INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

CHAPTER 1. INTRODUCTION
Automation is the technology by which a process or procedure is performed with minimal
human interference through the use of technological or mechanical devices. It is the
technique of making a process or a system operate automatically. Automation or automatic
control involves the use of various control systems for operating the various equipment
such as various machinery operations, numerous processes in factories, boilers and heat-
treating ovens, new networks, steering and stabilization of ships, aircraft and other
applications with minimal or reduced human intervention. Some processes have been
completely automated. The biggest benefit of automation is that it saves labour cost and
involvement. However, it is also used to save energy and materials and to improve quality,
accuracy. Industries were employed three main methods of transmission for transmitting
power from one point to another for their convenience,

• Mechanical transmission is through shafts, gears, chains, belts and many more.
• Electrical transmission is through wires, transformers.
• Fluid power is through Liquid or gas in a confined vessel.

1.1 History of Automation Systems

The term automation, inspired by the earlier word automatic (coming from automaton),
was not widely used before 1947 when General Motors established the automation
department. It was during this time that the industry was rapidly adopting feedback
controllers, which were introduced in the 1930s.

In 1913, Ford Motor Company introduced a car production assembly line which is
considered one of the pioneer types of automation in the manufacturing industry. Before
then, a car was built by a team of skilled and unskilled workers. Production automation
improved Ford’s production rates and increased its profits. The assembly line and mass car
production were the first of their kind globally. It reduced the car assembly time from 12
hours per car to about one and a half hours per car.

During the 1930s, Japan was a leader in developing components that facilitated industrial
manufacturing automation. One company developed the first micro- switch, protective
relays, and a highly accurate electrical timer. By this time, the rest of the world had started

Department of Mechanical Engineering, MCE Hassan 1

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

appreciating automation and significant research and development had occurred, like the
solid-state proximity switch. Between 1939 and 1945 during the Second World War,
automation was highly used in fighter airplanes, landing crafts, warships, and tanks.

Japan surrendered to the US and allied forces in 1945 and an industrial rebuilding program
was initiated. The program relied on new and superior technologies as opposed to the early
employed manufacturing methods that were being used by the rest of the world. Hence,
Japan became the world leader in industrial automation. Automobile companies like
Honda, Toyota, and Nissan could produce numerous high-quality and reliable cars. They
offered standard features that were classified as extras by other car manufacturers as well
as competitive prices that triggered the success of Japan’s automobile industry.

The current industrial robots feature high-quality computing capabilities, improved

operational degrees of freedom, and vision systems. However, they can only operate in
highly structured environments and still require a certain level of human intervention.
Moreover, they are quite inflexible and highly specialized for use in small and medium
sized industries, so industrial automation is usually better suited to large manufacturers and
long production runs. Automation in the manufacturing industry relies on computer and
software capabilities to automate, integrate and optimize different components of
manufacturing systems. As a result, it is also referred to as computer-integrated
manufacturing.

1.2 Types of Automation Systems

Automation systems can be categorized based on the flexibility and level of integration in
manufacturing process operations. Various automation systems can be classified as
follows,

• Fixed Automation: It is used in high-volume production with dedicated equipment,

which has a fixed set of operations and is designed to be efficient for this set.
Continuous flow and Discrete Mass Production systems use this automation. For
example, distillation Process, conveyors, automotive industries, automatic
assembly machines etc. A process using mechanized machinery to perform fixed
and repetitive operations to produce a high volume of similar parts.

Department of Mechanical Engineering, MCE Hassan 2

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• Programmable Automation: It is used for a changeable sequence of operation and

configuration of the machines using electronic controls. However, non-trivial
programming effort may be needed to reprogram the machine or sequence of
operations. Investment in programmable equipment is less, as the production
process is not changed frequently. It is typically used in the Batch process where
job variety is low, product volume is medium to high, and sometimes in mass
production. For example, steel rolling mills, paper mills, etc.
• Flexible Automation: It is used in Flexible Manufacturing Systems (FMS) which is
invariably computer controlled. Human operators give high-level commands in the
form of codes entered into the computer identifying the product and its location in
the sequence and the lower-level changes are done automatically. Each production
machine receives settings/instructions from the computer. These automatic
load/unloads required tools and carry out their processing instructions. After
processing, products are automatically transferred to the next machine. It is
typically employed in job shops and batch processes where product varieties are
high and job Automated Guided Vehicles (AGV) etc.
• Integrated Automation: It denotes complete automation of a manufacturing plant,
with all volumes medium to low. Such systems typically use Multi-purpose CNC
machines, processes functioning under computer control and under coordination
through digital information processing. It includes technologies such as computer-
aided design and manufacturing, computer-aided process planning, computer
numerical control machine tools, flexible machining systems, automated storage
and retrieval systems, automated material handling systems such as robots and
automated cranes and conveyors, and computerized scheduling and production
control. It may also integrate a business system through a common database. In
other words, it symbolizes the full integration of process and management
operations using information and communication technologies. Typical examples
of such technologies are seen in Advanced Process Automation Systems and
Computer Integrated Manufacturing (CIM).

Department of Mechanical Engineering, MCE Hassan 3

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

CHAPTER 2. AUTOMATION SYSTEMS

An automation system can be simply defined as the integration of sensors, controls, and
actuators designed to perform function with minimal or less human effort and that mainly
depend on hydraulics, pneumatics and electro-pneumatics.

