33981 - Integrated Processing Systems M

Learning outcomes

The student learns the main advanced integration architectures related to modern production systems, in which handling systems, electronic controls, sensors, calculators and software combine to define flexible and automated machinery. In particular, he acquires knowledge relating to computerized numerical control machine tools, CAD-CAM software and anthropomorphic robots, the latter both intended as means of enslavement to conventional production machines, and as real multi-axis manufacturing centers for the application non-conventional processes.

Course contents

Introduction to Industrial Automation

• Basic elements of an automated system.
• Levels of automation.

Control of Automated Systems

• Sensors.
• Actuators.
• Digital-to-Analog (D/A) and Analog-to-Digital (A/D) Conversion.
• Input/Output (I/O) Systems.
• Control strategies (open-loop and closed-loop control).
• Feedback and feedforward control.

Computer Numerical Control (CNC)

• Fundamentals of CNC technology.
• CNC in machine tools.
• EIA/ISO programming language.
• The part program.
• Main types of CNC programming instructions.
• Canned cycles.
• Parametric programming.

Industrial Robotics

• Main types of industrial robots.
• Coordinate systems in industrial robotics.
• Robot programming.
• Accuracy and repeatability issues.
• Singularities and motion planning strategies.
• Applications of industrial robots in manufacturing.

Integration of Robots into Industrial Systems

• Robots as material handling systems for industrial processes.
• Integration of machine tools, robots, and process monitoring systems.
• Main types of signals exchanged in automated manufacturing systems (digital signals, analog signals, and fieldbus communication).

Advanced Programming of Automated Systems

• CAD/CAM systems.
• CAM for advanced machining strategies, including trochoidal milling, tangential milling using ball-end, toroidal, and barrel cutters, and toolpath strategies to minimize tool wear and vibrations.
• Offline programming systems for industrial robots.
• Laboratory sessions using Eureka offline programming software for articulated industrial robots.
• Laboratory sessions using Eureka ISO-CNC toolpath simulation software.

Integration of Laser Manufacturing Systems

• Main types of laser sources.
• Design of the optical chain: spot diameter and collimated beam diameter.
• Integration of scanner heads: calculation of aperture size and working field.

Readings/Bibliography

Slides and lecture notes provided by the teacher via Virtuale. 

Teaching methods

The course includes:

• Classroom theoretical lectures.
  
• Computer CAD-CAM programming exercises

Assessment methods

The assessment consists of

1. A written examination comprising 30 questions, organized as follows:

• 24 True/False multiple-choice questions covering all the theoretical topics of the course.
• 4 open-ended questions, in which students are required to either write one of the formulas studied during the course or draw the conceptual diagram of a specific topic.
• 2 numerical exercises similar to those presented and solved during the lectures.

The total score for the 30 questions is 32 points. The final grade is calculated based on this score, with a maximum grade of 30/30 with honors (30 cum laude). During the examination, the use of any electronic device (including smartphones, smartwatches, laptops, tablets, etc.) or printed material (such as formula sheets, lecture slides, notes, handouts, or textbooks) is strictly prohibited. The use of any form of artificial intelligence is also not permitted. Any use of the aforementioned resources constitutes a violation of academic integrity. The use of a standard scientific calculator is permitted for solving the numerical exercises.

2. An independent practical assignment consisting of the development of a CNC part program to manufacture one or more mechanical components of the student's choice using machine tools. The part program must be correctly implemented and simulated using the Eureka software. The quality of the assignment will be assessed through a brief oral examination. The maximum score for this second component is 32 points, which will be combined with the score obtained in the written examination described above by calculating their arithmetic mean. The resulting value will constitute the final course grade. The use of any form of artificial intelligence is strictly prohibited while completing this assignment. Any use of such tools constitutes a violation of academic integrity.

Teaching tools

To enable students to complete the assignment at home, temporary individual licenses for the Eureka software will be provided. Students may install the software on their own desktop or laptop computers and complete the assignment independently, following the instructions provided during the lectures.

Office hours

See the website of Alessandro Ascari