Course Title: Flexible Manufacturing Systems

Program: Mechanical Engineering

1.0 Principles of Numeric Control (NC)

Q1. Describe the key components and features of a typical NC machine tool.
a) List and explain major components. (5 marks)
b) Provide a labeled sketch. (5 marks)

Q2. Create an NC part program to machine a rectangular slot of 50 mm × 20 mm at a depth of 5

mm on a steel workpiece using G-code.
a) Write the complete G-code with appropriate commands. (6 marks)
b) Illustrate the tool path diagram. (4 marks)

2.0 Computerized Numeric Control (CNC)

Q3. Explain the function of input/output devices in CNC systems.

a) Describe input device types and roles. (5 marks)
b) Describe output device types and their functions. (5 marks)

Q4. Describe the reference pulse technique in CNC calibration.

a) Explain the concept and purpose. (5 marks)
b) Sketch a typical reference pulse system. (5 marks)

Q5. Discuss the role of sample-data techniques in CNC control.

a) Explain sample-data control and its benefits. (5 marks)
b) Provide a numerical example illustrating sampling interval effects. (5 marks)

Q6. Explain the architecture of a microcomputer-based CNC system.

a) Describe main components. (5 marks)
b) Explain how real-time control is achieved. (5 marks)

3.0 System Devices

Q7. Compare different types of drive systems used in CNC machines.

a) Explain characteristics of DC, AC, stepper, and servo drives. (6 marks)
b) List examples of application for each. (4 marks)

Q8. Describe types and working principles of CNC feedback devices.

a) Explain optical and magnetic encoders. (5 marks)
b) Include a labeled diagram. (5 marks)

Q9. Explain the working of counting devices and converters in CNC.

a) Describe counting mechanisms. (4 marks)
b) Explain roles of A/D and D/A converters. (3 marks)
c) Provide a functional sketch. (3 marks)
Q10. Define interpolation in CNC.
a) Explain linear and circular interpolation. (5 marks)
b) Provide numerical examples for both. (5 marks)

Q11. Explain the working of a Digital Differential Analyzer (DDA).

a) Describe its function in hardware interpolation. (4 marks)
b) Provide a numerical example of movement in steps. (6 marks)

Q12. Compare software and hardware interpolators.

a) Discuss pros and cons of both. (4 marks)
b) Illustrate reference-word interpolation with example and sketch. (6 marks)

Q13. Describe the control loop in a closed-loop NC system.

a) Provide a block diagram. (5 marks)
b) Explain error detection and correction process. (5 marks)

4.0 Adaptive Control Systems

Q14. Differentiate between ACO and ACC systems.

a) Define both control types. (4 marks)
b) Provide industrial implementation examples. (6 marks)

Q15. Describe variable-gain adaptive control systems.

a) Explain working principles. (5 marks)
b) Illustrate gain variation benefits with a sketch. (5 marks)

Q16. Explain adaptive control in grinding operations.

a) Describe implementation technique. (4 marks)
b) Provide numerical example for feed rate adjustment. (6 marks)

5.0 Industrial Robots

Q17. List and describe six degrees of freedom in robot arms.

a) List each DOF and corresponding joint type. (6 marks)
b) Provide a 3D sketch of a manipulator. (4 marks)

Q18. Explain the role of robot control and drive systems.

a) Describe control loop operation. (5 marks)
b) Sketch schematic of controller and actuator interaction. (5 marks)

Q19. Develop a basic robot program for pick and place.

a) Write the pseudo-code. (5 marks)
b) Provide labeled flowchart or diagram. (5 marks)
Q20. Define intelligent robots in modern FMS.
a) List characteristics and AI features. (5 marks)
b) Provide real-world application examples. (5 marks)

1. NC Machine Tools: Functional Architecture

a) Describe the control architecture of an NC machine tool and explain the significance of each
component in motion control. (6 marks)
b) Evaluate the limitations of NC systems in high-precision aerospace part production. (4 marks)

2. NC vs. CNC: Control Paradigm Shift

a) Compare the control algorithms used in traditional NC and modern CNC systems. (5 marks)
b) Analyze how these algorithms influence machining accuracy and repeatability. (5 marks)

3. NC Part Programming Logic

a) Given a component drawing, outline a G-code sequence for facing and turning operations. (6
marks)
b) Identify and explain the logical structure of the program with reference to modal and non-
modal commands. (4 marks)

4. Tool Path Planning

a) Discuss tool radius compensation in NC part programming and its impact on dimensional
tolerance. (6 marks)
b) Explain how cutter compensation is applied in CNC for complex profiles. (4 marks)

5. I/O Devices in CNC Systems

a) Explain the role of digital and analog I/O modules in CNC machine data acquisition and
actuation. (6 marks)
b) Discuss signal conditioning techniques used to prevent noise and interference in industrial
environments. (4 marks)
6. Reference Pulse Calibration

a) Explain the calibration process using the reference pulse technique in CNC encoders. (5
marks)
b) Justify its importance in closed-loop positioning accuracy. (5 marks)

7. Sample-Data Feedback Control

a) Illustrate the working of a sample-data control loop with a block diagram. (6 marks)
b) Explain the impact of sampling frequency on CNC performance and system stability. (4
marks)

