INTRODUCTION TO AUTOMATION (Q1–Q10)
1. Q: What is automation in manufacturing?
A: It is the use of control systems and technology to operate equipment and processes with
minimal human intervention.
2. Q: What are the main objectives of automation?
A: Improve productivity, reduce labor cost, enhance quality, and increase safety.
3. Q: Name the types of automation.
A: Fixed (hard), programmable, and flexible (soft) automation.
4. Q: What is fixed automation?
A: Automation for high-volume production with dedicated equipment (e.g., transfer lines).
5. Q: What is programmable automation?
A: Used for batch production; can be reprogrammed for different tasks (e.g., CNC machines).
6. Q: What is flexible automation?
A: Allows quick changeover of products without reprogramming (e.g., robotics).
7. Q: What is the automation pyramid?
A: A hierarchy from field-level sensors/actuators to ERP-level decision systems.
8. Q: Define CAD and CAM.
A: CAD is Computer-Aided Design; CAM is Computer-Aided Manufacturing.
9. Q: What is CIM?
A: Computer Integrated Manufacturing—integrates CAD, CAM, and other functions into a
cohesive system.
10. Q: What are the disadvantages of automation?
A: High initial cost, skilled labor requirement, and potential job displacement.
🔹 INDUSTRIAL ROBOTICS (Q11–Q20)
11. Q: What is an industrial robot?
A: A reprogrammable machine used for performing tasks like welding, painting, and
assembly.
12. Q: What are the components of a robot?
A: Manipulator, controller, actuator, sensor, and end-effector.
13. Q: What is the DOF of a robot?
A: Degrees of freedom—the number of independent movements a robot can perform.
14. Q: What are end-effectors?
A: Devices attached to a robot’s wrist to interact with the environment (e.g., grippers, tools).
15. Q: Name common robot configurations.
A: Cartesian, cylindrical, SCARA, polar, and articulated.
16. Q: What is a teach pendant?
A: A handheld device used to program and control robots.
17. Q: What is a robot's work envelope?
A: The 3D space within which a robot can operate.
18. Q: What is the purpose of sensors in robotics?
A: To provide feedback for position, force, temperature, etc.
19. Q: What is the function of a robot controller?
A: It governs the robot's movement and task execution.
20. Q: What is robot calibration?
A: Adjusting the robot to improve accuracy and repeatability.
🔹 CNC & MACHINE AUTOMATION (Q21–Q30)
21. Q: What is a CNC machine?
A: Computer Numerical Control machine—automates tool control based on pre-coded
instructions.
22. Q: What are the main parts of a CNC system?
A: MCU (Machine Control Unit), drive motors, feedback system, and machine tool.
23. Q: What is G-code?
A: Programming language used to control CNC machines.
24. Q: What is M-code?
A: Machine-specific codes controlling auxiliary functions (coolant, spindle, etc.)
25. Q: What is DNC?
A: Direct Numerical Control—networked control of multiple CNC machines.
26. Q: What is interpolation in CNC?
A: Movement of tool along desired paths (linear, circular, etc.)
27. Q: What is backlash?
A: The mechanical lost motion in gear or screw systems affecting accuracy.
28. Q: What is tool wear compensation?
A: Adjusting tool path to account for wear during machining.
29. Q: What is adaptive control?
A: Automatic adjustment of machining parameters in real-time for optimized performance.
30. Q: What is retrofitting in CNC?
A: Upgrading old machines with new CNC controls.
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Here is the continuation of the Top 100 Questions and Answers on Automation in Manufacturing –
from Q31 to Q100.
🔹 SENSORS AND ACTUATORS (Q31–Q45)
31. Q: What is a sensor?
A: A device that detects physical input (temperature, proximity, etc.) and converts it into a
signal.
32. Q: Name types of sensors used in automation.
A: Proximity, photoelectric, ultrasonic, temperature, force, and vision sensors.
33. Q: What is an actuator?
A: A component that converts energy into mechanical motion.
34. Q: What are the types of actuators?
A: Hydraulic, pneumatic, electric, and piezoelectric.
35. Q: What is a proximity sensor?
A: Detects the presence of nearby objects without physical contact.
36. Q: What is a limit switch?
A: A mechanical sensor that detects the physical limit of a part's movement.
37. Q: What is the role of an encoder?
A: Measures position, velocity, and direction of a rotating shaft.
38. Q: What is the difference between analog and digital sensors?
A: Analog gives continuous signals; digital gives discrete ON/OFF signals.
39. Q: What is a vision sensor?
A: A camera system used for inspection, sorting, and guidance tasks.
40. Q: What is the function of a relay in automation?
A: Electrically operated switch used for controlling circuits.
41. Q: What is a solenoid?
A: An electromechanical actuator that converts electrical energy into linear motion.
42. Q: What is hysteresis in sensors?
A: The lag between input and output during increasing and decreasing cycles.
43. Q: What is a pressure transducer?
A: Converts pressure into electrical signals.
44. Q: What is a load cell?
A: A transducer that converts force into measurable electrical output.
45. Q: What is signal conditioning?
A: Preparing sensor signals for processing by amplifying, filtering, or converting.
🔹 PLCs (Programmable Logic Controllers) (Q46–Q60)
46. Q: What is a PLC?
A: A rugged industrial computer used for automation control of machines.
