robotics and automation

1

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPUR B.Tech. IV-I Sem (M.E) T P C 4 0 4

(9A03702) AUTOMATION & ROBOTICS UNIT I Introduction to Automation: Need , Types, Basic elements of an automated system, levels of automation, hardware components for automation and process control, mechanical feeders, hoppers, orienters, high speed automatic insertion devices. UNIT II Automated flow lines: Part transfer methods and mechanisms, types of Flow lines, flow line with/without buffer storage, qualitative analysis. UNIT III Assembly line balancing: Assembly process and systems assembly line, line balancing methods, ways of improving line balance, flexible assembly lines. UNIT IV Introduction to Industrial Robots: Classification. Robot configurations, Functional line diagram, Degrees of Freedom. Components, common types of arms, joints, grippers UNIT V Manipulator Kinematics: Homogeneous transformations as applicable to rotation and translation - D-H notation, Forward and inverse kinematics. Manipulator Dynamics: Differential transformation, Jacobians . Lagrange Euler and Newton Euler formations. UNIT VI Trajectory Planning: Trajectory planning and avoidance of obstacles, path planning, Skew motion, joint integrated motion straight line motion . Robot programming-Types features of languages and software packages UNIT VII Robot actuators and Feedback components: Actuators: Pneumatic, Hydraulic actuators, electric & stepper motors, comparison. Position sensors potentiometers, resolvers, encoders Velocity sensors, Tactile sensors, Proximity sensors. UNIT VIII Robot Application in Manufacturing: Material Transfer - Material handling, loading and unloading- Processing - spot and continuous arc welding & spray painting - Assembly and Inspection. TEXT BOOKS:

1. Automation, Production systems and CIM, M.P.Groover, Pearson Edu. 2. Industrial Robotics, M.P. Groover, TMH.

REFERENCES:

1. Robotics, Fu KS, McGraw Hill. 2. An Introduction to Robot Technology, P. Coiffet and M.Chaironze, Kogam Page Ltd. 1983 London. 3. Robotics Engineering, Richard D.Klafter, Prentice Hall 4. Robotics, fundamental Concepts and analysis, Ashitave Ghosal, Oxford Press, 2006 5. Robotics and Control, Mittal RK & Nagrath IJ, TMH. 6. Introduction to Robotics, John J. Craig, Pearson Edu

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PBR VISVODAYA INSTITUTE OF TECHNOLOGY AND SCIENCE, KAVALI

Department of Mechanical Engineering, 2012-13

Class : IV B.Tech ME Subject : AUTOMATION & ROBOTICS

Semester : I Name of the Faculty : Mahendra Babu. M

COURSE OBJECTIVE

At end of the course, the student will be able to .

1. Classify different types of automation.

2. Analyze the automated flow line for quality product.

3. Understand the importance of line balancing in an automated assembly lines

4. Familiarize with the concepts of robotization

5. Apply kinematic and dynamic analysis to the given robotic structure.

6. Plan the robot trajectory for a given application.

7. Differentiate the drives and sensors required in any robotic application.

8. Understand the wide range of robotic applications in manufacturing sector.

4

PBR VISVODAYA INSTITUTE OF TECHNOLOGY AND SCIENCE, KAVALI Department of Mechanical Engineering, 2012-13.

Class : IV B.Tech ME Subject : AUTOMATION & ROBOTICS Semester : I LESSON PLAN Name of the Faculty : Mahendra Babu. M

WEEK NO

WEEK

UNIT No. of

Classes

TOPIC

No. of periods in a Week

No. of periods per unit

1. 02-07-12 to

07-07-12 I

Intr

oduc

tion

T

o

2 2 1

Introduction, Need for an automation Types of automation Basic elements of an automated system,

5

14

2.

09-07-12 to 13-07-12

2 2

levels of automation, hardware components for automation process control,

4

16-07-12 to 21-07-12

3 2

mechanical feeders, hoppers, orienters, high speed automatic insertion devices.

5

3.

23-07-12 to 28-07-12

II

Aut

omat

ed f

low

li

nes

1 2 2

Automated flow lines-introduction Part transfer methods and mechanisms, types of Flow lines,

5

10

4. 30-07-12 to

04-08-12 2 3

flow line with/without buffer storage, qualitative analysis.

5

5. 06-08-12 to

11-8-12

III

Ass

embl

y lin

e ba

lanc

ing

1 1 1

Automated assembly line Assembly process systems assembly line,

3

07

6. 13-08-12 to

18-08-12

1 2 1

line balancing methods, ways of improving line balance, flexible assembly lines.

