

E book:
Integration and
Automation of
Manufacturing
Systems
page 1
Integration and Automation
of
Manufacturing Systems
by: Hugh Jack
© Copyright 1993-2001, Hugh Jack
page 2
PREFACE
1. INTEGRATED AND AUTOMATED MANUFACTURING . . . .13
1.1 INTRODUCTION 13
1.1.1 Why Integrate? 13
1.1.2 Why Automate? 14
1.2 THE BIG PICTURE 16

3. AN INTRODUCTION TO C/C++ PROGRAMMING . . . . . . . . .43
3.1 INTRODUCTION 43
3.2 PROGRAM PARTS 44
3.3 CLASSES AND OVERLOADING 50
3.4 HOW A ‘C’ COMPILER WORKS 52
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3.5 STRUCTURED ‘C’ CODE 53
3.6 COMPILING C PROGRAMS IN LINUX 54
3.6.1 Makefiles 55
3.7 ARCHITECTURE OF ‘C’ PROGRAMS (TOP-DOWN) 56
3.7.1 How? 56
3.7.2 Why? 57
3.8 CREATING TOP DOWN PROGRAMS 58
3.9 CASE STUDY - THE BEAMCAD PROGRAM 59
3.9.1 Objectives: 59
3.9.2 Problem Definition: 59
3.9.3 User Interface: 59
Screen Layout (also see figure): 59
Input: 60
Output: 60
Help: 60
Error Checking: 61
Miscellaneous: 61
3.9.4 Flow Program: 62
3.9.5 Expand Program: 62
3.9.6 Testing and Debugging: 64
3.9.7 Documentation 65
Users Manual: 65
Programmers Manual: 65
3.9.8 Listing of BeamCAD Program. 65

4.6 DESIGN CASES 102
4.7 SUMMARY 103
4.8 PRACTICE PROBLEMS 103
4.9 LABORATORY - NETWORKING 104
4.9.1 Prelab 105
4.9.2 Laboratory 107
5. DATABASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
5.1 SQL AND RELATIONAL DATABASES 109
5.2 DATABASE ISSUES 114
5.3 LABORATORY - SQL FOR DATABASE INTEGRATION 114
5.4 LABORATORY - USING C FOR DATABASE CALLS 116
6. COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
6.1 SERIAL COMMUNICATIONS 119
6.1.1 RS-232 122
6.2 SERIAL COMMUNICATIONS UNDER LINUX 125
6.3 PARALLEL COMMUNICATIONS 129
6.4 LABORATORY - SERIAL INTERFACING AND PROGRAMMING
130
6.5 LABORATORY - STEPPER MOTOR CONTROLLER 130
7. PROGRAMMABLE LOGIC CONTROLLERS (PLCs) . . . . . . .134
7.1 BASIC LADDER LOGIC 136
7.2 WHAT DOES LADDER LOGIC DO? 138
7.2.1 Connecting A PLC To A Process 139
7.2.2 PLC Operation 139
7.3 LADDER LOGIC 141
7.3.1 Relay Terminology 144
7.3.2 Ladder Logic Inputs 146
7.3.3 Ladder Logic Outputs 147
7.4 LADDER DIAGRAMS 147
7.4.1 Ladder Logic Design 148

7.13.3 Basic Data Handling 182
Move Functions 182
7.14 MATH FUNCTIONS 184
7.15 LOGICAL FUNCTIONS 191
7.15.1 Comparison of Values 191
7.16 BINARY FUNCTIONS 193
7.17 ADVANCED DATA HANDLING 194
7.17.1 Multiple Data Value Functions 195
7.17.2 Block Transfer Functions 196
7.18 COMPLEX FUNCTIONS 198
7.18.1 Shift Registers 198
7.18.2 Stacks 199
7.18.3 Sequencers 200
7.19 ASCII FUNCTIONS 202
7.20 DESIGN TECHNIQUES 203
7.20.1 State Diagrams 203
7.21 DESIGN CASES 206
7.21.1 If-Then 207
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7.21.2 For-Next 207
7.21.3 Conveyor 208
7.22 IMPLEMENTATION 209
7.23 PLC WIRING 209
7.23.1 SWITCHED INPUTS AND OUTPUTS 210
Input Modules 211
Actuators 212
Output Modules 213
7.24 THE PLC ENVIRONMENT 216
7.24.1 Electrical Wiring Diagrams 216
7.24.2 Wiring 219