47. Q: What are basic parts of a PLC?
A: CPU, input/output modules, power supply, programming device.
48. Q: What languages are used to program PLCs?
A: Ladder logic, Function block, Structured text, Instruction list.
49. Q: What is ladder logic?
A: Graphical programming language resembling electrical relay logic.
50. Q: What is a scan cycle in PLC?
A: Sequence of reading inputs, executing logic, and updating outputs.
51. Q: What is HMI?
A: Human-Machine Interface – allows users to interact with PLC systems.
52. Q: What is the difference between relay logic and PLC logic?
A: Relay logic is hardwired; PLC logic is software-based and more flexible.
53. Q: What is a contact and coil in ladder logic?
A: Contact = input condition; Coil = output action.
54. Q: What is a timer in PLC?
A: Delays output for a preset time.
55. Q: What is a counter in PLC?
A: Keeps track of the number of events or cycles.
56. Q: What is scan time in PLCs?
A: Time taken for a PLC to complete one full cycle of operations.
57. Q: What is the function of I/O modules?
A: Interface between field devices and the PLC processor.
58. Q: What is analog input module?
A: Accepts continuous signals like temperature, pressure.
59. Q: What is digital output module?
A: Sends ON/OFF control signals to actuators.
60. Q: What is interlocking in PLCs?
A: Prevents unsafe or unintended operation through logic conditions.
🔹 AUTOMATED MATERIAL HANDLING (Q61–Q75)
61. Q: What is automated material handling?
A: The use of machines to move materials in manufacturing without manual input.
62. Q: Name common material handling equipment.
A: Conveyors, AGVs, robots, cranes, hoists.
63. Q: What is an AGV?
A: Automated Guided Vehicle used to transport materials without human drivers.
64. Q: What is a conveyor system?
A: A continuous moving system used to transport materials or products.
65. Q: What are the types of conveyors?
A: Belt, roller, chain, screw, pneumatic.
66. Q: What is an AS/RS system?
A: Automated Storage and Retrieval System used in warehouses.
67. Q: What is FMS?
A: Flexible Manufacturing System – adapts quickly to product changes.
68. Q: What is a palletizer?
A: Machine that stacks products on pallets.
69. Q: What is a pick-and-place robot?
A: A robot that picks an object from one location and places it in another.
70. Q: What is Just-In-Time (JIT) material handling?
A: Providing materials only when needed, reducing inventory.
71. Q: What is a buffer storage?
A: Temporary storage to balance flow between processes.
72. Q: What is gravity roller conveyor?
A: A passive conveyor that uses gravity for movement.
73. Q: What is a smart factory?
A: A facility with interconnected machines and systems using IoT.
74. Q: What is material tracking?
A: Monitoring material movement using sensors, RFID, barcodes.
75. Q: What is route optimization in material handling?
A: Using algorithms to minimize time and distance in transport paths.
🔹 CONTROL SYSTEMS & INTEGRATION (Q76–Q90)
76. Q: What is an open-loop control system?
A: No feedback; the system doesn't check if the output is correct.
77. Q: What is a closed-loop system?
A: Uses feedback to control the output and improve accuracy.
78. Q: What is SCADA?
A: Supervisory Control and Data Acquisition – monitors and controls remote systems.
79. Q: What is MES?
A: Manufacturing Execution System – manages production data and activities.
80. Q: What is ERP?
A: Enterprise Resource Planning – integrates business processes across departments.
81. Q: What is data logging?
A: Recording data from sensors and devices over time.
82. Q: What is PID control?
A: Proportional-Integral-Derivative control – used in precise closed-loop systems.
83. Q: What is feedback in control systems?
A: Information about the output used to adjust the input.
84. Q: What is automation integration?
A: Connecting different automation systems to work seamlessly.
85. Q: What is Industrial Ethernet?
A: Network protocol used for communication in automation systems.
86. Q: What is Modbus?
A: Communication protocol used in industrial automation for device connection.
87. Q: What is OPC in automation?
A: Open Platform Communications – a standard for data exchange in automation.
88. Q: What is a smart sensor?
A: Sensor with embedded processing and communication capabilities.
89. Q: What is real-time monitoring?
A: Tracking system performance as it happens.
90. Q: What is a distributed control system (DCS)?
A: A control system where control elements are distributed throughout the system.
🔹 EMERGING TECHNOLOGIES (Q91–Q100)
91. Q: What is Industry 4.0?
A: The current trend of automation with IoT, AI, and cyber-physical systems.
92. Q: What is IoT in manufacturing?
A: Internet of Things – interconnecting devices to collect and share data.
93. Q: What is predictive maintenance?
A: Using data analytics to predict equipment failure before it happens.
94. Q: What is a digital twin?
A: A virtual model of a real-world system used for simulation and monitoring.
95. Q: What is cobot?
A: Collaborative robot – works safely alongside humans.
96. Q: What is additive manufacturing?
A: 3D printing – creating parts layer by layer.
97. Q: What is cyber-physical system?
A: Integration of computation with physical processes.
98. Q: What is machine learning in automation?
A: Using algorithms to let machines learn patterns and improve performance.
99. Q: What is cloud manufacturing?
A: Using cloud computing resources for production and design processes.
100. Q: What is smart manufacturing?
A: Using advanced data analytics and digital technologies to optimize manufacturing