2.1 Pneumatic systems

2.1.1 Introduction

The English word pneumatic and its associate noun pneumatics are derived from the Greek
“pneuma” meaning breath or air. Originally coined to give a name to the science of the
motions and properties of air. Compressed air is a vital utility- just like water, gas, and
electricity used in countless ways to benefit everyday life. Pneumatics is an application of
compressed air (pressurized air) to power machines or control or regulate machines. Simply
put, Pneumatics may be defined as a branch of engineering science that deals with the study
of the behaviour and application of compressed air. Pneumatics can also be defined as the
branch of fluid power technology that deals with the generation, transmission, and control
of power using pressurized air. Gas in a pneumatic system behaves like a spring since it is
compressible. Any gas can be used in a pneumatic system but the air is the most usual, for
obvious reasons. Exceptions are most likely to occur on aircraft and space vehicles where
an inert gas such as nitrogen is preferred or the gas one which is generated on board. Pure
nitrogen may be used if there is a danger of combustion in a work environment. In
Pneumatic control, compressed air is used as the working medium, normally at a pressure
from 6 bar to 8 bar. Using Pneumatic Control, a maximum force of up to 50 KN can be
developed. Actuation of the controls can be manual, Pneumatic, or Electrical actuation.
Signal medium such as compressed air at a pressure of 1-2 bar can be used [Pilot operated
Pneumatics] or Electrical signals [D.C or A.C source- 24V – 230V] can be used [Electro
pneumatics].

2.1.2 Fundamentals and basic principles

Pneumatics is all about using compressed air to do the work. Compressed air is the air from
the atmosphere which is reduced in volume by a device called a compressor thus increasing
its pressure. Pneumatics is all about using compressed air to do the work. Compressed air

Department of Mechanical Engineering, MCE Hassan 4

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

is the air from the atmosphere which is reduced in volume by a device called a compressor
thus increasing its pressure. It is used as a working medium normally at a pressure of 6
kg/mm2 to 8 kg/mm2 for doing work. It can be controlled manually, pneumatically to do
work by acting on a piston or vane. The compressor sucks in air from the atmosphere and
stores it in a high pressure tank called a receiver. This compressed air is then supplied to
the system through a series of pipes and valves.

2.1.3 Basic components of Pneumatic systems

Fig 2.1.3 Basic components of pneumatic system

The main basic components of pneumatic system are

1. Compressor

2. Pressure regulating component

3. Direction control valves

4. Control valves

5. Actuators

1. Compressor - A compressor can compress air to the required pressures. It can

convert the mechanical energy from motors and engines into the potential energy in
compressed air. A single central compressor can supply various pneumatic

Department of Mechanical Engineering, MCE Hassan 5

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

components with compressed air, which is transported through pipes from the
cylinder to the pneumatic components. Compressors are classified into two classes
namely reciprocating and rotary compressors.

Fig 1.2.1(a) Compressor

2. Pressure regulating component - Pressure regulating components are formed by various

components, each of which has its own pneumatic symbol. Filter that can remove impurities
from compressed air before it is fed to the pneumatic components, pressure regulator that
is used to stabilize the pressure and regulate the operation of pneumatic components and
lubricator used to provide lubrication for pneumatic components and all the components
together known as FRL unit.

Fig 1.2.1(b) Pressure regulating component

3. Direction control valves - Directional control valves ensure the flow of air
between air ports by opening, closing and switching their internal connections. Their
classification is determined by the number of ports, the number of switching
positions, the normal position of the valve and its method of operation. Common
types of directional control valves include 2/2, 3/2, 5/2, etc. The first number
represents the number of ports; the second number represents the number of

Department of Mechanical Engineering, MCE Hassan 6

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

positions. A directional control valve that has two ports and five positions can be
represented by the drawing in Fig. 8, as well as its own unique pneumatic symbol.
These direction control valves are further classified as
• 2/2 Directional control valve
The structure of a 2/2 directional control valve is very simple. It uses the
thrust from the spring to open and close the valve, restricting or completely
blocking compressed air from flowing towards working tube ‘A’ from air
inlet ‘P’.When a force is applied to the control axis, the valve will be pushed
open, connecting ‘P’ with ‘A’. The force applied to the control axis has to
overcome both air pressure and the repulsive force of the spring. The control
valve can be driven manually or mechanically, and restored to its original
position by the spring.

Fig 1.2.1(3a) 2/2 Direction control valve

• 3/2 Directional control valve
A 3/2 directional control valve can be used to control a singleacting
cylinders. The open valves in the middle will close until ‘P’ and ‘A’ are
connected together. Then another valve will open the sealed base between
‘A’ and ‘R’ (exhaust). The valves can be driven manually, mechanically,
electrically or pneumatically. 3/2 directional control valves can further be
divided into two classes: Normally open type (N.O.) and normally closed
type (N.C.).

Department of Mechanical Engineering, MCE Hassan 7

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 1.2.1(3b) 3/2 Direction control valve

• 5/2 Directional control valve
When a pressure pulse is input into the pressure control port ‘P’, the spool
will move to the left,connecting inlet ‘P’ and work passage ‘B’. Work passage
‘A’ will then make a release of air through ‘R1’ and ‘R2‘. The directional valves
will remain in this operational position until signals of thecontrary are received.
Therefore, this type of directional control valves is said to have the function of
memory.

Fig 1.2.1 (3c) 5/2 Direction control valve

4. Control valves - A control valve is a valve that controls the flow of air
which includes include non-return valves, flow controlvalves, shuttle valves, etc.
• Non-return valve
A non-return valve allows air to flow in one direction only. When air
flows in the opposite direction,the valve will close. Another name for non-
return valve is poppet valve.

Department of Mechanical Engineering, MCE Hassan 8

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 1.2.1(4a) Non return valve

• Flow control valve - A flow control valve is formed by a non-return valve and a
variable throttle.

Fig 1.2.1(4b) Flow control valve

• Shuttle valve (OR Valve) - It is also known as a double control valve (or) double
check valve. A shuttle valve has two inlets and one outlet. At any one time, flow is
shut off in the direction of whichever inlet is unloaded and is open from the loaded
inlet to the outlet
For example: When a cylinder or control unit (valve) is to be actuated from two
points, which may be remote from one other.

Fig 1.2.1(4c) Shuttle valve

Department of Mechanical Engineering, MCE Hassan 9

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

5. Actuators - Pneumatic execution components provide rectilinear or rotary

movement. Examples of pneumatic execution components include cylinder pistons,
pneumatic motors, etc. Rectilinear motion is produced by cylinder pistons, while
pneumatic motors provide continuous rotations. There are many kinds of cylinders,
such as single acting cylinders and double acting cylinders.