9.3 MECHANISMS 281
9.4 ACTUATORS 282
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9.5 A COMMERCIAL ROBOT 283
9.5.1 Mitsubishi RV-M1 Manipulator 284
9.5.2 Movemaster Programs 286
Language Examples 286
9.5.3 Command Summary 290
9.6 PRACTICE PROBLEMS 291
9.7 LABORATORY - MITSUBISHI RV-M1 ROBOT 296
9.8 TUTORIAL - MITSUBISHI RV-M1 296
10. OTHER INDUSTRIAL ROBOTS . . . . . . . . . . . . . . . . . . . . . . . .299
10.1 SEIKO RT 3000 MANIPULATOR 299
10.1.1 DARL Programs 300
Language Examples 301
Commands Summary 305
10.2 IBM 7535 MANIPULATOR 308
10.2.1 AML Programs 312
10.3 ASEA IRB-1000 317
10.4 UNIMATION PUMA (360, 550, 560 SERIES) 319
10.5 PRACTICE PROBLEMS 320
10.6 LABORATORY - SEIKO RT-3000 ROBOT 330
10.7 TUTORIAL - SEIKO RT-3000 ROBOT 331
10.8 LABORATORY - ASEA IRB-1000 ROBOT 332
10.9 TUTORIAL - ASEA IRB-1000 ROBOT 332
11. ROBOT APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
11.0.1 Overview 333
11.0.2 Spray Painting and Finishing 335
11.0.3 Welding 335
11.0.4 Assembly 336

12.4 DYNAMICS FOR KINEMATICS CHAINS 372
12.4.1 Euler-Lagrange 372
12.4.2 Newton-Euler 375
12.5 REFERENCES 375
12.6 PRACTICE PROBLEMS 376
13. MOTION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
13.1 KINEMATICS 390
13.1.1 Basic Terms 390
13.1.2 Kinematics 391
Geometry Methods for Forward Kinematics 392
Geometry Methods for Inverse Kinematics 393
13.1.3 Modeling the Robot 394
13.2 PATH PLANNING 395
13.2.1 Slew Motion 395
Joint Interpolated Motion 397
Straight-line motion 397
13.2.2 Computer Control of Robot Paths (Incremental Interpolation)400
13.3 PRACTICE PROBLEMS 403
13.4 LABORATORY - AXIS AND MOTION CONTROL 408
14. CNC MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
14.1 MACHINE AXES 409
14.2 NUMERICAL CONTROL (NC) 409
14.2.1 NC Tapes 410
14.2.2 Computer Numerical Control (CNC) 411
14.2.3 Direct/Distributed Numerical Control (DNC) 412
14.3 EXAMPLES OF EQUIPMENT 414
14.3.1 EMCO PC Turn 50 414
14.3.2 Light Machines Corp. proLIGHT Mill 415
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14.4 PRACTICE PROBLEMS 417

17.6 IMAGE PREPROCESSING 486
17.7 FILTERING 487
17.7.1 Thresholding 487
17.8 EDGE DETECTION 487
17.9 SEGMENTATION 488
17.9.1 Segment Mass Properties 490
17.10 RECOGNITION 491
17.10.1 Form Fitting 491
17.10.2 Decision Trees 492
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17.11 PRACTICE PROBLEMS 494
17.12 TUTORIAL - LABVIEW BASED IMAQ VISION 499
17.13 LABORATORY - VISION SYSTEMS FOR INSPECTION 500
18. INTEGRATION ISSUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
18.1 CORPORATE STRUCTURES 502
18.2 CORPORATE COMMUNICATIONS 502
18.3 COMPUTER CONTROLLED BATCH PROCESSES 514
18.4 PRACTICE PROBLEMS 516
18.5 LABORATORY - WORKCELL INTEGRATION 516
19. MATERIAL HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518
19.1 INTRODUCTION 518
19.2 VIBRATORY FEEDERS 520
19.3 PRACTICE QUESTIONS 521
19.4 LABORATORY - MATERIAL HANDLING SYSTEM 521
19.4.1 System Assembly and Simple Controls 521
19.5 AN EXAMPLE OF AN FMS CELL 523
19.5.1 Overview 523
19.5.2 Workcell Specifications 525
19.5.3 Operation of The Cell 526
19.6 THE NEED FOR CONCURRENT PROCESSING 534

