Text II Numerical Control and Automated Assembly

EXERCISE 1

Read the following information and be ready to discuss it. Translate the text using the vocabulary:

Numerical control is a form of programmable auto­mation in which a machine is controlled by numbers (and other symbols) that have been coded on punched paper tape or an alternative storage medium. The initial appli­cation of numerical control was in the machine tool in­dustry, to control the position of a cutting tool relative to the work part being machined. The NC part program represents the set of machining instructions for the par­ticular part. The coded numbers in the program specify x-y-z coordinates in a Cartesian axis system, defining the various positions of the cutting tool in relation to the work part. By sequencing these positions in the program, the machine tool is directed to accomplish the machining of the part. A position feedback control system is used in most NC machines to verify that the coded instruc­tions have been correctly performed. Today a small com­puter is used as the controller in an NC machine tool. Since this form of numerical control is implemented by computer, it is called computer numerical control, or CNC. Another variation in the implementation of nu­merical control involves sending part programs over tel­ecommunications lines from a central computer to indi­vidual machine tools in the factory. This form of numeri­cal control is called direct numerical control, or DNC.

Many applications of numerical control have been de­veloped since its initial use to control machine tools. Other machines using numerical control include compo­nent-insertion machines used in electronics assembly, drafting machines that prepare engineering drawings, coordinate measuring machines that perform accurate inspections of parts. In these applications coded numeri­cal data are employed to control the position of a tool or workhead relative to some object. Such machines are used to position electronic components (e.g., semiconductor chip modules) onto a printed circuit board (PCB). It is basically an x-y positioning table that moves the printed circuit board relative to the part-insertion head, which then places the individual component into position on the board. A typical printed circuit board has dozens of in­dividual components that must be placed on its surface; in many cases, the lead wires of the components must be inserted into small holes in the board, requiring great precision by the insertion machine. The program that controls the machine indicates which components are to be placed on the board and their locations. This informa­tion is contained in the product-design database and is typically communicated directly from the computer to the insertion machine.

Assembly operations have traditionally been per­formed manually, either at single assembly workstations or on assembly lines with multiple stations. Owing to the high labour content and high cost of manual labour, greater attention has been given in recent years to the use of automation for assembly work. Assembly opera­tions can be automated using production line principles if the quantities are large, the product is small, and the design is simple (e.g., mechanical pencils, pens, and ciga­rette lighters). For products that do not satisfy these conditions, manual assembly is generally required.

Automated assembly machines have been developed that operate in a manner similar to machining transfer lines, with the difference being that assembly operations, instead of machining, are performed at the workstations. A typical assembly machine consists of several stations, each equipped with a supply of components and a mecha­nism for delivering the components into position for as­sembly. A workhead at each station performs the actual attachment of the component. Typical workheads include automatic screwdrivers, welding heads and other join­ing devices. A new component is added to the partially completed product at each workstation, thus building up the product gradually as it proceeds through the line. Assembly machines of this type are considered to be ex­amples of fixed automation, because they are generally configured for a particular product made in high volume. Programmable assembly machines are represented by the component-insertion machines employed in the electron­ics industry.

EXERCISE 2

You have read the text about the important role of automation in industry. Answer the questions using conversation patterns: In ту opinion; I think; I suppose; In fact; In your opinion; Actually; If I’m not mistaken:

     1. What does an automated production line consist of? 2. How do you understand the term “fixed automation”? 3. What is the function of programmable logic controllers? 4. What do you understand by "flexible automation"? 5. Which other forms of programmable auto­mation are mentioned in the text? 6. How is the process of building the product performed at the automated assembly machines?

 

EXERCISE 3

Complete the following sentences using facts from the texts.

1. Each station is designed to perform a specific processing op­eration, ... . 2. Program­mable logic controllers are special computers that ... . 3. The initial appli­cation of numerical control was in the machine tool in­dustry, ... . 4. A position feedback control system is used... . 5. Other machines using numerical control include... . 6. Assembly opera­tions can be automated using production line principles... . 7. Automated assembly machines operate in a manner … .

EXERCISE 4

Give short retelling of the text “Automation in industry. Fixed and programmable automation”. Use the following key words.