• Single acting cylinder

A single acting cylinder has only one entrance that allows compressed air
to flow through. Therefore,it can only produce thrust in one direction . The
piston rod is propelled in the opposite direction by an internal spring, or by
the external force provided by mechanical movement or weight of a load.
The thrust from the piston rod is greatly lowered because it has to overcome
the force from the spring. Therefore, in order to provide the driving force for
machines, the diameter of the cylinder should be increased. In order to match
the length of the spring, the length of the cylinder should also be increased,
thus limiting the length of the path. Single acting cylinders are used in
stamping, printing, moving materials, etc.

Fig 1.2.1(5a) Single acting cylinder

• Double acting cylinder

In a double acting cylinder, air pressure is applied alternately to the relative
surface of the piston, producing a propelling force and a retracting force as
the effective area of the piston is small, the thrust produced during retraction
is relatively weak. The impeccable tubes of double acting cylinders are
usually made of steel and the working surface with chromium to reduce
wear. The double acting cylinders are available in diameters from few mm

Department of Mechanical Engineering, MCE Hassan 10

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

to around 300 mm and stroke lengths of few mm up to 2 meters. Force is

exerted by the piston both during forward and return motion of cylinder and
during the return motion supply air admitted at the rod side while the piston
side volume is connected to the exhaust.

Fig 1.2.1(5b) Double acting cylinder

2.2.4 Advantages and Limitations of Pneumatic system

A. Advantages of pneumatic systems

• Efficient - The atmosphere contains an unlimited supply of air for the

production of compressed air, which can be stored easily in a large volume.
Not only can compress air but also can be easily transported through pipes but
after its use can be released into atmosphere without any further processing.
• Reliable - Pneumatic system components form Best Pneumatic Systems are
extremely durable and reliable. Compared to electromotive components, pneumatic
parts are proven to last longer and require less maintenance.

• Simple - Pneumatic system components are relatively simple, which makes them
suitable for less complicated automatic control systems. You can choose from a
choice of movements, including linear or angular rotational movement, coupled
with continuously variable operational speeds.
• Safe - Pneumatic systems can work in inflammable environments without the risk
of fire or explosion. Unlike of electromotive components, pneumatic system
components do not overheat when overloaded and are therefore less of a fire hazard.

Department of Mechanical Engineering, MCE Hassan 11

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• Economical - Pneumatic system components are relatively inexpensive, making

the initial outlay for pneumatic systems very cost-effective. Furthermore, because
pneumatic systems are so durable and reliable, maintenance costs are significantly
lower than with other systems.

B. Limitations of pneumatic systems

• Control and Speed - Air is a compressible gas, which makes control and speed in a
pneumatic system more difficult, in comparison to electric or hydraulic
systems. When specific speeds are needed, additional devices have to be attached
to the pneumatic system in order to procure the desired result.
• Maintenance - Pneumatic systems are less durable that hydraulic counterparts. Due
to moisture accumulation the system can freeze up.
• Safety - Pipes that feed the system air have the ability to move on uncontrollably
on their own, which could cause serious injuries to those nearby
• Environment suitability - Devices are known to fail over long periods of time due
to the dampening of inside edges in the tubes. Additionally, systems cannot
operate underwater and are sensitive to changing temperatures and vibrations
• Toxins and chemicals - Sometimes, pneumatic systems use hazardous chemicals
in their design. This can result in accidental launches of chemicals into the air,
which can be harmful to the surrounding environment.

2.1.5 Pneumatic circuit problems

2.1.5(a) A double acting cylinder is to be controlled by two 3/2-Way valves (Push button),
such that the piston travels out when the first valve is actuated and remains in the forwarded
position even after the release of the first valve. The signal for the return movement is given
through the Second 3/2-Way valve. The piston speed of the cylinder is to be adjusted for
the advance and return movement and separately throttled

Department of Mechanical Engineering, MCE Hassan 12

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Component List:

1. Double acting cylinder

2. One way flow control valve.
3. 5/2 Direction control valve (double Pilot Operated)
4. 3/2-way valve (Push button operated with spring return) - Two Nos.

Fig 2.1.5(a) Pneumatic circuit

2.1.5(b) A double acting cylinder is to be controlled by two 3/2-way valves, such that the
piston travels out when the first valve is actuated and remains in the forward end position
even after the release of the first valve the signal for the return movement is given through
the second 3/2-way valve. The piston speed of the cylinder is to be adjustable for the
advance movement and for the return movement the speed should be increased.

Department of Mechanical Engineering, MCE Hassan 13

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Component list :

1.Double acting cylinder

2. Quick exhaust valve
3. One way flow control valve
4. 5/2 Direction control valve (Double pilot operated)
5. 3/2-way valve (Push button operated with spring return – Two Nos.

Fig 2.1.5(b) Pneumatic circuit

2.1.5(c) The piston of a single acting cylinder is to travel out after any one of the
push button is operated andreturn to its end position after the push button is
released.
Component list:
1) Single acting cylinder
2) Shuttle valve
3) 3/2 way push button valve with spring return – Two Nos.

Department of Mechanical Engineering, MCE Hassan 14

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 2.1.5(c) Pneumatic circuit

2.1.5(d) A double-acting cylinder is to be controlled by two 3/2-way valves, such that the
piston travels out when both the push button operated at a time after the release of any one
of the pushbuttons the piston will retract its original position and also release both the push
button piston retract its original position.

