Walla Walla College
School of Engineering

ENGR480 Manufacturing Systems

Course Topics - Spring 2007

1. Analyzing the product and the process
   1. Key Characteristics
   2. Manufacturing and Assembly Variation
   3. Assembly Features
   4. Mathematical modeling of assemblies
2. Documentation
   1. Memos and reports
   2. Photos, Drawings, Dimensions, and Tolerance
3. Generating Motion
   1. Linear motion
      1. Pneumatics
      2. Electric solenoids
   2. Rotary motion
      1. DC motors
      2. AC motors
         1. Stepper
         2. Brushless
         3. Induction
   3. Conversion between rotary and linear
      1. lead screws
      2. rack & pinion
      3. four-bar linkage
4. Assembly
   1. Feeding
   2. Orientation
5. Fabrication
   1. Material removal processes
      1. Drilling, Milling, Turning, Tapping
      2. CNC programming
      3. Grinding
   2. Additive processes
      1. Molding, Casting, Sintering
      2. Welding
6. Control of Motion
   1. On/Off Control
      1. pneumatic logic
      2. electric controls
         1. Relays
         2. programmable logic controllers (PLC)
            1. digital logic
            2. ladder diagrams
            3. timing diagrams
            4. state machines
               1. state diagrams
               2. state transition tables
               3. state logic equations
               4. RLL-Plus stage programming
            5. input and output
               1. DC
                  1. sinking
                  2. sourcing
               2. AC
            6. higher level functions
               1. timers
               2. counters
               3. memory
               4. math
         3. position sensing
            1. mechanical
            2. optical
            3. magnetic
            4. other
   2. Proportional control
      1. sensors
         1. resistive
         2. optical
            1. incremental
            2. absolute
         3. magnetostrictive
         4. 4-20mA interface
         5. PLC analog I/O
      2. PLC high-speed I/O
      3. Motion Controllers
         1. Positioners
         2. Indexers
         3. Coordination with PLC
      4. PID control
         1. PLC PID control functions
         2. basic control theory
            1. P,I,D control
            2. PI,PD,PID composite control
            3. analog and pneumatic controllers
      5. Machine vision
   3. Factory communications
      1. wiring
         1. noise sources
            1. common impedance coupling
            2. magnetic field coupling
            3. electric field coupling
         2. twisted pair
         3. coax
         4. shielding and grounding
         5. reflections and termination
      2. signalling
         1. RS-232
         2. RS-485
         3. Ethernet
      3. protocols
         1. master/slave vs. peer-to-peer
         2. deterministic vs. asynchronous
         3. examples
            1. TCP/IP
            2. DeviceNet
      4. PLC communications
   4. Human/machine interface (HMI)
      1. system control
      2. data acquisition
      3. analysis and display
      4. factory database
      5. resource and work-in-progress tracking
      6. statistical process control
      7. alarms and logging
7. Topics not covered
   1. non-discrete manufacturing
      1. web materials
      2. continuous flow processes