8. Microprocessor-Based CNC Design

a) Describe the signal processing pipeline from motion command input to actuator output in a
microcomputer-based CNC. (6 marks)
b) Discuss the advantages of interrupt-driven control over polling in CNC systems. (4 marks)

9. Servo Drive Analysis

a) Model a DC servo motor used in CNC with its transfer function and explain the tuning
parameters. (6 marks)
b) Discuss how PID control is applied in CNC servo loops. (4 marks)

10. Stepper Motor Limitations

a) Analyze the resolution and torque characteristics of a stepper motor in high-speed CNC
operations. (5 marks)
b) Suggest techniques to mitigate missed steps in open-loop systems. (5 marks)

11. Encoder Technologies

a) Compare incremental and absolute encoders used in CNC machines. (6 marks)

b) Discuss their interfacing with motion control hardware. (4 marks)
12. Role of Counters and DACs

a) Explain how digital counters are used to calculate position feedback in CNC systems. (5
marks)
b) Describe a practical application of a DAC in spindle speed control. (5 marks)

13. Interpolation: Motion Execution

a) Define interpolation in CNC and explain the principle of NURBS interpolation. (6 marks)
b) Justify its use in complex surface machining. (4 marks)

14. Hardware DDA Interpolation

a) Derive the algorithm used in a digital differential analyzer for linear path generation. (6
marks)
b) Illustrate its hardware implementation using timing diagrams. (4 marks)

15. Software-Based Interpolation

a) Outline a software algorithm for circular interpolation using parametric equations. (6 marks)
b) Evaluate its computational complexity in real-time applications. (4 marks)

16. Reference Word Interpolation

a) Explain reference-word interpolation with respect to high-speed CNC contouring. (6 marks)

b) Demonstrate its use in 3-axis tool movement synchronization. (4 marks)

17. NC Control Loops

a) Discuss the architecture and signal flow in a closed-loop NC servo control system. (6 marks)
b) Identify how loop gain affects dynamic response and positioning error. (4 marks)
18. Adaptive Control Fundamentals

a) Model an adaptive control system for turning using block diagrams. (5 marks)
b) Explain how real-time machining parameters are adjusted for optimal performance. (5 marks)

19. Adaptive Control with Optimization (ACO)

a) Analyze how ACO dynamically adjusts feed rate and spindle speed. (6 marks)
b) Assess its effect on tool life and surface finish in milling operations. (4 marks)

20. Adaptive Control with Constraints (ACC)

a) Develop a logic flow for an ACC system used in boring operations. (6 marks)
b) Compare this with ACO under varying load conditions. (4 marks)

21. Variable-Gain AC Systems

a) Explain the concept of variable gain in control loops and its implementation in CNC. (5
marks)
b) Analyze stability implications when using adaptive gain in a servo drive. (5 marks)

22. Adaptive Grinding Control

a) Discuss the control variables monitored in adaptive grinding. (5 marks)

b) Propose a control algorithm to minimize wheel wear and improve geometry retention. (5
marks)

23. Robot Arm Kinematics

a) Derive the forward kinematic equations for a 2-DOF planar manipulator. (6 marks)
b) Apply the results to determine the end-effector position. (4 marks)

24. Robot Dynamics

a) Discuss the dynamic modeling of a robot joint using the Euler-Lagrange method. (6 marks)
b) Apply it to a single rotary joint with torque input. (4 marks)

25. Robot Actuators

a) Compare the performance of servo motors vs. hydraulic actuators for robotic applications. (6
marks)
b) Recommend actuator selection for a spot-welding robot. (4 marks)

26. Trajectory Planning

a) Design a 5-point trajectory using cubic spline interpolation. (6 marks)

b) Explain its role in smooth end-effector movement. (4 marks)

27. Offline Robot Programming

a) Discuss how offline programming is used to reduce robot commissioning time. (5 marks)
b) Describe the limitations when deployed in real-time industrial environments. (5 marks)

28. Intelligent Robots

a) Define intelligent control in robots and describe its architecture. (6 marks)

b) Discuss one industrial application of AI-based decision-making. (4 marks)

29. CIM Architecture

a) Construct a hierarchical CIM model and describe the data flow at each level. (6 marks)
b) Analyze its contribution to end-to-end traceability in production. (4 marks)

30. Flexible Manufacturing System Components

a) Identify and describe four major components of an FMS. (6 marks)

b) Analyze their integration via an industrial communication protocol (e.g., OPC UA). (4 marks)
31. CAD/CAM Data Exchange

a) Describe the IGES or STEP standard and its role in CAD/CAM interoperability. (6 marks)
b) Explain how model integrity is preserved across platforms. (4 marks)

32. CAM NC Code Generation

a) Outline how CAM software generates tool paths based on surface geometry. (6 marks)
b) Identify the post-processing steps required before CNC execution. (4 marks)

33. Manufacturing Database Design

a) Design a relational database schematic for production scheduling and inventory control. (6
marks)
b) Explain normalization and query optimization in this context. (4 marks)