4

7. 20-08-12 to 25-08-12

IV

Intr

oduc

tion

to

1 1 1 1

Introduction to robotics, Classification by co-ordinate system Function line diagram robot arm Common types of arms & components

4

09

8. 27-08-12 to

01-09-12

2 1 1

Architecture, robot characteristics, Robotics wrists,Robotic end effectors, hydraulics, pneumatics& locomotion devices

5

9. 03-09-12 to

05-09-12 I MID EXAMS

5

10. 06-09-12 to

08-09-12

V

Man

ipul

ator

Kin

emat

ics

&

Motion analysis- Homogeneous transformations Specifications of matrices

1

10 11.

10-09-12 to 15-09-12

1 1 1 1 1

D-H notation, joint & world coordinates Forward Kinematics inverse Kinematics Differential transformation and manipulators Jacobians, problems

5

12. 17-09-12 to

22-09-12 2 2

Dynamics Lagrange-Euler formulation Newton-Euler formulation

4

13. 24-09-12 to

29-09-12

VI

Tra

ject

ory

Plan

ning

&

Prog

ram

min

g

2 2 1

Trajectory planning -Path planning Joint integrated motion Trajectory planning & avoidance of obstacles

5

09

14. 01-10-12 to

06-10-12 1 3

Straight line motion,problems Robot programming-Languages, packages

4

15. 08-10-12 to

13-10-12

VII

R

obot

act

uato

rs &

se

nsor

s

3 2

ACTUATORS-hydraulic, pneumatic, Electricactuators -stepper motors

5

10

16. 15-10-12 to

20-10-12

2 1 2

Feed back devices-position proximity sensors, velocity sensors encoders

5

17. 22-10-12 to

27-10-12

VII

I R

obot

App

lica

tions

in

Man

ufac

turi

ng 2

1

Material Transfer Application - Material handling, loading and unloading- Processing Application - arc welding

3

06

18. 29-10-12 to

31-10-12 1 2

spray painting. Assembly and Inspection applications

3

Total number of classes 73

6

PBR VISVODAYA INSTITUTE OF TECHNOLOGY AND SCIENCE, KAVALI DEPARTMENT OF MECHANICAL ENGINEERING

Class : IV B.Tech (I sem) I MID EXAM (Descriptive type) Time : 90 min Date : 03-09-12 ( AN ) Automation &Robotics Marks : 20

Answer any THREE questions

1. What are the different types automation? Discuss them briefly.

2. Draw the neat sketches of the following mechanisms and discuss briefly: a) Rachet and Pawl mechanism b) Over and Under type chain drive mechanism c) Cam mechanism d) Walking Beam mechanism.

3. a) What is ranked positional weight value? Explain its importance in solving line balancing problems by using Ranked Positional Weights Method. b) Discuss any four methods that should be considered by the designer of a flow line for improving the efficiency of the assembly line.

4. What are the basic components of Industrial robot? Explain the functional of the components briefly.

5. a) What is an end effector? b)Give the classification of grippers.? c) What is a mechanical gripper? What are the two ways of constraining the part in the mechanical gripper?

.


Class : IV B.Tech (I sem) II MID EXAM Time : 90 min Date : 01-11-12 ( AN ) ROBOTICS Marks : 20

Answer any THREE of the following.

1. Explain a 3-5-3 trajectory plan to represent a pick and place movement for an assembly operation. 2. Explain the different types of actuators that can be used for the robot joints. 3. Find the manipulator Jacobian matrix J (q) of the five axis spherical co-ordinate robot.. 4. (a). Explain the Lagrange Eulers formulation for robot arm.

(b). Explain Denavit-Hartenberg convention for selecting frames of reference in robotic application 5. Classify & Explain manufacturing applications of robots

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Class : IV B.Tech (I sem) I MID EXAM (Objective type) Time : 20 min Date : 03-09-12 ( AN ) Automation &Robotics Marks : 20

1. Technology that is concerned with the use of mechanical, electronic and computer based systems in the operation and control of production [ ] a). Mechanization b). Automation c). Industrialization. d). all the above.

2. use of machines to do the work of animals/people [ ] a). Mechanization b). Automation c). Industrialization. d). all the above.