Component List:

1. Double-acting cylinder

2. Double pressure value

3. 5/2 Direction control valve (Double pilot operated)

4. 3/2-way valve (Push button operated with spring return)

5. 5/2-way detent valve

Department of Mechanical Engineering, MCE Hassan 15

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 2.1.5(d) Pneumatic circuit

2.2 Electro pneumatic system

2.2.1 Introduction
The electro-pneumatic action is a control system by the mean of air pressure for
pipe organs, whereby air pressure, controlled by an electric current and operated
by the keys of an organ console, opens and closes valves within wind chests,
allowing the pipes to speak. Electro pneumatics are now commonly used in
many areas of m e d i u m a n d s m a l l s c a l e industries where low cost
automation is required. They are alsoused extensively in production, assembly,
pharmaceutical, chemical and packaging systems. There is asignificant change
in controls systems. Relays have increasingly been replaced by the
programmable logic controllers in order to meet the growing demand for more
flexible automation.
Electro-pneumatic control consists of electrical control systems operating
pneumatic power systems. In this solenoid valves are used as interface between
the electrical and pneumatic systems. Devices like limitswitches and proximity

Department of Mechanical Engineering, MCE Hassan 16

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

sensors are used as feedback elements. Electro Pneumatic control integrates

pneumatic and electrical technologies, is more widely used for large
applications. In Electro Pneumatics, the signal medium is the electrical signal
either AC or DC source is used. Working medium is compressed air. Operating
voltages from around 12 V to 220 Volts are often used. The final control valve
is activated by solenoid actuation.

2.2.2 Advantages of electro-pneumatics

• Higher reliability due to the lower number of mechanical parts that are required to
move or are subject to wear and tear.
• Less effort and expense for planning and commissioning (particularly for complex
controls).
• Less time required for installation, particularly when using more modern, more
compact assemblies like valve terminals.
• Simple and rapid modification of open- and closed-loop control strategies using
programmable logic controls.
• Easy exchange of information between several control systems.

2.2.3 Limitations of electro-pneumatics

• A pneumatic device is sensitive to extreme changes in temperature as well as
vibration.
• Compressed air is more expensive than electricity.
• It is essential to ensure that there are no leaks in a pneumatic system because
compressed air escaping leads to energy loss.
• Pneumatic systems are known for making a loud noise. As a solution, you can install
a silencer in every dump line.
• Installation cost increases when the instrument requires specially designed pipes.
• Pneumatic systems are not upgradable to become compatible with smart electronics.

Department of Mechanical Engineering, MCE Hassan 17

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

2.2.4 Electro-pneumatics circuit problems

2.2.4(a) The piston rod of the doble acting cylinder (Z1) should then extend when
push button S1 "AND" pushbutton S2 are actuated.

Fig 2.2.4(a) Electro-pneumatic circuit

Department of Mechanical Engineering, MCE Hassan 18

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

CHAPTER 3. SENSORICS

3.1 Introduction
Pneumatic sensors are otherwise called pressure sensors. Pressure sensors are used for
control and monitoring in thousands of everyday applications. Pressure sensors can also be
used to indirectly measure other variables such as fluid/gas flow, speed, water level and
altitude. Pressure sensors can alternatively be called pressure transducers, pressure
transmitters, pressure senders, pressure indicators, piezometers and manometers, among
other names

Example, altitude sensing this is useful in aircraft, rockets, satellites, weather balloons, and
many other applications.

These various sensors equipped with automation systems to achieve greater accuracy in
works and in pneumatic systems signal is pressure of a gas (or air) in a pipe, instead of
electrical current. It is difficult to control very low pressures accurately with a simple
regulator, and also have to provide vacuum to allow for calibration and measurement
hysteresis and repeatability errors and in hydraulic systems signal are self-propagating
changes in water (fluid) pressure. In electrical systems signal is a voltage OR current which
conveys information, usually it means a voltage.

3.2 Basic concept and types of sensors in Industrial automation

In the industrial automation, sensors play a vital part to make the products intellectual and
exceptionally automatic. These permit one to detect, analyze, measure and process a
variety of transformations like alteration in position, length, height, exterior and
dislocation that occurs in the Industrial manufacture sites.

These sensors also play a pivotal role in predicting and preventing numerous potential
proceedings, thus, catering to the requirements of many sensing applications.

The following are the various types of sensors used in automation:

Department of Mechanical Engineering, MCE Hassan 19

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• Temperature Sensors
• Pressure sensors
• Micro-Electro-Mechanical-Systems (MEMS) Sensors
• Proximity sensors

• Temperature Sensors: A temperature sensor is a device that collects information

concerning the temperature from a resource and changes it to a form that can be
understood by another device. These are commonly used category of sensors which
detect Temperature or Heat and it also measures the temperature of a medium.
Digital Temperature Sensors and Humidity & Temperature Sensors are few of the
main temperature sensors used in automation.

Fig 3.2(a) Temperature sensors

• Pressure Sensors: The pressure sensor is an Instrument that apprehends pressure

and changes it into an electric signal where the quantity depends upon the pressure
applied. Turned parts for Pressure Sensors and vaccum Sensors are few of the major
pressure sensors used in Industrial automation.

Fig 3.2(b) Pressure sensors

• MEMS Sensors (Micro-electro-mechanical Systems): These MEMS sensors

convert measured mechanical signals into electrical signals. Acceleration and

Department of Mechanical Engineering, MCE Hassan 20

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Motion MEMS are few important sensors used in industrial automation.

Acceleration sensors are one of the main inertial sensors and are dynamic sensor
competent of have a greater range of sensing capabilities.

Fig 3.2(c) Micro-electro-mechanical sensors

• Proximity sensors: These sensors, consisting of a sensor head (optical, inductive,

and capacitive), amplifier, detector circuit, and an output circuit (TTL, solid-state
relay), detect closed objects' presence and sense any physical contact. These are
found in Industrial Automation latched to conveyor lines, machine tools with digital
sensors to detect an object's presence or absence. Optical Proximity sensors are one
of the type of proximity sensors comprise a light source (LED) and a light detector
(phototransistor). The signal is modulated to minimize the ambient lighting
conditions. Generally used in box-counting, stack height control, and fluid level
control, these sensors work in three operational modes, beam mode of 20 m range,
retro-reflective with a 1-3meters, and diffuse-reflective mode with a 12-300mm
range. Ultrasonic proximity sensors use a 40 kHz-2MHz frequency range sound
pulse to measure the time of flight and amplitude. They are employed as an
approach warning before probable collisions and detect solid and liquid levels. As
shown in the following figure 3, these sensors detect objects where the normal
photocells cannot be employed for level measurement of solids and liquids,
diameter or loop detection for materials like sheet iron, paper, and transparent
objects detection like plastic, plastic filters, and glass bottles etc.