34. AS/RS System Modeling

a) Model an AS/RS system using queuing theory. (5 marks)

b) Calculate throughput based on cycle time and bin allocation. (5 marks)

35. Product Lifecycle Integration in CAD/CAM

a) Explain the role of PDM (Product Data Management) in CAD/CAM integration. (6 marks)
b) Assess how change management is handled in concurrent engineering. (4 marks)

36. Trends in Factory Automation

a) Critically analyze the impact of Industry 4.0 on discrete manufacturing. (6 marks)

b) Compare digital twin and cyber-physical systems in automation. (4 marks)
37. Automated Production Line Layout

a) Design a control logic layout for an automated bottling line using PLC. (6 marks)
b) Explain how sensors and actuators are synchronized. (4 marks)

38. PLC Ladder Logic Programming

a) Develop a ladder logic for a motor-controlled conveyor with interlocks. (6 marks)

b) Simulate the logic using Boolean algebra expressions. (4 marks)

39. Timers and Counters in PLC

a) Implement a PLC timer and counter combination for batch processing. (5 marks)
b) Explain reset conditions and scan cycle dependency. (5 marks)

40. Fault Diagnosis in PLCs

a) Identify three common faults in PLC-controlled systems. (3 marks)

b) Propose systematic troubleshooting procedures for each. (7 marks)

41. CNC-Robot Cell Integration

a) Design a control system for a CNC-robot cell with synchronized motion. (6 marks)
b) Explain inter-process communication using a fieldbus system. (4 marks)

42. Cybersecurity in CIM

a) Discuss potential cyber threats in networked manufacturing environments. (6 marks)

b) Propose mitigation strategies for data and control integrity. (4 marks)

43. Machine Vision for Inspection

a) Explain how machine vision is integrated into FMS for defect detection. (6 marks)
b) Provide an algorithm for edge detection or pattern recognition. (4 marks)

44. Digital Twin for Manufacturing

a) Define a digital twin and describe its structure for an FMS. (6 marks)
b) Evaluate its role in predictive maintenance. (4 marks)

45. Industrial IoT Integration

a) Describe how IIoT enables real-time data monitoring in FMS. (5 marks)

b) Explain the data communication protocols involved. (5 marks)

46. CNC Machine Learning Applications

a) Discuss how machine learning algorithms are used to predict tool wear. (6 marks)
b) Propose a supervised learning model for feed rate optimization. (4 marks)

47. Simulation in Manufacturing

a) Design a discrete event simulation model for a CNC machining cell. (6 marks)
b) Evaluate its use in capacity planning. (4 marks)

48. Human-Machine Interface Design

a) Define the design considerations of an effective CNC HMI. (5 marks)

b) Propose improvements for operator error reduction. (5 marks)

49. Safety Systems in Automation

a) Analyze the functional safety requirements of an automated assembly line. (6 marks)

b) Explain how safety relays and light curtains are integrated. (4 marks)
50. Cloud Manufacturing Models

a) Compare IaaS, PaaS, and SaaS models for cloud manufacturing deployment. (6 marks)
b) Evaluate their use in distributed CNC operations. (4 marks)

Q1. NC Machine Tools: Functional Architecture

a) Explain the control architecture including:

• Input unit (e.g., punched tape reader, modern USB)

• Machine Control Unit (MCU) handling control logic
• Drive system (actuators for axes/spindle)
• Feedback system (for closed-loop positioning)
• Display/monitoring unit (e.g., HMI)
→ 6 marks

b) Evaluate at least two limitations:

• No feedback mechanism (open-loop)

• Limited to simple geometries
• Rigid hardwired logic without programmability
→ 4 marks

Q2. NC vs. CNC: Control Paradigm Shift

a) Comparison elements:

• NC uses hardwired logic; CNC uses microcontrollers/software

• CNC supports complex part geometries and parametric programs
• Higher flexibility and easier updates in CNC
→ 5 marks

b) Analysis points:

• CNC accuracy due to real-time feedback loops

• Repeatability through programmable motion
• Human error reduction through automation
→ 5 marks

Q3. NC Part Programming Logic

a) G-code program includes:

• Proper syntax: G90 (absolute), G00 (rapid), G01 (linear), F-feed, S-spindle
• Clear logic: start, tool move, cutting, retract
• Tool change, spindle ON/OFF as required
→ 6 marks

b) Explain:

• Modal (stay active) vs non-modal (execute once)

• Logical sequencing (startup → operation → shutdown)
• Role of comments and block structure
→ 4 marks

Q4. Tool Path Planning

a) Tool radius compensation:

• G41 (left), G42 (right), G40 (cancel)

• Real path vs programmed path differences
• Importance for precision in profile cutting
→ 6 marks

b) Cutter compensation in CNC:

• Offset registers used to define tool geometry

• Enables re-use of programs with different tool sizes
→ 4 marks

Q5. I/O Devices in CNC Systems

a) Description of:

• Digital I/O for binary devices (e.g., sensors, relays)

• Analog I/O for variable control (e.g., spindle speed)
• Role in real-time control and automation
→ 6 marks

b) Signal integrity techniques:

• Use of twisted pairs, shielding, differential signaling

 • Ground loops prevention and noise filters
→ 4 marks

Q6. Reference Pulse Techniques in CNC

a) Describe:

• Role of reference pulse in establishing machine zero

• Homing procedure using limit switches and encoders
• Importance of establishing absolute positioning
→ 6 marks

b) Significance:

• Incremental encoders lack absolute position memory

• System requires referencing on startup to avoid cumulative error
→ 4 marks

Q7. Sample-Data Techniques

a) Operation:

• Discrete control using time-sampled data

• Includes ADC/DAC conversion, zero-order hold, and digital filters
• Practical CNC implementation
→ 5 marks

b) Effect of sampling rate:

• Low rates cause aliasing, instability, lag

• High rates increase control precision, reduce error but increase computation
→ 5 marks

Q8. Microcomputer-Based CNC

a) Architecture:

• CPU for logic/control

• RAM/ROM for temporary storage and firmware
• I/O interfaces for devices
• Buses (data/control/address) to interconnect units
→ 6 marks
b) Support for real-time tasks:

• Timer interrupts, multitasking OS

• Non-volatile storage for part programs (e.g., EEPROM, flash)
→ 4 marks

Q9. Drives: Stepper vs Servo

a) Comparison:

• Servo: high torque at high speeds, feedback loop, closed-loop

• Stepper: simpler, open-loop, risk of missing steps
• Include examples like CNC routers (servo) vs 3D printers (stepper)
→ 6 marks

b) Suitability:

• Servo better for CNC: higher resolution, adaptive correction

• Closed-loop feedback ensures precision under load
→ 4 marks

Q10. Feedback Devices in CNC

a) Feedback types:

• Rotary encoders (incremental, absolute)

• Linear scales for linear position feedback
• Absolute encoders retain position after power loss
→ 6 marks

b) Closed-loop control:

• Compare actual vs commanded position

• Error signal adjusts motor to correct position
→ 4 marks

Q11. Counting Devices and Data Converters

a) Describe:

• Role of counting devices (up/down counters) in pulse counting from encoders

 • Use in tracking motor shaft position or linear displacement
→ 6 marks

b) A/D and D/A conversion:

• A/D: converts analog signals (from sensors) to digital for logic processing
• D/A: sends control signals (e.g., speed commands) to analog actuators
→ 4 marks

Q12. Interpolation Techniques in CNC

a) Define and explain:

• Interpolation: calculation of intermediate positions between points

• Linear (G01) and circular (G02/G03) interpolation
• Include trajectory diagrams for clarity
→ 6 marks

b) Contribution to accuracy:

• Smooth movement along programmed paths

• Reduces mechanical jerks and improves surface finish
→ 4 marks

Q13. Digital Differential Analyzer (DDA)

a) Structure and function:

• DDA: generates incremental steps to approximate straight/circular paths

• Operates using simple add/subtract logic in real-time
→ 6 marks

b) DDA hardware vs software:

• Hardware: fast, less flexible

• Software: programmable, scalable for complex paths
→ 4 marks

Q14. CNC Interpolators

a) Explanation:

• Software interpolator: uses CPU for trajectory generation

• Reference-word interpolator: pre-defined motion blocks interpreted by controller
→ 6 marks

b) Evaluation:

• Software interpolators allow flexible control over multi-axis movement

• Reference-word suited for high-speed, repetitive machining
→ 4 marks

Q15. CNC Control Loops

a) Control loop components:

• Reference input → Comparator → Controller (PID) → Actuator (motor) → Plant

(machine) → Feedback (encoder)
• Diagram may be included
→ 6 marks

b) Gain tuning:

• Affects responsiveness, damping, stability

• Poor tuning leads to oscillations or slow response
→ 4 marks

Q16. Adaptive Control in CNC

a) Concept explanation:

• Real-time monitoring of parameters (cutting force, temperature, vibration)

• Adjusts spindle speed, feed rate, or depth of cut automatically
→ 6 marks

b) Benefits:

• Increases productivity through optimal machining speeds

• Enhances tool life by preventing overload or overheating
→ 4 marks

Q17. Adaptive Control with Optimization

a) Working principle:

• Objective function (e.g., maximize material removal rate)

• Feedback from sensors used to adjust inputs
• Uses optimization algorithms in real time
→ 6 marks

b) Challenges:

• High processing power required

• Difficulty in managing nonlinear system behavior in real-time
→ 4 marks

Q18. Adaptive Control with Constraints

a) Explanation:

• System monitors constraints like spindle torque, vibration, or deflection

• Adjusts cutting conditions to stay within safe limits
→ 6 marks

b) Control loop:

• Sensors (force, acceleration, etc.) provide constraint data

• Controller modifies inputs to maintain system within limits
→ 4 marks

Q19. Variable-Gain Adaptive Control Systems

a) Operation:

• Control gain adjusted dynamically based on error trends or system state

• For example, higher gain during roughing, lower gain during finishing
→ 6 marks

b) Robustness:

• Compensates for process variation (tool wear, material inhomogeneity)

• Improves stability and response in unpredictable environments
→ 4 marks
Q20. Adaptive Control for Grinding

a) Application:

• Controls wheel speed, feed rate, and spark-out time

• Adapts to wheel wear, workpiece material, and heat generation
→ 6 marks

b) Impact:

• Improves surface quality and consistency

• Reduces risk of thermal damage and dimensional inaccuracy
→ 4 marks

Q21. Industrial Robots – Basic Concepts

a) Explain:

• Definition of an industrial robot (per ISO)

• Key features: programmability, multi-functionality, reprogrammability, and degrees of
freedom
→ 6 marks

b) Applications:

• Arc welding, pick and place, assembly, painting

• Explain how robotics improves productivity and safety
→ 4 marks

Q22. The Manipulator

a) Structure:

• Links and joints: revolute and prismatic

• Configuration types (e.g., SCARA, Cartesian, articulated)
• Forward and inverse kinematics
→ 6 marks

b) Joint constraints:

• Joint limits, backlash, compliance

 • How they affect workspace and accuracy
→ 4 marks

Q23. Robot Control and Drives

a) Control systems:

• Point-to-point vs continuous path control

• Open-loop vs closed-loop systems
→ 6 marks

b) Drive types:

• Electrical (servo, stepper), pneumatic, hydraulic

• Evaluate based on payload, speed, and precision
→ 4 marks

Q24. Robot Programming

a) Techniques:

• Online (teaching pendant) vs offline programming (simulation software)

• Programming languages: VAL, RAPID, KRL
→ 6 marks

b) Application-specific example:

• Pick-and-place: define movement, coordinates, gripper actuation

→ 4 marks

Q25. Intelligent Robots

a) Characteristics:

• Use of AI: vision systems, decision-making, sensor fusion

• Learning capability, self-calibration, environmental adaptation
→ 6 marks

b) Integration:
 • How intelligent robots adapt in unstructured environments (e.g., warehouse automation)
• Interaction with humans (cobots)
→ 4 marks

Q26. Computer Integrated Manufacturing (CIM)

a) Define and explain:

• CIM as the integration of CAD, CAM, robotics, material handling, and control systems
• Objectives: efficiency, flexibility, and real-time production management
→ 6 marks

b) Benefits:

• Reduced lead times, better inventory control, data consistency

→ 4 marks

Q27. Hierarchical Computer Control in CIM

a) Hierarchy levels:

• Plant level (business planning), cell level (production control), machine level (servo
control)
• Explain roles at each level with examples
→ 6 marks

b) Coordination:

• Information flow across layers

• Role of central database or communication network
→ 4 marks

Q28. Flexible Manufacturing Systems (FMS)

a) Components of FMS:

• CNC machines, material handling systems, control systems

• Flexibility in routing and machine scheduling
→ 6 marks

b) Advantages over conventional systems:

 • Reduced setup time, better utilization, adaptability to change
→ 4 marks

Q29. CAD/CAM Systems

a) Integration process:

• From product design (CAD) to automated manufacturing (CAM)

• File formats (e.g., DXF, IGES), toolpath generation
→ 6 marks

b) Example:

• Design-to-manufacturing of a machined bracket using CAD and CAM software

→ 4 marks

Q30. Database-Based Production Management

a) Role of database:

• Stores product data, process plans, schedules, inventory, and quality records
• Supports decision-making through real-time access
→ 6 marks

b) Advantages:

• Traceability, consistency, integration across departments

→ 4 marks

Q31. Automatic Storage and Retrieval Systems (AS/RS)

a) Components and operation:

• Storage racks, conveyors, shuttles/cranes, and control systems

• Automated handling of materials based on inventory systems
→ 6 marks

b) Application and benefits:

• Use in warehouses and FMS

• Space optimization, accuracy, labor reduction
→ 4 marks
Q32. Product Design in CAD/CAM

a) Product design cycle in CAD/CAM:

• Conceptual design → detailed modeling → analysis (FEA/CFD) → manufacturing

• CAD features: parametric modeling, constraints, simulation
→ 6 marks

b) Integration advantage:

• Eliminates data redundancy, enhances design validation and speed to market

→ 4 marks

Q33. Trends in Factory Automation

a) Emerging technologies:

• Industry 4.0, IoT, cyber-physical systems, smart sensors

• AI and ML in predictive maintenance
→ 6 marks

b) Impact on manufacturing:

• Increased flexibility, real-time control, reduced downtime

→ 4 marks

Q34. Automated Production Lines

a) Structure and operation:

• Sequential arrangement of machines with automated part handling

• Types: synchronous, asynchronous, semi-automated
→ 6 marks

b) Suitability:

• Mass production of standardized components (e.g., automotive)

• Enhances throughput and quality control
→ 4 marks
Q35. PLC Programming

a) PLC structure and logic:

• CPU, memory, I/O modules

• Programming languages: Ladder logic, FBD, STL
→ 6 marks

b) Example application:

• Develop a ladder diagram to control a conveyor system with start/stop sensors

→ 4 marks

Q36. Industrial Automation: Concepts

a) Define industrial automation:

• Use of control systems (PLC, CNC, SCADA) for operating equipment with minimal
human intervention
• Types: fixed, programmable, flexible, integrated
→ 6 marks

b) Impact on manufacturing:

• Improved quality, increased throughput, reduced labor costs

→ 4 marks

Q37. Automation vs Mechanization

a) Comparison:

• Automation: full control of processes, includes feedback and decision-making

• Mechanization: human-operated tools with mechanical power
→ 6 marks

b) Practical implications:

• Examples: CNC vs manual lathe; robot welding vs manual welding

→ 4 marks
Q38. Integration of PLC with SCADA

a) Architecture:

• PLC as real-time hardware controller

• SCADA as supervisory interface for monitoring and logging
• Communication protocols (Modbus, Ethernet/IP)
→ 6 marks

b) Industrial benefits:

• Real-time diagnostics, remote access, alarm management

→ 4 marks

Q39. Safety in Automated Systems

a) Safety mechanisms:

• Emergency stops, light curtains, interlocks, fail-safe relays

• Safety PLCs and ISO 13849/IEC 62061 compliance
→ 6 marks

b) Risk mitigation:

• Human error prevention, hazard reduction, safe robot interaction

→ 4 marks

Q40. Simulation in FMS

a) Use of simulation tools:

• Simulating material flow, machine operation, layout optimization

• Tools: Arena, Siemens Plant Simulation, FlexSim
→ 6 marks

b) Benefits:

• Bottleneck identification, production planning, reduced downtime

→ 4 marks

Q41. Communication Protocols in CIM

a) Key protocols:

• RS232/RS485, Ethernet, Modbus, PROFIBUS, OPC-UA

• Role in enabling interoperability among machines, sensors, and controllers
→ 6 marks

b) Application example:

• Data exchange between CNC machines and central database using OPC-UA
→ 4 marks

Q42. Role of Sensors in Automation

a) Types and roles:

• Proximity, temperature, pressure, vision sensors

• Used for feedback, quality control, process regulation
→ 6 marks

b) Example:

• Proximity sensors in pick-and-place robot for part presence verification

→ 4 marks

Q43. Integration of Vision Systems in Robotics

a) Vision system components:

• Camera, lighting, processor, software algorithms

• Used for object detection, measurement, guidance
→ 6 marks

b) Industrial use-case:

• Robot bin picking using 3D vision system

→ 4 marks

Q44. Cybersecurity in Smart Manufacturing

a) Threats and vulnerabilities:

 • Unauthorized access, data breaches, malware in PLCs/SCADA
→ 6 marks

b) Countermeasures:

• Firewalls, access control, encryption, regular patching

→ 4 marks

Q45. Human-Machine Interface (HMI)

a) Functionality:

• Displays machine/process status, allows user control and configuration

• Real-time monitoring dashboards, alarms, user inputs
→ 6 marks

b) Design principles:

• Intuitive layout, real-time feedback, safety indicators

→ 4 marks

Q46. SCADA in Manufacturing Systems

a) Components and functions:

• Supervisory control, real-time data acquisition, HMI, communication protocols

• Monitors sensors and actuators, provides trends and alarms
→ 6 marks

b) Use-case:

• SCADA controlling and monitoring an automated bottling plant

→ 4 marks

Q47. Role of Artificial Intelligence in Manufacturing

a) Applications:

• Predictive maintenance, defect detection, process optimization

• Use of ML models for decision-making
→ 6 marks
b) Case example:

• AI-based vision system for automatic quality inspection in CNC machining

→ 4 marks

Q48. Digital Twin Technology

a) Concept:

• Virtual replica of physical system with real-time data synchronization

• Enables simulation, monitoring, predictive analytics
→ 6 marks

b) Benefits:

• Real-time decision support, failure prediction, performance optimization

→ 4 marks

Q49. Cloud Computing in Smart Factories

a) Role and architecture:

• Centralized data storage, accessibility, scalability

• Supports applications like MES, ERP integration
→ 6 marks

b) Industrial benefits:

• Enables global monitoring, reduces infrastructure costs, facilitates big data analytics
→ 4 marks

Q50. Sustainable Manufacturing through Automation

a) Techniques:

• Energy-efficient machines, predictive maintenance, material optimization

→ 6 marks

b) Benefits:
 • Reduced carbon footprint, waste minimization, compliance with green standards
→ 4 marks

#4

1. Flexible Manufacturing Systems (FMS)

a) Analyze the main components and workflow of a Flexible Manufacturing System. (8 marks)
b) Evaluate the advantages and limitations of implementing FMS in a modern manufacturing
plant. (6 marks)
c) Discuss real-world scenarios where FMS significantly improved production efficiency. (6
marks)

2. CAD/CAM Systems and CAM

a) Explain how CAD and CAM systems integrate to enhance manufacturing processes. (6 marks)
b) Analyze the impact of CAM automation on machining accuracy and cycle times. (6 marks)
c) Evaluate the challenges associated with implementing CAD/CAM systems in small to medium
enterprises (SMEs). (8 marks)

3. Databased Production Management

a) Describe the structure and role of production databases in manufacturing management. (6

marks)
b) Analyze how database management systems improve production scheduling and inventory
control. (7 marks)
c) Evaluate risks related to data security and integrity in databased production environments.
Suggest mitigation strategies. (7 marks)

