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

528 Pages·2010·42.19 MB·English

by  Daniel Kandray

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