An automated production line; an example of fixed automation; sequenced and co­ordinated properly; controlled by program­mable logic controllers; to be utilized; a form of programmable auto­mation; to be controlled by numbers; to define the various positions of the cutting tool; CNC/ DNC; assembly opera­tions; production line principles; building up the product gradually; includes; are capable of performing; for example; has set up; is made up of; has been installed; are responsible for; the main benefits include

EXERCISE 5

Read texts A, B, C. Single out the main idea of each text and give them titles.

Text A

Automation is the system of manufacture perform­ing certain tasks, previously done by people, by machines only. The sequences of operations are controlled auto­matically. The most familiar example of a highly auto­mated system is an assembly plant for automobiles or other complex products.

The term automation is also used to describe non-manufacturing systems in which automatic devices can op­erate independently of human control. Such devices as automatic pilots, automatic telephone equipment and automated control systems are used to perform various operations much faster and better than could be done by people.

Industrial robots, originally designed only to perform simple tasks in environments dangerous to human work­ers, are now widely used to transfer, manipulate, and position both light and heavy workpieces performing all the functions of a transfer machine.

The feedback principle is used in all automatic-con­trol mechanisms when machines have ability to correct themselves. Using feedback devices, machines can start, stop, speed up, slow down, count, inspect, test, compare, and measure. These operations are commonly applied to a wide variety of production operations.

Text B

Computers gave rise to the development of numerically controlled machines. The motions of these machines are controlled by punched paper or magnetic tapes. In numerically controlled ma­chining centres machine tools can perform several dif­ferent machining operations.

More recently, the introduction of microprocessors and computers have made possible the development of computer-aided design and computer-aided manufacture (CAD and CAM) technologies. When using these systems a designer draws a part and indicates its dimensions with the help of a mouse, light pen, or other input device. Af­ter the drawing has been completed the computer automatically gives the instructions that direct a machining centre to machine the part.

Another development using automation are the flex­ible manufacturing systems (FMS). A computer in FMS can be used to monitor and control the operation of the whole factory.

Many industries are highly automated or use automa­tion technology in some part of their operation. In com­munications and especially in the telephone industry dialing and transmission are all done automatically. Rail­ways are also controlled by automatic signaling devices, which have sensors that detect carriages passing a par­ticular point. In this way the movement and location of trains can be monitored.

Text C

Fixed automation, sometimes called «hard automa­tion» refers to automated machines in which the equip­ment configuration allows fixed sequence of processing operations. These machines are programmed to make only certain processing operations. That is why it is suitable for products that are made in large volumes. Examples of fixed automation are machining transfer lines found in the automobile industry, automatic assem­bly machines and certain chemical processes.

Programmable automation is a form of automation for producing products in large quantities, ranging from several dozen to several thousand units at a time. For each new product the production equipment must be reprogrammed and changed over. This reprogramming and changeover take a period of non-productive time. A numerical-control machine-tool is a good example of programmable automation. The program is coded in computer memory for each differ­ent product style and the machine-tool is controlled by the computer programme.

Flexible automation is a kind of programmable au­tomation. Programmable automation requires time to re-program and change over the production equipment for each series of new product. This is lost production time, which is expensive. In flexible automation the number of products is limited so that the changeover of the equip­ment can be done very quickly and automatically. The reprogramming of the equipment in flexible automation is done at a computer terminal without using the pro­duction equipment itself. Flexible automation allows a mixture of different products to be produced one right after another.

EXERCISE 6

Discuss with your groupmates the most interesting facts from the previous exercise. Ask and answer 5-7 questions in pairs.

EXERCISE 7

Find English equivalents to the following word combinations.

1. автоматические устройства

2. автоматизированное производство

3. выполнять простые задачи

4. как легкие, так и тяжелые детали

5.интегрированная система производства

6. принцип обратной связи

7. печатная плата

8. компьютер автоматически посылает команды

9. высокоавтоматизированная система

10. непроизводственная система

11. жёсткая автоматизация

12. деталь частичной сборки

13. полупроводниковый кристалл

14. автоматическая сборочная линия

15. потерянное производственное время

16. фиксированная последовательность операций

EXERCISE 8

Translate into English the following abstract. Title it.