Department of Mechanical Engineering, MCE Hassan 21

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 3.2(d) Proximity sensors

3.3 Applications of sensors

• Exceptional accuracy and stability.

• For measurements in complex industrial applications.
• For measurements under rough operating conditions.
• Used to measure pressure below than the atmospheric pressure at a given location.
• Used in weather instrumentation, aircrafts, vehicles, and any other machinery that
has pressure functionality implemented.
• Position Detection on a Mechanical Moving Part
• Making Sound Detection Decisions
• Valve Position Control during Processing

Department of Mechanical Engineering, MCE Hassan 22

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

CHAPTER 4. CNC PROGRAMMING

4.1 Fundamentals of machining

• Machining is the manufacturing process in which the size, shape or surface
properties of a part are changed by removing the excess material.
• It should be specified only when high accuracy and good surface finish are
required.
• Five types of machine tools to perform machining: lathe or turning machine,
drilling or boring machine, milling machine, shaper or planer and grinder.
• Material removal mechanism may be chemical, electrical or thermal.
• e.g.: Electrochemical machining (ECM), Electrical discharge machining (EDM),
Laser beam machining. Variables changed by the part programmer that affect the
rate of metal removal: cutting speed and size of cut (depth) .
• Cutting speed (v): relative velocity between the cutting tool and the work material
(ft/min or m/min). In NC machines the spindle speed, rather than the cutting speed
is programmed.
• The spindle speed is calculated by the part programmer based on the required
cutting speed and diameter of the work piece
• Depth of cut (d): distance the cutting tool projects below the original surface of
the work (mm)
• Feed (f): relative lateral movement between the tool and the work piece
(mm/rev). In NC machines, feed rate (mm/min)
• The product of speed, feed and depth of cut determines the metal removal rate
(MRR). The productivity of the machine during cutting is proportional to the
MRR.

4.2 Fundamentals of numerical control

• Controlling a machine tool by means of a prepared program is known as numerical

control or NC.
• Operators of CNC machine tools need not be skilled machinists.

Department of Mechanical Engineering, MCE Hassan 23

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• They have to monitor the operation of the machine, and replace the work piece.
• Preparing the part program for a NC machine tool requires a part programmer.
• Part programmers write the part program manually or by using a computer-assisted
language.

4.3 Advantages of CNC systems

• Flexibility.
• Accuracy.
• Shorter production time.
• Possibility of manufacturing a part of complicated contour.
• Easy adjustment of the machine, which requires less time.
• Need for a highly skilled and experienced operator is avoided.

4.4 Limitations of CNC systems

• Relatively high cost.

• More complicated maintenance.
• Highly skilled and trained part programmer is needed.

4.5 Elements of CNC systems

• Input Device
• Machine Control Unit Driving System
• Machine Tool
• Feedback Devices
• Display Unit

Department of Mechanical Engineering, MCE Hassan 24

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 4.5(a) Elements of CNC

4.6 CNC machining centres

• CNC machine tools were redesigned with greater emphasis on the structural rigidity,
power available as well as the ability to perform a variety of functions.
• Modern CNC milling machines have expanded machining capabilities by the
addition of accessory devices, making them more versatile.
• Therefore milling machines are now called as machining centres.
• Two types of machining centres:
1.Vertical axis machining centres
2.Horizontal axis machining centres

4.7 Machine control panel

• CNC on/off: Used to turn on or off the power for the CNC device and the
machine control panel.
• Emergency: Machine goes to emergency stop state.

Department of Mechanical Engineering, MCE Hassan 25

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• Machine reset: Used to stop processing the current programs and clear
alarms/messages.
• Coolant-1 (on/off switch)
• Coolant-2 (on/off switch)
• Cycle start: To execute automatic operation and to restart the cycle.
• Cycle stop: To stop the running cycle.
• Machine Lamp.
• Program edit key switch: Used when editing existing programs and creating
new programs.
• Mode selector: EDIT, SBK, AUTO, MDI, MPG/STEP, JOG & ZRN modes
can be selected by this switch.
o Edit – to create and edit the programs
o SBK (Single Block) – to execute program block by block
o Auto – to execute automatic operation • MDI (Manual Data
Input) – to enter G/M code commands block by block and
immediately execute them for setting up the machine.
o MPG (Manual Pulse Generator)/Step – selected when step feed
is used
o JOG – it activates manual mode to move the axes in manual
control
o ZRN (Zero Return Mode) – After selecting ZRN mode, if we
press cycle start push button, the axes return to zero position
• Feed Override % - this allows adjustment of feed rate for X and Z axis.
• Rapid OVR % / MPG-Step Feed.
• Spindle Speed Override % .
• JOG keys 15. Spindle Control.
• Auxiliary Functions.
• Tool Station – to display number of present tool station on the turret.
• Display LED’s.
• MPG/Hand Wheel- used to move axis in positive and negative direction.
• Foot Switch – Chuck Clamp/ De-clamp.
• Foot Switch – Tailstock Quill forward/ reverse.

Department of Mechanical Engineering, MCE Hassan 26

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 4.7 Machine control panels

4.8 Work offset

Work offset is the distance between machine zero and work zero in X and Z (in diametrical
and length wise) direction.

4.8.1 Steps for simulation of work offset on Swan Soft NC simulation

• SINUMERIK 828 D T – run.

• CNC on – release emergency stop- reset - spindle start – feed start.
• Workpiece setup- diameter and length – 0k • Tools management – select tools
– add to tool turret- specify station number – tool magazine – select – mount
tool – ok.
• Reference point – Z + & X +.
• Jog- Move tool near work part.
• Jog- measure tool – manual- tool name- select tool- enter – in manual.
• X-30 – set length – save position.
• Z-0 – set length – save position.
• Reference point - Z + & X +.
• Reset.

