9.5 PRACTICE PROBLEMS

1. For the part shown below, design a part feeder.

2. For the product below describe the various DFA problems and suggest solutions.

3. Design a system for making coffee and pouring it into styrofoam cups. Lids must be put on after the coffee is complete. The user should be able to select 1 or 2 creams and/or sugars by pressing buttons. This should include rough mechanical layout, electrical connections, actuators and sensors, feeders, etc.

4. For the robot pictured below,

a) calculate 5 (x,y) points along a straight line path from (0.5,0.5) to (-0.5,0.5).

b) Develop the inverse kinematic equations and calculate the joint angles at each of the points in part a)

1. Briefly describe the relationship between CAD, CAM and CIM. (3%)

1. Show graphically how we would choose between manual labor and fixed automation. (3%)

1. What technological limitations reduce the chance of success when implementing a new CIM/FMS system? (2%)

1. Give examples of equipment for each of the four levels of the Shop Floor Production Model. (4%)

1. What use would the IDEF0 model have in an automated factory? (2%)

1. What use would a graphical user interface (GUI) have in workcell control. Use an example to illustrate your reason. (3%)

1. What robotic configurations (e.g., SCARA) and number of degrees of freedom are suitable for the following tasks. If needed write any assumptions made as footnotes below the table. (6%)

1. Design a material handling system based on vibratory feeders to sort the parts below. Assume the parts are mixed together in the same bin, and the parts will emerge from the same vibratory feeder in two separate tracks. (8%)

1. The part below is to be assembled in an automated facility. We want to apply design for assembly principles to reduce our assembly time and cost.

* A sketch of a simple assemblyXXXXX

a) what is the theoretical minimum number of parts? (2%)

b) for each of the parts in the assembly describe DFA oriented problems. (4%)

c) select parts that are candidates for redesign, combination or elimination. (3%)

d) develop a new design based on your analysis. Rough sketches are required. (8%)

1. We want to design a 2 d.o.f. robot for gluing on continuous paths. The robot will be articulated, as shown below. We want to do some high and low level design before ordering components, fabricating parts and writing software.

a) What are forward kinematic equations? (6%)

b) What are the inverse kinematic equations? Give all possible solutions. (6%)

c) Develop the Jacobian matrix for the robot, also find the Inverse Jacobian. (6%)

d) select suitable actuators for positioning the robot. (3%)

e) select suitable sensors for determining joint positions. (3%)

f) roughly design the EOAT for picking up spherical objects. (6%)

g) Develop the equations needed to find points on the robots straight line (point to point) motion paths. The robot should start and stop smoothly. (6%)

h) Develop a complete block diagram of the robotic system. Clearly name all of the boxes and label the inputs and outputs. (10%)

i) Assuming that the robot uses the AML programming language, write a program to track a square with the bottom left corner at (2m, 1m), and the top right corner at (3m, 1.5m). Make any reasonable assumptions needed. (6%)