Все системы автоматизации можно разделить на два класса: жесткие – с набором типовых настроек (mySAPBusinessSuite, OracleE-BusinessSuite, Галактика)  и гибкие – с возможностью модифицировать функциональность (1C, MicrosoftAxapta).  Это касается любых систем, от решения локальных задач до автоматизации деятельности крупных предприятий. 

Чтобы определить, «жесткая» или «гибкая» система нужна в  конкретном случае, необходимо понять, насколько динамично будет меняться предприятие и его бизнес-процессы в течение ближайших 2-4 лет.  Если имеется стабильно работающее предприятие, и в ближайшее время принципиальных  изменений в системе управления не планируется, то можно примерять «жесткие» системы. Но, выбрав и начав внедрять такую систему, мы будем вынуждены привести свою деятельность в соответствие с моделью бизнес-процессов, заложенной в систему, что для наших предприятий не всегда является допустимым.

Если же бизнес часто реформируется  и окончательная система управления еще не сложилась, то нужна гибкая система, позволяющая достаточно просто вносить изменения и без больших затрат модифицировать систему.

EXERCISE 10

Say which information in Unit 3 may be interesting for a Computer Science engineer. Could you use such information in your course paper/ diploma project? What exactly?

EXERCISE 11

Make up the summary to the text “Automated production lines”.

UNIT IV

TELEMETRY&TELEMECHANICS

Text I

Telemetry

EXERCISE 1

Read and translate the text.

Telelemetry is the highly automated communications process by which measurements are made and other data collected at remote or inaccessible points and transmitted to receiving equipment for monitoring. The word is derived from Greek: tele = remote, metron = measure.

Although the term commonly refers to wireless data transfer mechanisms using radio, hypersonic, or infrared systems, it also encompasses data transferred over other media such as a telephone or computer network, optical link or other wired communications. Many modern telemetry systems take advantage of the low cost and ubiquity of GSMnetworks by using SMS to receive and transmit telemetry data.

Early Soviet missile and space telemetry systems used either pulse-position modulation or pulse-duration modulation. Later Soviet interplanetary probes used redundant radio systems, transmitting telemetry.

Telemetry has been used in meteorology by weather balloons for transmitting meteorological data since 1920. It is used in Oil and gas industry to transmit drilling mechanics and formation evaluation information uphole, in real time, as a well is drilled. Telemetry is used by manned or unmanned spacecraft for data transmission.

Telemetry is a key factor in modern motor racing, allowing race engineers to interpret data collected during a test or race and use it to properly tune the car for optimum performance. Systems used in series such as Formula One have become advanced to the point where the potential lap time of the car can be calculated, and this time is what the driver is expected to meet. Examples of measurements on a race car include accelerations in three axes, temperature readings, wheel speed, and suspension displacement. Later developments include two-way telemetry which allows engineers to update calibrations on the car in real time, even while it is out on the track. Telemetry has also been applied in yacht racing.

Most activities related to healthy crops and good yields depend on timely availability of weather and soil data. Therefore, wireless weather stations play a major role in disease prevention and precision irrigation. These stations transmit parameters necessary for decision-making to a base station: air temperature and relative humidity, precipitation and leaf wetness, solar radiation and wind speed to calculate evapotranspiration¹, and soil moisture (crucial to irrigation decisions).

Telemetry is important in water management, including water quality and stream gauging² functions. Major applications include automatic meter reading, groundwater monitoring, leak detection in pipelines and equipment surveillance. Telemetry control allows you to intervene with assets such as pumps and allows you to remotely switch pumps on or off depending on the circumstances.

Space agencies such as NASA, the European Space Agency use telemetry systems to collect data from spacecraft and satellites.

Telemetry is vital in the development of missiles, satellites and aircraft because the system might be destroyed during or after the test. Engineers need critical system parameters to analyze the performance of the system.

Telemetry also is used for patients (biotelemetry) who are at risk of abnormal heart activity. Such patients are outfitted with measuring, recording and transmitting devices. A data log can be useful in diagnosis of the patient's condition by doctors.

Telemetry hardware is useful in law enforcement for tracking persons and property. An ankle collar worn by convicts on probation can warn authorities if a person violates the terms of his parole, such as by straying from authorized boundaries or visiting an unauthorized location.