3. .................................................................... Robot comes under type of automation. .......................................................................... [ ] a), programmable b). Flexible c). Fixed d). (a) & (b)

4. following is the work transfer mechanism in an automated flow line [ ] a). walking beam transferbar mechanism b). powered roller conveyor system c). chain drive conveyor system d). any of the above

5. number of buufers in an n staged line [ ] a). n b). n-1 c). n+1 d)1/n

6. Work station continue to operate with no part to work on is called.. [ ] a). blocking of stations b). idling of stations c). starving of stations d). any of the above.

7. The following is the performance measure of line efficiency [ ] a). cost per item b). average production rate c). proportion of down time d). all the above

8. Following is the mechanical fastener [ ] a). threaded fastener b). Rivet c). press fit d). All the above

9. Following are the constraints in the line balancing problem [ ] a). precedence constraints b). zoning constraints c). position constraints d). all the above

10. Graphical representation of the sequence of work elements as defined by the precedence constraints[ ] a). flow diagram b). network diagram c). precedence diagram d). all the above.

11. following is the measure of line in-efficiency [ ] a). balance delay b). downtime proportion c). buffer capacity d). (a)&(b)

12. following method improves the balance of the line. [ ] a). dividing work elements b). methods analysis c). parallel stations d). all the above.

13. Following is the method of line balancing [ ] a). largest candidate rule b). RPW method c). kilbridge-Wester method c).all the above.

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14. The attractive feature of SCARA robot [ ] a), more tolerance b). Selective compliance c). Accuracy d). Repeatability

15. the robot configuration, which is used in high reach applications [ ] a), polar b). jointed arm c). spherical d). (a) & (b).

16. Interface between the last link of the manipulator and the end effector is called [ ] a), critical joint b). Gripper c). Wrist d). Tool flange / too mounting plate.

17. The device which is used to interpret the data stored in a memory of a robot. [ ] a), sensor b). controller c). Sequencer d). Synchronizer.

18. "Only one surface required to grasp or hold the object" by [ ] a) vacuum gripper b) magnetic gripper c) adhesive gripper d). any of the above.

19. Magnetic gripper is used only for ........ materials. [ ] a), stainless steel b). non-ferrous c). ferrous d). plastic

20. Number degrees of freedom exhibited by robot wrist [ ] a). 1 b). 2 c). 3 d). 4


DEPARTMENT OF MECHANICAL ENGINEERING Class : IV B.Tech (I Sem) II MID EXAM (objective type) Time : 20 min Date : 01-11-12 ( FN ) ROBOTICS Marks : 20

... Name: Roll No:

20 X 1=20 1. Jacobian relates the velocities of joints to the velocities of . [ ] (a). Tool point (b). Manipulator (c). Joint d). None of the above. 2. if A- is a non-singular square matrix, then A-I = . [ ] (a). adjA X detA (b). adj A + detA (c). adjA detA (d). detA adjA 3. dynamic model of a robotic arm can be studied by [ ] (a). Newtonian Laws (b). Lagrangian Laws (c). Eularian Laws (d). all the above. 4. Lagrangian Function L= f( Kinetic Energy, Potential Energy )= [ ] (a). KE + PE (b). KE PE . KE PE (d). PE KE 5. Measure of mass distribution.. [ ] (a). Radius of gyration (b).acceleration (c). moment of inertia (d). any of the above. 6. Newton Euler formulation is used to analyze the behavior of the manipulator. (a). Static (b). Dynamic (c). Kinematic (d). Kinetic. [ ] 7. Dynamic equations of motion of robot arm allows [ ] (a). Analysis (b). Synthesis (c). Simulation (d). All the above. 8. In Lagrange Euler Equation [ ]

Where L Lagrangian function = KE PE , qi Generalised co-ordinate

(a). Velocity (Vi) (b). Acceleration (ai) (c). Torque (Ti) (d). None of the above 9. Newtons equation gives the relationship between [ ]

(a). Torque, mass, jerk (b). Force, mass, acceleration . Power, force, velocity (d). Energy, mass, velocity 10. Differential change in the manipulator can be computed by. [ ] (a). Jacobian (b) Inverse Jacobian (c) Any of the above (d) None of the above. 11 Trajectory planning satisfies [ ]

a) Only path constraints b). Only path specifications c). Only dynamic constraints d). All the above.