Department of Mechanical Engineering, MCE Hassan 27

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

4.9 M-code and G-code

4.9.1 M-codes (Miscellaneous codes)

M codes are related to the machine functions that is stop/start machines and also it activates
the PLC of the machine.

• M00 – Program Stop

• M01 – Optional Stop
• M02 – End of Program
• M03 – CW Spindle Rotation
• M04 – CCW Spindle Rotation
• M05 – Spindle Stop
• M06 – Change Tool
• M07 or M08 – Coolant on
• M09 – Coolant Off
• M10 – Chuck Unclamp
• M11 – Chuck Clamp
• M30 – End of Main Program
• M46 – Door Open
• M47 – Door Close
• M72 – Activate foot switch
• M73 – Deactivate foot switch

4.9.2 G-codes (Preparatory codes)

G-codes are geometric codes and is used for product design. G-code activates the
Numerical Control(NC) machine.

• G01 – Linear interpolation

• G02 – Circular interpolation (CW)
• G03 – Circular interpolation (CCW)
• G20 – Inch input

Department of Mechanical Engineering, MCE Hassan 28

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• G21 – Metric input (mm)

• G28 – Zero return
• G32/76 – Thread Cutting
• G40/G41/G42 – Tool nose radius compensation
• G50/G92 – Maximum spindle speed setting (RPM)
• G70 – Finishing cycle
• G71 - Stock removal in turning
• G72 – Stock removal in facing
• G73 – Pattern repeating
• G74 – Peck drilling on Z axis
• G75 – Grooving on X axis
• G96 – Spindle speed
• G97 – Constant surface spindle speed

4.9.3 Part program – 1 (Facing operation)

Facing is the process of removing metal from the end of a workpiece to produce a flat
surface. It is a turning operation in which the workpiece is machined to its centre which
involves moving the cutting tool perpendicular to the workpiece's axis of rotation.

• Program manager – new – name – ok

To specify size of the workpiece

• Various – blank
• XA (dia. of workpiece) – 30
• ZA – 0
• Z1 (overall length of workpiece) - -150
• ZB (length of workpiece in front of chuck) - -110
• Accept – input

Department of Mechanical Engineering, MCE Hassan 29

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

To bring tool home position

• G75 X0 Z0
To select tool
• M06 T01 D1 M03 S100 LIMS=1500
• M07

Rapid tool travel

• G00 X30 Z2

Details of finished work part

• Turning- stock removal

• SC (safety distance) – 1
• F (feed rate) – 0.200
• Face
• X – 30, Z-0, X1-0, Z1- -2
• D(depth of cut) – 0.1
• UX – 0.01
• UZ – 0.01
• Accept
• X32
• G75 X0 Z0
• M05 M09
• M30

4.9.4 Part program – 2 (Facing and turning operation)

Fig 4.9.4 Workpiece model for facing and turning

Department of Mechanical Engineering, MCE Hassan 30

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• Program manager – new – name – ok

To specify size of the workpiece

• Various – blank
• XA (dia. of workpiece) – 30
• ZA – 0
• Z1 (overall length of workpiece) - -150
• ZB (length of workpiece in front of chuck) - -110
• Accept - input

To bring tool to home position

• G75 X0 Z0

To select tool

• M06 T01 D1 M03 S100 LIMS=1500

• M07

Rapid tool travel

• G00 X30 Z2

Details of finished work part (facing)

• Turning- stock removal

• SC (safety distance) – 1
• F (feed rate) – 0.200
• Face
• X – 30, Z-0, X1-0, Z1- -5
• D(depth of cut) – 0.1
• UX – 0.01
• UZ – 0.01
• Accept
Details of finished work part (Turning)
• Turning- stock removal
• SC (safety distance) – 1

Department of Mechanical Engineering, MCE Hassan 31

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• F (feed rate) – 0.200

• Longitudinal
• X – 30, Z-0, X1-25, Z1- -50
• D (depth of cut) – 0.1
• UX – 0.01
• UZ – 0.01
• Accept
• X32
• G75 X0 Z0
• M05 M09
• M30

4.9.5 Part program – 3 (Worked model)

Fig 4.9.5 Worked model

• Program manager – new – name – ok

To specify size of the workpiece
• Various – blank
• XA (dia. of workpiece) – 32
• ZA – 0
• Z1 (overall length of workpiece) - -150
• ZB (length of workpiece in front of chuck) - -125

Department of Mechanical Engineering, MCE Hassan 32

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• Accept – input
To bring tool to home position
• G75 X0 Z0
To select tool
• M06 T01 D1
Spindle
• G96 M03 S300 LIMS=1500
Coolant
• M07
Rapid tool travel
• G00 X32 Z2
Cycle 951 (Facing )
• Turning- stock removal
• SC (safety distance) – 1
• F (feed rate) – 0.200
• Face
• X – 32, Z-0, X1--2, Z1- -2
• D(depth of cut) – 0.2
• UX – 0.01
• UZ – 0.01
• Accept
Cycle 62
• Contour turning- contour- contour call- labels- OD(label 1)- END (label 2)- accept
Cycle 952 (Contour Turning)
• Contour turning- back- stock removal
• PRG- OD
• SC (safety distance) – 1
• F (feed rate) – 0.200
• Machining- Roughing+Finishing
• FS- 0.1
• Longitudinal- outside
• D(depth of cut) – 0.2

Department of Mechanical Engineering, MCE Hassan 33

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• UX – 0.01
• UZ – 0.01
• XD- 31.5
• ZD- 0
• Relief cut- No
• Accept
• OD:
• G01 X0 Z0
• G03 X10 Z-15 CR=10
• G01 X20 Z-30
• G01 X23 Z-30
• G01 X23 Z-45
• G02 X28 Z-50 CR=5
• G01 X28 Z-90
• G01 X20 Z-110
• G01 X30 Z-110
• G01 X30 Z-120
• X32
• END:
• G75 X0 Z0
• M05 M09
Grooving
• M06 T07 D1
• G96 M03 S500 LIMS=1500
• M07
Cycle 930 (Grooving)
• SC-1.00
• F-0.100
• Machining, roughing an finishing
• X0-28
• Z0--85
• B1-4

