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Programmable automation technologies : an introduction to CNC, robotics and PLCs PDF

528 Pages·2010·42.19 MB·English
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Programmable Automation Technologies An Introduction to CNC, Robotics and PLCs Daniel E. Kandray, P.E. Industrial Press Inc. New York Library of Congress Cataloging-in-Publication Data Kandray, Daniel. Programmable automation / Daniel Kandray. p. cm. Includes bibliographical references. ISBN 978-0-8311-3346-7 1. Manufacturing processes--Automation. 2. Machine-tools--Numerical control--Programming. 3. Robots, industrial--Programming. 4. Programmable controllers. I. Title. TS183.K365 2010 670.42'7--dc22 2009047466 Industrial Press, Inc. 989 Avenue of the Americas New York, NY 10018 Sponsoring Editor: John Carleo Interior Text Management: Chris McCauley Interior Text and Cover Design: Janet Romano Developmental Editor: Kathy McKenzie Copyright © 2010 by Industrial Press Inc., New York. Printed in the United States of America. All rights reserved. This book, or any parts thereof, may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the publisher. Figure Credits Courtesy of : AIM, Incorporated, Addison, IL, Figure 3-7 Fanuc Robotics, Copyright © Figures 6-24, 6-25, 6-26, 6-27. 10 9 8 7 6 5 4 3 2 1 Dedication For my wife, Tammie and my children—Dan, Ian, and Sydney; to my father Bill, and to my mother Evelyn, in loving memory TABLE OF CONTENTS vii Preface xiii Chapter 1 1 Introduction to Programmable Automation 1 1.2 The Manufacturing Process 2 1.3 Automation 11 1.4 Manufacturing Performance Measures 20 1.5 Benefits of Automation 22 1.6 Automation Strategies 24 1.7 Summary 26 1.8 Key Words 28 1.9 Review Questions 28 1.10 Bibliography 29 Chapter 2 31 Automation Justification and Productivity Concepts 31 2.1 Automation Justification and Productivity 32 2.2 Productivity Calculations 32 2.3 Process Outputs and Mathematical Concepts for Quantifying Production 35 2.4 Process Inputs and Manufacturing Costs 48 2.5 Comparing Alternatives with Productivity Calculations 53 2.6 The Impact of Production Volume on Alternatives 62 2.7 Productivity and the USA Principle 67 2.8 Summary 68 2.9 Key Words 70 2.10 Review Questions 70 2.11 Bibliography 73 Chapter 3 75 Introduction to Computer Numerical Control (CNC) 75 3.1 Introduction to CNC Technology 76 3.2 CNC System Components 82 3.3 Coordinate Systems and Reference Points 96 3.4 The Ten Steps of CNC Programming 105 3.5 Advantages and Disadvantages of CNC Technology 107 3.6 When to Use CNC Technology 109 3.7 Summary 110 3.8 Key Words 112 3.9 Review Questions 112 3.10 Bibliography 114 viii TABLE OF CONTENTS Chapter 4 115 CNC Programming 115 4.1 Overview of CNC Programming 116 4.2 Program Code 120 4.3 Cutting Parameters 162 4.4 Program Organization 166 4.5 Programming Process 169 4.6 Turning Programs 176 4.7 Summary 182 4.8 Key Words 183 4.9 Review Questions 184 4.10 Bibliography 188 Chapter 5 191 CNC Simulation Software 191 5.1 Overview of CNC Simulation Software 192 5.2 Installation and Setup of CncSimulator® 195 5.3 User Interface 201 5.4 Simulation Examples 219 5.5 Summary 249 5.6 Key Words 250 5.7 Review Questions 251 5.8 Bibliography 255 Chapter 6 257 Introduction to Robotics Technology 257 6.1 Industrial Robotics 258 6.2 Robot Hardware 261 6.3 Robot Applications 280 6.4 Robot Safety 283 6.6 Robot Selection Considerations 287 6.7 Summary 288 6.8 Key Words 290 6.9 Review Questions 291 6.10 Bibliography 292 TABLE OF CONTENTS ix Chapter 7 293 Robot Programming 293 7.1 Robot Programming Concepts 294 7.2 Programming Methods 295 7.3 Robot Programming Languages 301 7.4 Robot Program Development, Organization, and Structure 304 7.5 Writing Robot Program of Instructions 335 7.6 Robot Simulation 343 7.7 Robot Program Simulation Example 366 7.8 Summary 371 7.9 Key Words 372 7.10 Review Questions 372 7.11 Bibliography 373 Chapter 8 375 Introduction to Programmable Logic Controllers (PLCs) 375 8.1 Programmable Logic Control Overview 376 8.2 Industrial Process Control 378 8.3 PLC Terminology 385 8.4 PLC Hardware Components 387 8.5 PLC Applications 389 8.6 Sensors and Actuators 390 8.7 Implementing Automation with PLCs 408 8.8 Summary 413 8.9 Key Words 416 8.10 Review Questions 416 8.11 Bibliography 417 Chapter 9 419 Programming PLCs 419 9.1 Programming Concepts 420 9.2 Ladder Logic Terminology 428 9.3 Typical PLC Instruction Set 431 9.4 PLC Programming Process 441 9.5 PLC Program Simulation 452 9.6 PLC Programming Example 470 9.7 Summary 483 9.8 Key Words 485 9.9 Review Questions 486 9.10 Bibliography 487 x TABLE OF CONTENTS Chapter 10 489 Automated Workstations and Work Cells 489 10.1 Automated Workstations and Work Cells 490 10.2 Workstation and Work Cell Components 493 10.3 Automated Workstation and Work Cell Examples 501 10.4 Summary 506 10.5 Key Words 506 10.6 Review Questions 506 10.7 Bibliography 507 Index 507

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