).......,.........3,2,1..(..........**

ni

q

L

q

L

dt

d

ii

==

9

12 An N-joint manipulator will have.number of trajectories. [ ] a) N b) (N+1) c). (N-1) d). (N+2).

13 Type of actuator used in robot to move sizable loads [ ] a) hydraulic b) pneumatic c). electrical d) mechanical

14 Type of actuator used in PICK and PLACE robot. [ ] a). hydraulic b) pneumatic c) electrical d) mechanical hydraulic

15 Stepper motor works based on the principle of [ ] a) Minimum reluctance b). Maximum reluctance c). Minimum resistance d). Maximum resistance

16 Path end points can be specified in.. [ ] a) Joint co-ordinates (b) Cartesian co-ordinates (c) (a) and (b) (d) none of the above

17 Mathematical functions used in trajectory planning problems. [ ] a) Fourier (b) laplace (c)polynomial (d) all the above.

18 Product of two quaternion is a [ ] a) scalar (b)vector (c) quaternion (d)none of the above

19 Characteristic of Pneumatic actuator [ ] a) under damped applications (b)fast movements (c) accurate movements (d) all the above

20. In Inertia Tensor. all the elements are.. [ ] (a) Zeros (b) Zeros Except diagonal elements (c) Ones (d) Cant say

PBR VISVODAYA INSTITUTE OF TECHNOLOGY AND SCIENCE, KAVALI Department of Mechanical Engineering, 2012-13.

Class : IV B.Tech ME Subject : AUTOMATION & ROBOTICS Semester : I Name of the Faculty : Mahendra Babu. M

QUESTION BANK

3. What are the different types automation? Discuss them briefly.

4. Describe the function and working of the following automated machine tools:

(i) Transfer Machine (ii) Single Station Machine.

5. a) Discuss the general methods of transporting work pieces on flow lines.

b) Discuss the advantages and limitations of the continuous transfer mechanisms.

6. a) Discuss the general terminology used in the analysis of an automated flow line.

b) Discuss briefly about the following terms used in automated flow lines:

(i) Buffer stock effectiveness (ii) Partial Automation

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7. a)With the help of neat sketches, explain the following linear transfer mechanisms:

i) Powered Roller Conveyor System ii) Walking Beam Transfer System

b) Explain the advantages and limitations of synchronous transfer mechanisms.

8. a) Explain how the efficiency of the flow line increases by adding one or more parts storage

buffers between work stations along the line.

b) Discuss the analysis of a two-stage automated flow line

9. a) With the help of neat sketches, explain the following linear transfer mechanisms:

(i) Walking Beam Transfer System (ii) Chain Drive Conveyor System

b) Enumerate the differences between synchronous and asynchronous transfer mechanisms.

10. a) What is partial automation and what are the reasons for the existence of partially automated production lines

in the shop floors?

b) Discuss the following terms used in the automated flow lines:

(i) Starving of stations (ii) Blocking of stations.

11. What are the important mechanical feeding devices used in automated systems? Discuss them briefly.

12. Draw the neat sketches of the following mechanisms and discuss briefly:

a) Rachet and Pawl mechanism

b) Over and Under type chain drive mechanism

c) Cam mechanism

d) Walking Beam mechanism.

13. What are the two basic approaches used in the analysis of transfer lines without storage? Explain them briefly.

12. a)What are the various assembly systems used in industry to accomplish the assembly processes.

b) Explain the steps used in solving the line balancing problem by using Largest Candidate Rule method.

13. a) What is ranked positional weight value? Explain its importance in solving line balancing problems by using

Ranked Positional Weights Method.

b) Discuss any four methods that should be considered by the designer of a flow line for improving the efficiency

of the assembly line.

14. a)Explain the different ways in which the work is moved on the line between operator workstations in Manual

Assembly Line.

b)What is Flexible Assembly Line? Discuss its important features.

15. a)Briefly discuss the following assembly processes:

(i) Adhesive bonding (ii) Joining Methods

b)With the help of suitable example explain the procedure to solve the line balancing problem by Kilbridge and

Westers Method.

16. What are the basic components of Industrial robot? Explain the functional of the components briefly.

11

17. a) What is an end effector?

b)Give the classification of grippers.?

c) What is a mechanical gripper? What are the two ways of constraining the part in the mechanical gripper?

18 a).Define robot ?

b)Describe different robot configurations with neat sketches.

19. Robot comes under what type of automation ? why?

20. Explain tool as an end effector ?

21. Enumerate the functions of a robotic system ?

22. (a) Describe the degrees of freedom of a robot wrist with the help of a neat sketch. (b) Describe the common types of robot arms.