23. PLANNING AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . .581
23.1 FACTORS TO CONSIDER 581
23.2 PROJECT COST ACCOUNTING 583
24. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587
25. APPENDIX A - PROJECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588
25.1 TOPIC SELECTION 588
25.1.1 Previous Project Topics 588
25.2 CURRENT PROJECT DESCRIPTIONS 590
26. APPENDIX B - COMMON REFERENCES . . . . . . . . . . . . . . . .591
26.1 JIC ELECTRICAL SYMBOLS 591
26.2 NEMA ENCLOSURES 592
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PREFACE
I have been involved in teaching laboratory based integrated manufacturing courses since
1993. Over that time I have used many textbooks, but I have always been unsatisfied with their
technical depth. To offset this I had to supply supplemental materials. These supplemental materi-
als have evolved into this book.
This book is designed to focus on topics relevant to the modern manufacturer, while avoiding
topics that are more research oriented. This allows the chapters to focus on the applicable theory
for the integrated systems, and then discuss implementation.
Many of the chapters of this book use the Linux operating system. Some might argue that
Microsoft products are more pervasive, and so should be emphasized, but I disagree with this. It is
much easier to implement a complex system in Linux, and once implemented the system is more
reliable, secure and easier to maintain. In addition the Microsoft operating system is designed
with a model that focuses on entertainment and office use and is incompatible with the needs of
manufacturing professionals. Most notably there is a constant pressure to upgrade every 2-3 years
adding a burden.
The reader is expected to have some knowledge of C, or C++ programming, although a
review chapter is provided. When possible a programming example is supplied to allow the reader
to develop their own programs for integration and automation.

- ignore employee input to the process
- try to implement all at once (if possible)
• Justification of integration and automation,
- consider “BIG” picture
- determine key problems that must be solved
- highlight areas that will be impacted in enterprise
- determine kind of flexibility needed
- determine what kind of integration to use
- look at FMS impacts
- consider implementation cost based on above
• Factors to consider in integration decision,
- volume of product
- previous experience of company with FMS
- product mix
- scheduling / production mixes
- extent of information system usage in organization (eg. MRP)
- use of CAD/CAM at the front end.
- availability of process planning and process data
* Process planning is only part of CIM, and cannot stand alone.
1.1.2 Why Automate?
• Why ? - In many cases there are valid reasons for assisting humans
- tedious work consistency required
- dangerous
- tasks are beyond normal human abilities (e.g., weight, time, size, etc)
- economics
page 15
• When?
Figure 1.1 - Automation Tradeoffs
• Advantages of Automated Manufacturing,
- improved work flow

