aided engineering
47、and productionsystem(CAD/CAM systems)streamline a firms operation.Definition is the engineering design process.Translation is the manufacturing engineering that provides the initiating actions for the manufacturing processes,including tool orders for the production tools to accomplish fabrication an
48、d assembly.Construction(production)consists of the physical actions of fabrication and assembly of the product.Support is the preparation of maintenance manuals,parts catalogs,and spares,together with field support of the customer.These basic phases are bound together by management control systems t
49、hat provide scheduling,budgets,job tracking,shop loading and control,order writing,procurement and inventory control,and so on.CAD Pure Computer-aided DesignAnalysisConcept DevelopmentEtc.CAD/CAM Common Requirements of Eng&MfgGeometric CharacteristicsParts Content and Applications Assembly Breakdown
50、sProcessesMaterial Type/Size/Condition Etc.CAMPure Computer-Aided ManufacturingMfg Operation Sequences and InstructionMachine and Tool AssignmentsTool Configuration and ManufactureAutomated Parts/Assembly MakingNC ProgramsRoboticsParts HandlingTestEtc.Integrated compute-aided engineering and product