23. Illustrate a robot gripper with [5+5+6] (a) cam operated (b) gear operated (c) lever (links) operated fingers

24. Give the classification of robots based on control system and describe their characteristic features.


Department of Mechanical Engineering, 2012-13. Class : IV B.Tech ME Subject : AUTOMATION & ROBOTICS Semester : I Name of the Faculty : Mahendra Babu. M .

21. Technology that is concerned with the use of mechanical, electronic and computer based systems in the operation and control of production a). Mechanization b). Automation c). Industrialization. d). all the above.

22. .................................................................. Highly integrated transfer lines comes under type of automation. a), programmable b). Flexible c). Fixed d). (a) & (b)

23. use of machines to do the work of animals/people a). Mechanization b). Automation c). Industrialization. d). all the above.

24. .................................................................. Numerically controlled machines comes under type of automation. a), programmable b). Flexible c). Fixed d). (a) & (b)

25. .................................................................. Robot comes under type of automation. a), programmable b). Flexible c). Fixed d). (a) & (b)

26. following is the method of work transfer in an automated flow line a). synchronous b). asynchronous c) continuos d). all the above.

27. following is the work transfer mechanism in an automated flow line a). walking beam transferbar mechanism b). powered roller conveyor system c). chain drive conveyor system d). any of the above

28. motion conversion in geneva mechanism a). rotary to linear b). rotary to rotary c). linear to linear d). any of the above

29. the approach in which the work part is not removed from the station when the breakdown occurs during the analysis a). lower bound approach b). upper bound approach c). none of the above d). any of the above

12

30. number of buufers in an n staged line a). n b). n-1 c). n+1 d)1/n

31. Work station continue to operate with no part to work on is called.. a). blocking of stations b). idling of stations c). starving of stations d). any of the above.

32. Line efficiency + downtime proportion = a). zero b). 1 c).-1 d). cant say

33. The following is the performance measure of line efficiency a). cost per item b). average production rate c). proportion of down time d). all the above

34. Following is the mechanical fastener a). threaded fastener b). Rivet c). press fit d). All the above

35. Following are the constraints in the line balancing problem a). precedence constraints b). zoning constraints c). position constraints d). all the above

36. Graphical representation of the sequence of work elements as defined by the precedence constraints a). flow diagram b). network diagram c). precedence diagram d). all the above.

37. Measure of line in-efficiency due to imperfect allocation of work to stations a). balance delay b). downtime proportion c). buffer capacity d). all the above

38. following is the measure of line in-efficiency a). balance delay b). downtime proportion c). buffer capacity d). (a)&(b)

39. following method improves the balance of the line. a). dividing work elements b). methods analysis c). parallel stations d). all the above.

40. Following is the method of line balancing a). largest candidate rule b). RPW method c). kilbridge-Wester method c).all the above.

41. Type of control used in Bang - Bang robot. a), servo b). non-servo c). None of the above d). all the above.

42. SCARA robot is used in ..... applications. a).quality control b).assembly. c).defense. d). all the above.

43. Following is the robotic like device. a). Telecherics. b). exo-skeleton c). locomotive device d). all the above.

44. Number of linear co-ordinates in a cylindrical co-ordinate robot. a). 2 b). 3 c). 1 d). 0

45. Work volume of a spherical robot a), cylinder b). paraboloid c). sphere d). cube

46. Wrist motions of the robot among the following. a), yaw b). pitch c). roll d). all the above.

47. The attractive feature of SCARA robot a), more tolerance b). Selective compliance c). Accuracy d). Repeatability

48. Type of control used in Cartesian robot. a), servo b). non-servo c).pneumatic d). hydraulic

49. .type of robot uses feed back from the control system a), non-servo b). servo c). (a) & (b). d). Pneumatic

50. Type of robot used in spray painting applications a), point to point b).bang-bang c). end point d). continuous path

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51. Preferred robot system for load carrying applications a), hydraulic b). Pneumatic c). Electrical d). Mechanical

52. Interface between the last link of the manipulator and the end effector is called a), critical joint b). Gripper c). Wrist d). Tool flange

53. Preferred robot system for high repeatability applications a), cylindrical b). Cartesian c). spherical d). any of the above

54. Type of robot used in transferring the object a), point to point b).bang-bang c). end point d). continuous path

55. Type of robotic like device used in undersea applications a).Telecherics. b). exo-skeleton c). locomotive device d). prosthesis

56. The shape of work volume of a cylindrical robot is.... a), paraboloid b). sphere c). cylinder d). cube

57. Number of polar co-ordinates in a jointed arm configuration a). 2 b). 3 c). 1 d). 0

58. Type of robot used in grinding applications. a), point to point b).bang-bang c). end point d). continuous path

59. the technical name of a hand attached to the wrist of the robot a), gripper b). end effector c). joint d). any of the above

60. the arm and the body joints of the manipulator are used to .......... the end effector a), orient b). position c). shake d). any of the above.