Department of Mechanical Engineering, MCE Hassan 34

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• T1-20
• D-0.1
• UX-0.20
• UZ-0.20
• N-1
• ACCEPT
• X32
• M05 M09
• G75 X0 Z0
(External Thread Cutting)
• M06 T03 D1
• M07
• G96 M04 S150 LIMS=500
• Turning-Thread-Thread long-Input-Complete
Cycle 99 (External Thread Cutting)
• P-1.800 mm per revolution
• G-0.0
• Machining Roughing+Finishing
• Linear-External Thread
• X-28
• Z0--52
• Z1--85
• LW-1
• LR-0.0
• H1- 1.104
• ALPHA P-30
• D1-0.050
• U-0.000
• NN-1
• VR-1.00
• MULTIPLE-NO
• ALPHA-0.0

Department of Mechanical Engineering, MCE Hassan 35

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• ACCEPT (END OF THREADING CYCLE)

• X32
• G75 X0 Z0
• M05 M09
• M30

4.10 Milling centre

4.10.1 Simulation of the part program using Swan soft CNC

Fig 4.10.1 Milling work piece

Initial step

• FANUC OiM

• Remove emergency stop - select key - reference position - Z+, Y+, X+ Workpiece

• Workpiece setup – stock size and WCS - 100x100x25 – ok

• Workpiece setup - workpiece clamp - edge clamp – ok Tool

• Tools management – select - add into the magazine - tool station – ok

• MDI – PROG – MDI - M06T01; - enter - cycle start

• Workpiece setup - rapid position – ok

Department of Mechanical Engineering, MCE Hassan 36

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• Jog - offset setting – work - G54 - X0 – measure - Y0 – measure - Z0 – measure -

reference position

• Empty NC code

• Auto • G90G21G40;

• G28X0Y0Z0;

• M06T01;

• M03S1000M08;

• G00X0Y0Z5;

• G00X15Y15Z5;

• G01Z-10F100;

• G01X15Y70;

• G02X30Y85R15;

• G01X85Y85;

• G01X85Y30;

• G03X70Y15R15;

• G01X15Y15;

• G00Z05;

• G28X0Y0Z0;

• M05M09M30;

Department of Mechanical Engineering, MCE Hassan 37

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

CHAPTER 5. ADDITIVE MANUFACTURING (3PRINTING)

5.1 Introduction

Additive manufacturing, also known as 3D printing, rapid prototyping or freeform

fabrication, is ‘the process of joining materials to make objects from 3D model data,
usually layer upon layer, as opposed to subtractive manufacturing methodologies’
such as machining. The use of Additive Manufacturing (AM) with metal powders is
a new and growing industry sector with many of its leading companies based in
Europe. It became a suitable process to produce complex metal net shape parts, and
not only prototypes, as before. Additive manufacturing now enables both a design
and industrial revolution, in various industrial sectors such as aerospace, energy,
automotive, medical, tooling and consumer goods.

5.2 Fundamentals and basic principles

Additive manufacturing (AM) is the process of joining materials to make objects

from Computer Aided Design (CAD) model data, usually layer upon layer, as
opposed to subtractive manufacturing methods. Additive manufacturing is also called
3D printing, additive fabrication, or freeform fabrication.

Additive manufacturing is a novel method of manufacturing parts directly from

digital model by using layer by layer material build-up approach. This tool-less
manufacturing method can produce fully dense metallic parts in short time, with high
precision. Features of additive manufacturing like freedom of part design, part
complexity, light weighting, part consolidation and design for function are garnering
particular interests in metal additive manufacturing for aerospace, oil & gas, marine
and automobile applications.

computer-aided design (CAD) is created and exported to stereolithography (STL)

file format that is read by the AM equipment. There are many techniques available,
which can be categorized according to their raw material. They are: powder-based,
liquid-based and solid based. Some examples of powder-based techniques include

Department of Mechanical Engineering, MCE Hassan 38

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

selective laser melting (SLM), selective laser sintering (SLS), and electron beam
melting (EBM). Liquid-based techniques include stereolithography apparatus (SLA)
and poly jet while solid-based techniques include laminated object manufacturing
(LOM) and fused deposition modeling (FDM). The strengths of AM compared to
conventional manufacturing methods are listed further.

5.3 Steps in Additive manufacturing

Step 1: Create or Find a Design The first step of 3D printing typically starts on a
computer. You must create your design using a 3D design software, typically a CAD
(computer-aided design) software. If you are unable to create the design yourself, you
can also find many free resources online with free designs.

Step 2: Export the STL File Once you have created or chosen a design, you must
either export or download the STL file. The STL file is what stores the information
about your conceptual 3D object.

Step 3: Choose Your Materials Typically, you may have an idea about what kind of
material you will use before you print. There are many different 3D printing materials
available, and you can choose them based on the properties that you want your object
to have. We will discuss this more in- depth below.

Step 4: Choose Your Parameters The next step is then deciding on the different
parameters of your object and the printing process. This includes deciding on the size
and placement of your print.

Step 5: Create the G-code You will then import the STL file into a slicing software,
like BCN3Dcura. The slicing software will convert the information from the STL file
into a G code, which is a specific code containing exact instructions for the printer.

Step 6: Print This is when the magic happens! The printer will create the object layer
by layer. Depending on the size of your object, your printer, and the materials used,
the job can be done in a matter of minutes or over several hours.

Department of Mechanical Engineering, MCE Hassan 39

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

5.4 Process in Fluid Deposition Modelling (FDM) and process setup

Fused deposition modelling (FDM) 3D printing, also known as fused filament

fabrication (FFF), is an additive manufacturing (AM) process within the realm of
material extrusion. FDM builds parts layer by layer by selectively depositing melted
material in a predetermined path, and uses thermoplastic polymers that come in the
form of filaments.