4. Automatic Storage and Retrieval Systems (AS/RS)

a) Explain the operating principles of AS/RS and their role in flexible manufacturing. (7 marks)
b) Analyze the effect of AS/RS implementation on warehouse efficiency and order fulfillment
times. (6 marks)
c) Evaluate cost-benefit factors influencing the decision to automate storage in manufacturing
facilities. (7 marks)

5. Product Design and CAD/CAM

a) Analyze the role of CAD in early product design stages and its impact on downstream
manufacturing. (7 marks)
b) Explain how CAD data is utilized in CAM for process planning and tooling. (6 marks)
c) Evaluate the benefits and drawbacks of integrating product lifecycle management (PLM) with
CAD/CAM systems. (7 marks)
6. Trends in Factory Automation

a) Identify and analyze recent trends in factory automation technologies. (7 marks)

b) Evaluate how Industry 4.0 concepts like IoT and cyber-physical systems are transforming
manufacturing. (7 marks)
c) Discuss barriers to adoption of advanced automation in traditional manufacturing settings. (6
marks)

7. Automated Production Lines

a) Analyze the design considerations for an automated production line for mass manufacturing.
(7 marks)
b) Evaluate the trade-offs between flexibility and efficiency in automated production lines. (7
marks)
c) Discuss how downtime and maintenance are managed in automated production environments.
(6 marks)

8. PLC Programming

a) Analyze the structure and function of a typical PLC used in industrial automation. (7 marks)
b) Explain the logic behind ladder programming and how it controls manufacturing equipment.
(7 marks)
c) Evaluate troubleshooting techniques and their importance in maintaining PLC-based systems.
(6 marks)

9. Industrial Automation

a) Describe the key components and architecture of industrial automation systems. (6 marks)
b) Analyze the benefits and challenges of integrating robotics within automated manufacturing
systems. (7 marks)
c) Evaluate how automation influences workforce skills requirements and training in industry. (7
marks)

10. Integrated Flexible Manufacturing

a) Analyze how integration of CAD/CAM, databased management, and automation optimizes

flexible manufacturing systems. (8 marks)
b) Evaluate the role of real-time data and communication networks in system responsiveness and
control. (6 marks)
c) Discuss potential future developments and their implications for flexible manufacturing. (6
marks)

1. Flexible Manufacturing Systems (FMS)

a) Analyze the main components and workflow of a Flexible Manufacturing System.

• Main components:
o Workstations: Automated CNC machines or assembly stations.
o Material Handling System: Automated guided vehicles (AGVs), conveyors, or
robotic arms.
o Central Control System: Supervisory computer managing scheduling, routing, and
resource allocation.
o Communication Network: Links workstations, storage, and control units.
• Workflow:
o Raw materials enter the system → assigned to appropriate machines →
processing according to programmed sequence → intermediate storage or
buffering → assembly or finishing → final product dispatch.

b) Evaluate the advantages and limitations of implementing FMS in a modern

manufacturing plant.

• Advantages:
o High flexibility in product variety and volume.
o Reduced setup and changeover times.
o Improved productivity and utilization of machines.
o Enhanced quality control through automation.
• Limitations:
o High initial capital investment.
o Complexity in system integration and programming.
o Requires skilled workforce for maintenance and operation.
o Dependence on reliable communication and control systems.

c) Discuss real-world scenarios where FMS significantly improved production efficiency.

• Automotive industry: FMS used for flexible production of various car models with
minimal downtime.
• Aerospace: Producing small batches with high customization and precision.
• Electronics manufacturing: Rapid reconfiguration for changing product designs and
volumes.
• Resulted in shorter lead times, improved on-time delivery, and reduced work-in-process
inventory.

2. CAD/CAM Systems and CAM

a) Explain how CAD and CAM systems integrate to enhance manufacturing processes.

• CAD systems create detailed digital models of products.

• CAM uses CAD data to generate tool paths and machine instructions automatically.
 • Integration enables seamless transition from design to manufacturing, reducing errors and
manual data entry.

b) Analyze the impact of CAM automation on machining accuracy and cycle times.

• CAM reduces human errors by automating tool path generation.

• Optimizes machining parameters for material removal rates and tool life.
• Shortens cycle times through efficient path planning and operation sequencing.

c) Evaluate the challenges associated with implementing CAD/CAM systems in SMEs.

• High initial cost for software licenses and hardware.

• Need for trained personnel to operate and maintain systems.
• Resistance to change from traditional manufacturing methods.
• Compatibility issues between different CAD/CAM software.

3. Databased Production Management

a) Describe the structure and role of production databases in manufacturing management.

• Production databases store information on orders, inventory, machine status, schedules,

and quality data.
• Structured to enable quick retrieval and update, often relational databases.
• Support decision-making, tracking, and reporting.

b) Analyze how database management systems improve production scheduling and

inventory control.

• Real-time data enables dynamic scheduling adjustments based on resource availability.

• Inventory levels monitored accurately, reducing stockouts and overstocking.
• Automation reduces manual errors and enhances coordination.

c) Evaluate risks related to data security and integrity in databased production

environments. Suggest mitigation strategies.

• Risks: Unauthorized access, data corruption, system failures.

• Mitigation: Use of firewalls, encryption, regular backups, user authentication, and audit
trails.