61. the robot configuration, which is used in high reach applications a), polar b). jointed arm c). spherical d). (a) & (b).

62. high repeatability applications of Cartesian configurations is due to ...... a), linear joints b). high stiffness of links c). its rigid structure d). all the above.

63. "piston movement inside the engine cylinder" is ......... type of joint. a), prismatic b). rotational c). twisting d). revolving

64. Interface between the last link of the manipulator and the end effector is called a), critical joint b). Gripper c). Wrist d). Tool flange / too mounting plate.

65. The intelligence which is required to control the manipulator will be provided by a), sensor b). controller c). Sequencer d). Synchronizer.

66. The device which is used to interpret the data stored in a memory of a robot. a), sensor b). controller c). Sequencer d). Synchronizer.

67. The device which is used to hold or grasp the object a), end effector b). gripper c). (a) or (b). d). none of the above.

68. "Only one surface required to grasp or hold the object" by a), vacuum gripper b). magnetic gripper c). adhesive gripper d). any of the above.

69. Magnetic gripper is used only for ........ materials.[ a), stainless steel b). non-ferrous c). ferrous d). plastic

70. Ability of the wrist socket to yield elastically, when subjected to a force is called ........... a), elasticity b). stiffness c). strength d). compliance.

71. Remote Centered Compliance ( RCC ) devices are used in ............ applications. a), assembly b). defense c). undersea d). mining

72. Number degrees of freedom exhibited by robot wrist a). 1 b). 2 c). 3 d). 4

73. Type of robot used in spot-welding applications. a), point to point b).sequential c). end point d). continuous path

74. Type of drive used for larger robots a), electrical b). mechanical c). pneumatic d). hydraulic

75. Type of power used in robot for precision work applications a), electrical b). mechanical c). pneumatic d). hydraulic

76. Smallest increment of the movement into which the robot can divide its work volume a), control resolution b). spatial resolution c). repeatability d). accuracy

77. Mechanical inaccuracy among the following a), gear backlash b). leakage of hydraulic fluid

14

78. c). stretching of pulley cards d). all the above. 79. Relation between spatial resolution, control resolution and mechanical inaccuracies is

a) spatial resolution = control resolution + mechanical inaccuracies b) spatial resolution = control resolution - mechanical inaccuracies c) spatial resolution = control resolution x mechanical inaccuracies d) spatial resolution = control resolution / mechanical inaccuracies

80. Suitable automation for mass production system a). transfer line b). robot c). general purpose CNC machine d). all the above


Class : IV B.Tech (I sem) (objective type BITS) UNITS: V,VI,VII,VIII AUTOMATION & ROBOTICS

1. Jacobin is the method of control of in a co-ordinate fashion. [ ] (a). controller (b). Sequencer (c). Manipulator(d). Sensor 2. Jacobian relates the velocities of joints to the velocities of . [ ] (a). Tool point (b). Manipulator (c). Joint d). None of the above. 3. Jacobian is a time varying quantity [ ] (a). False for all (b). True for all (c). Cant say (d). Some times. 4. if A- is a non-singular square matrix, then A-I = . [ ] (a). adjA X detA (b). adj A + detA (c). adjA detA (d). detA adjA 5. dynamic model of a robotic arm can be studied by [ ] (a). Newtonian Laws (b). Lagrangian Laws (c). Eularian Laws (d). all the above. 6. ..representation has been used to describe the special displacement between two links [ ] (a). Identity Matrix. (b). Null Matrix. (c). D-H Matrix.(d). none of the above. 7. Lagrangian Function L= f( Kinetic Energy, Potential Energy )= [ ] (a). KE + PE (b). KE PE . KE PE (d). PE KE 8. Measure of mass distribution.. [ ] (a). Radius of gyration (b).acceleration (c). moment of inertia (d). any of the above. 9. Inertia Tensor characterizes the ..distribution of the body in space [ ] (a). velocity (b).acceleration (c). Strength (d). Mass. 10. inertia tensor for a rectangular body will depends on its [ ] (a). Length (b). Breadth (c). Height (d). All the above. 11. the theorem used to relate the inertia tensor of one frame to another [ ] (a). Pythagoras theorem (b). Parallel Axes theorem (c). Super position theorem (d). any of the above. 12. Newton Euler formulation is used to analyze the behavior of the manipulator. [ ] (a). Static (b). Dynamic (c). Kinematic (d). Kinetic. 13. Use of dynamic equations of motion of robot arm [ ] (a). in computer robotic simulation. (b). in the design of control equations. . To evaluate the kinematic structure of robot arm. (d). all the above 14. Dynamic equations of motion of robot arm allows [ ] (a). Analysis (b). Synthesis (c). Simulation (d). All the above. 15. In Lagrange Euler Equation [ ] Where L Lagrangian function = KE PE qi Generalised co-ordinate (a). Velocity (Vi) (b). Acceleration (ai) (c). Torque (Ti) (d). None of the above 16. Generalization of scalar moment of inertia.. [ ] (a). Polar moment of inertia (b). Inertia tensor (c). Centre of mass (d). None of the above. 17. in Inertia Tensor. all the elements are.. [ ]