Composing the largest installed base of desktop and industrial-grade 3D printers

worldwide, FDM is the most widely used technology and likely the first process you
think of when 3D printing comes up.

FDM 3D printing is a technology that works both horizontally and vertically, where
an extrusion nozzle moves over a build platform. The process involves the use of
thermoplastic material that reaches a melting point and is then forced out, to create a
3D object layer by layer. As the design takes shape, it is clear to see each layer as a
horizontal cross-section.

Fig 5.3 Fluid deposition modelling

5.5 Modelling Software (Solid works)

SolidWorks as you might already know is a solid modeling CAD and CAE program.
Owned by Dassault Systems, SolidWorks is used by millions of engineers and designers
worldwide. With so many capabilities, it’s no surprise to find that it competes with the best
in the CAD industry—allowing users to push the boundaries with design and engineering.

Department of Mechanical Engineering, MCE Hassan 40

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

SolidWorks was founded in December 1993 by Jon Hirschtick who used the $1 million he
made while a member of the MIT Blackjack Team to set up the company. Hirschtick then
recruited a team of engineers who set out with the aim of creating 3D CAD software. It was
intended to be accessible, affordable and available on Windows desktop.

Soon after, in November 1995, SolidWorks was released. It was the first significant
modeler for Windows. This proved to be a huge step in the subsequent evolution of CAD.
While AutoCAD had been released much earlier, SolidWorks brought something new to
the table 3D modeling. Consequently, 3D CAD became the focal point of the 1990s. Within
months, SolidWorks changed the way engineers brought their creations to life.

SolidWorks was so impressive in fact, that by 1997 it was acquired by none other than
Dassault systems best known for CATIA for a staggering $320 million in stock. Jon
Hirschtick stayed on board for the next 14 years. Under his leadership, SolidWorks grew
to a $100 million revenue company. Hirschtick later left to found another familiar company,
on shape, offering cloud-based CAD.

Features of SolidWorks

• Create sophisticated part and assembly designs quickly and efficiently using
powerful, easy-to-use software.
• Design Reuse and Automation.
• Part and assembly modeling.
• Interference Check.
• Design for Cost: Manufacturing Cost Estimation and Quoting.
• 2D Drawings.
• Design Analysis.

Advantages of SolidWorks

• Efficient 3D design.
• SOLIDWORKS is an easy to use parametric design modular, meaning you can
easily edit the design at any stage in the design process.
• Customer/Supplier Compatibility.
• Built-In Applications.
• Short Learning Curve.

Department of Mechanical Engineering, MCE Hassan 41

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

• After Sales Support

• Disadvantages of SolidWorks
• Solid works is continually improving its product, however, more focus could be put
into traditional drawings as opposed to MBD.
• Crashes can at times happen without warning or symptoms.
• The newer focus on cloud-based applications is a bit late to the game and needs
some work to bring it up to enterprise-class.

Applications of SolidWorks

• 3-D Model Design (CAD).

• Assembly of Parts.
• Analysis of Part (CAE).
• Making 2D Drawings.
• Making (CAM) Programming (CNC Machining).
• Making Additive Manufacturing (AM) (3D Printing).

5.6 3D Printed model

The below shown figure 5.8(a) is the “Bush bearing”, the model of the clamp bracket
is prepared using the Solid works and it is printed using the “ENDER 3PRO” printing
machine, the specifications are,

Printer name Ender 3 Pro

Material used PLA (Poly Lactic Acid)
Melting temperature 195 – 210 °c
Bed heating temperature 50 – 60 °c
Filament diameter 1.75mm
Slicing Parameters
Layer height 0.2mm
Density 20%
Fill pattern Grid type
Wall thickness 0.8mm
Top and bottom thickness 0.8mm

Department of Mechanical Engineering, MCE Hassan 42

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

Fig 5.6(a) Ender 3 pro 3D printer

Prepared 3d model of Bush bearing using solid works

Fig 5.6(b) Bush bearing model

Fig 5.6(c) 3D printed model of Bush bearing

Department of Mechanical Engineering, MCE Hassan 43

INDUSTRIAL AUTOMATION, CNC PROGRAMMING,SENSORICS,ADDITIVE MANUFACTURING

CHAPTER 6. SELF EVALUATION

6.1 Self evaluation
I thoroughly enjoyed a 4week internship under the expert’s guidance and now have a very
valuable experience under my belt. We all know that practical experience is the best, and
internships give students that hands-on experience they need. I also felt that quality
internships are essential to develop key skills. I gained a lot of insights especially in the
automation field and design and also had the privilege to interact with an industry expert
from MCE-Bosch Rexroth which was the biggest takeaway from this internship.

In the first part of internship program, we came to have a theoretical and in-hand practical
knowledge about pneumatics and electro pneumatics and in later stages we used these
components to build pneumatic circuits. We got to know about many practical scenarios
where we use these and their working phenomenon with these pneumatic circuits gave us
an insight towards the automation in industries. In Electro pneumatics we learnt about
different input signal devices like switches and their symbols. In parallel to this we
simulated some of the circuits in automation studio software and also the wide importance
and application of sensors in industrial automation.

In the next part of internship, we worked on computer numerical control (CNC) where we
came across different element elements of CNC system like input devices, machine control
unit (MCU), driving system, machine tool and feedback devices and also about different
codes like G-code and M-codes which are necessary to build a part program and to guide
machine and also had a hands-on experience in the CNC machine. In final part of Internship
program, we learnt about Computer Aided Design Software such as solid works we learnt
about 3D modelling and also the use of modelling software in additive manufacturing.

Overall, I found the internship experience quite useful. I hope, I will be able to apply the
experience I have gained during this period to my career as an engineer. Each and every
day was interesting where a new topic related to industry was taught. The trainings
regarding the above mentioned have proven to be really helpful in enhancing my
knowledge regarding various industrial automations.

Department of Mechanical Engineering, MCE Hassan 44