4. Automatic Storage and Retrieval Systems (AS/RS)

a) Explain the operating principles of AS/RS and their role in flexible manufacturing.
 • AS/RS use automated mechanisms (cranes, shuttles) to store and retrieve materials.
• Operate via computer control systems integrated with production schedules.
• Reduce manual labor, improve space utilization, and speed up material handling.

b) Analyze the effect of AS/RS implementation on warehouse efficiency and order

fulfillment times.

• Increases throughput by reducing retrieval times.

• Enhances accuracy and reduces errors in picking.
• Improves inventory control and storage density.

c) Evaluate cost-benefit factors influencing the decision to automate storage in

manufacturing facilities.

• Costs: Capital investment, maintenance, training.

• Benefits: Labor savings, improved productivity, reduced inventory holding costs.
• Decision depends on throughput requirements, labor costs, and space constraints.

5. Product Design and CAD/CAM

a) Analyze the role of CAD in early product design stages and its impact on downstream
manufacturing.

• CAD enables detailed and precise design, allowing simulation and testing before physical
production.
• Facilitates design for manufacturability, reducing redesigns and errors.
• Enhances collaboration across departments.

b) Explain how CAD data is utilized in CAM for process planning and tooling.

• CAD geometries are translated into tool paths and machine instructions.
• Enables selection of optimal tools, cutting parameters, and machining sequences.
• CAM software simulates machining to identify potential issues.

c) Evaluate the benefits and drawbacks of integrating product lifecycle management

(PLM) with CAD/CAM systems.

• Benefits: Centralized data management, version control, and collaboration.

• Drawbacks: Complexity, cost, and the need for extensive training.

6. Trends in Factory Automation

a) Identify and analyze recent trends in factory automation technologies.

• Adoption of IoT for real-time monitoring.

• Use of AI and machine learning for predictive maintenance.
• Integration of collaborative robots (cobots).
• Advanced sensors and vision systems for quality control.

b) Evaluate how Industry 4.0 concepts like IoT and cyber-physical systems are
transforming manufacturing.

• Enable smart factories with autonomous decision-making.

• Increase flexibility and responsiveness to market changes.
• Improve efficiency through predictive analytics.

c) Discuss barriers to adoption of advanced automation in traditional manufacturing

settings.

• High cost and complexity of new technologies.

• Legacy equipment incompatibility.
• Workforce resistance due to job security concerns.
• Cybersecurity risks.

7. Automated Production Lines

a) Analyze the design considerations for an automated production line for mass
manufacturing.

• Layout planning for minimal material movement.

• Selection of appropriate automation and robotics.
• Balancing line speed and workload.
• Safety and maintenance access.

b) Evaluate the trade-offs between flexibility and efficiency in automated production lines.

• Highly specialized lines are efficient but inflexible.

• Flexible lines handle product variety but may have lower throughput.
• Decision depends on product demand and lifecycle.

c) Discuss how downtime and maintenance are managed in automated production

environments.

• Scheduled preventive maintenance.

• Condition monitoring and predictive maintenance.
• Rapid fault diagnosis and modular replacement.
8. PLC Programming

a) Analyze the structure and function of a typical PLC used in industrial automation.

• Components: CPU, memory, input/output modules, power supply.

• Function: Executes control logic to operate machinery based on input signals.

b) Explain the logic behind ladder programming and how it controls manufacturing
equipment.

• Ladder logic mimics relay control circuits.

• Uses contacts and coils to represent inputs and outputs.
• Facilitates easy programming and troubleshooting.

c) Evaluate troubleshooting techniques and their importance in maintaining PLC-based

systems.

• Techniques: Monitoring I/O status, checking timers/counters, using diagnostic tools.

• Importance: Minimizes downtime, ensures process reliability, and prevents costly
production losses.

9. Industrial Automation

a) Describe the key components and architecture of industrial automation systems.

• Sensors and actuators.

• Controllers (PLCs, CNCs, DCS).
• Human-Machine Interfaces (HMIs).
• Communication networks.

b) Analyze the benefits and challenges of integrating robotics within automated

manufacturing systems.

• Benefits: Increased precision, speed, and safety.

• Challenges: High cost, complex programming, and integration issues.

c) Evaluate how automation influences workforce skills requirements and training in

industry.

• Shift towards high-tech skills like programming and system integration.

• Need for continuous learning and adaptability.
• Potential reduction in manual labor but increase in technical jobs.
10. Integrated Flexible Manufacturing

a) Analyze how integration of CAD/CAM, databased management, and automation

optimizes flexible manufacturing systems.

• Enables seamless data flow from design to production.

• Improves responsiveness to design changes and demand fluctuations.
• Enhances traceability and quality control.

b) Evaluate the role of real-time data and communication networks in system

responsiveness and control.

• Real-time data allows instant adjustments to production schedules.

• Networks enable coordination between machines and systems.
• Reduces latency and errors.

c) Discuss potential future developments and their implications for flexible manufacturing.

• Increased use of AI for autonomous decision making.

• Greater adoption of digital twins and simulation.
• Enhanced human-machine collaboration.
• Potential for fully decentralized manufacturing