).......,.........3,2,1..(..........**

ni

q

L

q

L

dt

d

ii

==

15

(a). Zeros (b). Zeros Except diagonal elements (c). Ones (d). Cant say 18. Eulers equation gives [ ] (a). Force acting on the body (b). Velocity of the body . Acceleration of the body (d). Torque acting on the body 19. Newtons equation gives the relationship between [ ] (a). Torque, mass, jerk (b). Force, mass, acceleration . Power, force, velocity (d). Energy, mass, velocity 20. Differential change in the manipulator can be computed by. [ ] (a). Jacobian (b). Inverse Jacobian (c). Any of the above (d). None of the above. 21 Trajectory planning satisfies [ ]

b) Only path constraints c) Only path specifications d) Only dynamic constraints e) All the above.

22 An N-joint manipulator will have.number of trajectories. [ ] b) N c) (N+1) d) (N-1) e) (N+2).

23 Quaternion Representation of a trajectory is generally used for [ ] a) Closed mechanics b) Special mechanics c) (a) and (b) d) None of the above.

24 If S is a scalar part of Q and V=ai+bj+ck then unit quaternion is equal to S+ ai+bj+ck Where S2+a2+b2+c2= [ ]

a) 0 b) a c) 1 d) 2

25 example for power transmission system [ ] a) pulley b) gear c) screw d) all the above

26 type of actuator used in robot to move sizable loads [ ] b) hydraulic c) pneumatic d) electrical e) mechanical

27 type of actuator used in over damped applications. [ ] a) hydraulic b) pneumatic c) electrical d) mechanical

28 type of actuator used in PICK and PLACE robot. [ ] a) hydraulic b) pneumatic c) electrical d) mechanical

29 the stepper motor can be operated in [ ] a) closed loop manner b) an open loop manner

16

c) (a) and (b) d) none of the above.

30 Most costly actuator [ ] a) hydraulic b) pneumatic c) electrical d) mechanical

31 The actuator which gives high positional accuracy [ ] a) hydraulic b) pneumatic c) electrical d) mechanical

32 Stepper motor works based on the principle of [ ] b) Minimum reluctance c) Maximum reluctance d) Minimum resistance e) Maximum resistance.

33 If S is a scalar part of Q and vector V=ai+bj+ck then (S-V) is of Q [ ] a) Normal b) conjugate c) reciprocal d) none of the above

34 Path end points can be specified in.. [ ] b) Joint co-ordinates c) Cartesian co-ordinates d) (a) and (b) e) none of the above

35 An N-joint manipulator will have.number of trajectory segments [ ] a) 3N b) 5N c) (a) and (b) d) none of the above

36 Mathematical functions used in trajectory planning problems. [ ]

b) Fourier (b) laplace (c) polynomial (d) all the above.