cesses for production, machine selection, tool selection, etc.
PPC - Production Planning and Control - also known as scheduling. Up to this stage each
process is dealt with separately. Here they are mixed with other products, as
required by customer demand, and subject to limited availability of manufacturing
resources.
Factory Control - On a minute by minute basis this will split up schedules into their
required parts, and deal with mixed processes on a factory wide basis. (This is very
factory specific, and is often software written for particular facilities) An example
system would track car color and options on an assembly line.
Workcell Control - At this system level computers deal with coordination of a number of
machines. The most common example is a PLC that runs material handling sys-
CAD
CAE
CAPP PPC CAM
page 17
tems, as well as interlocks with NC machines.
Machine Control - Low level process control that deals with turning motors on/off, regu-
lating speeds, etc., to perform a single process. This is often done by the manufac-
turers of industrial machinery.
1.2.1 CAD/CAM?
• A common part of an integrated system
• In CAD we design product geometries, do analysis (also called CAE), and produce final
documentation.
• In CAM, parts are planned for manufacturing (eg. generating NC code), and then manufac-
tured with the aid of computers.
• CAD/CAM tends to provide solutions to existing problems. For example, analysis of a part
under stress is much easier to do with FEM, than by equations, or by building prototypes.
• CAD/CAM systems are easy to mix with humans.
• This technology is proven, and has been a success for many companies.
• There is no ‘ONE WAY’ of describing CAD/CAM. It is a collection of technologies which

- CNC - Computer Numerical Control
- DNC - Direct Numerical Control of all the machine tools in the FMS. Both CNC and
DNC functions can be incorporated into a single FMS.
- Computer control of the materials handling system
- Monitoring - collection of production related data such as piece counts, tool changes, and
machine utilization
- Supervisory control - functions related to production control, traffic control, tool control,
and so on.
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1.2.3 General Concepts
• Manufacturing requires computers for two functions,
- Information Processing - This is characterized by programs that can operate in a batch
mode.
- Control - These programs must analyze sensory information, and control devices while
observing time constraints.
• An integrated system is made up of Interfaced and Networked Computers. The general
structure is hierarchical,
• The plant computers tend to drive the orders in the factory.
• The plant floor computers focus on departmental control. In particular,
- synchronization of processes.
- downloading data, programs, etc., for process control.
- analysis of results (e.g., inspection results).
• Process control computers are local to machines to control the specifics of the individual
processes. Some of their attributes are,
- program storage and execution (e.g., NC Code),
- sensor analysis,
- actuator control,
- process modeling,
- observe time constraints (real time control).
• The diagram shows how the characteristics of the computers must change as different func-

- Micro-processors, small computers with simple operating systems (like PC’s with
msdos) well suited to control. Most computerized machines use a micro-processor
Faster
Response
Times
More
Complex
Computations
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architecture.
• A Graphical Depiction of a Workstation Controller
Detail of Workstation Controller
Planning
Algorithm
Process
Plans
Simulation
Expert
Scheduling
System
Deadlock
Detection &
Avoidance
Error
Detection &
Recovery
Control
Logic
Status
Database

page 23
2. AN INTRODUCTION TO LINUX/UNIX
2.1 OVERVIEW
Linux is a free UNIX clone that was developed by volunteers around the world. Although
Linux is almost a decade old, it went largely unnoticed by the general public until a couple of
years ago. Since then it has become very popular with individual users, universities and large cor-
porations. For example, IBM has made it a major part of their business strategy for server hard-
ware. Many software companies already offer Linux versions of their software, including
products such as Oracle, Labview and MSC Nastran. Other companies have developed embedded
applications using Linux. Currently Linux can be found in devices as small as a wristwatch [1]
and as large as a Beowulf class supercomputer [2]. The popularity of Linux is based on three fac-
tors:
- costs are lower because the software is free and it runs well on less expensive hardware.
- it has more software, capabilities, and features than other operating systems.
- the source code is open, so users can customize the operating system to meet their needs.
This chapter will present the Linux operating system in general, and its current status in comput-
ing.
2.1.1 What is it?
Linux is an open source operating system. It is open because users and developers can use the
source code any way they want. This allows anyone to customize it, improve it and add desired
features. As a result Linux is dynamic, evolving to respond to the desires and needs of the users.
In contrast, closed operating systems are developed by a single corporation using static snapshots
of market models and profit driven constraints.
Linux is free. This allows companies to use it without adding cost to products. It also allows
people to trade it freely. And, with the profit motive gone, developers have a heightened sense of
page 24
community interest. The Linux community has developed a tremendous spirit because of these
core development concepts.
2.1.2 A (Brief) History
Linux has existed since the early 1990s [3], but it grew out of previous developments in com-