37 Methods used in straight line trajectory planning. [ ] a) Cartesian path control b) bounded deviation joint path c) (a) and (b) d) none of the above

38 product of two quaternion is a [ ] b) scalar c) vector d) quaternion e) none of the above

39 characteristic of Pneumatic actuator [ ] b) under damped applications c) fast movements d) accurate movements e) all the above

40 discrete motion of the manipulator possible by [ ] a) hydraulic (b)pneumatic (c) stepper motor (d) mechanical

18

Code: 9A03702 B.Tech IV Year I Semester (R09) Supplementary Examinations, May 2013

AUTOMATION AND ROBOTICS (Mechanical Engineering)

Time: 3 hours Max Marks: 70 Answer any FIVE questions All questions carry equal marks

1. List out and discuss about the basic elements of an automated system.

2. List out the various types of flow lines. Discuss flow line with and without buffer storage.

3. What are the considerations to be made in assembly line design?

4. Explain various configurations of robot with neat sketches.

5. Explain in detail about DH representation of robot with a suitable example.

6. Discuss the following methods of robot programming: (i) Lead through teaching. (ii)Walk through teaching. (iii) Off-line programming.

7. (

Classify different sensors and actuators used in robotics.

(b) Discuss the working of following actuators: (i) Pneumatic actuators. (ii) Hydraulic actuators.

8. (

What are the desirable features of a robot for successful machine tool load/unload applications?

(b) Describe the applications of a robot in press working operation

19

Code: R5 321305

R5 B.Tech III Year II Semester (R05) Supplementary Examinations, April / MAY 2012

ROBOTICS AND AUTOMATION

(Electronics and Control Engineering)

Time: 3 hours Max Marks: 80

Answer any FIVE questions

All questions carry

equal marks

1

a

What are the various generation of robotics? Briefly explain the importance of each.

(b) Write short notes on dynamic stabilization of robotics. 2 (

Discuss the working principle of hydraulic drives with the help of neat sketch.

(b) Distinguish between electric drives and pharmamatic drives. 3 (

Write short notes an path determination in robotics.

(b) Discuss the working principle and advantage of fiber optic sensors in robotics. 4 ( With a neat sketch describe the working of pneumatic actuator.

(b) Discuss the design consideration of robotic gripper. 5 ( Define work envelope and discuss the jacobian work envelope for any type of robotic configuration.

(b) What are the advantages of using robot programming languages? 6 Discuss the various Hillelimbing techniques in robotic. 7 What are the various robot programming software packages? Explain theircharacteristics.

8 (

Explain the considerations to be mode in the design of a robot work cell.

(b) Write short notes an robot machine interface.

20


Class : IV B.Tech (I sem) DESCRIPTIVE TYPE UNITS: V,VI,VII,VIII AUTOMATION & ROBOTICS

1. Find the manipulator Jacobian matrix J (q) of the five axis spherical co-ordinate robot. [16] 2. Explain Direct and Inverse dynamics with a block diagram applied to a simple task.[16] 3. A manipulator with a single link is to rotate from (0) = 300 to (2) = 1000 in 2 seconds. The joint velocity and acceleration are both zero at the initial and final positions. [16] (a) Determine the co-efficients of a cubic polynomial that accomplishes the motion. (b) Determine the co-efficients of a quartic polynomial that accomplishes the motion and (c) Determine the co-efficients of a quintic polynomial that accomplishes the motion. 4. Under what conditions a hydraulic motor is preferred, compared to stepper or DC servomotor. Briefly explain the functioning of a hydraulic motor. [16] 5. Find the manipulator Jacobian matrix J (q) of the five axis spherical co-ordinate robot. [16] 6. Derive the expression for joint torques for a planar R-P robotic manipulator using Lagranze-Euler formulation. [16] 7. An automated guided vehicle has to be designed to aid visually disadvantages people. What strategy would you adopt to avoid obstacles and path planning?[16] 8. (a) Explain various devices used as position sensors in robots. [8] (b) Discuss any one device that can be used as velocity sensor in robot. [8] 9. Find the manipulator Jacobian matrix J (q) of the five axis spherical co-ordinate robot. [16] 10. In the re cursive Newton Euler equations of motion referred to its own link co ordinate frame, the matrix (iRo Ic oRi)is the inertial tensor of link i about the ith co ordinate frame. Derive the relationship between the matrix and the pseudo inertica matrix Ji of the Lagrange - Euler equations of motion. [16] 11. (a) What are the conditions under which a position sensor is preferred versus encoder based systems? Where are encoders placed with respect to drive system and where are position sensors placed? Can both the systems be used on the same robot? [12] (b) Why are absolute encoders preferred? 12. Consider a two-link robot arm and assume that each link is 1 m long. The robot arm is required to move from an initial position (xo, yo) = (1.96, 0.50) to a final position (xf , yf ) = (1.00 , 0.75). The initial and final velocity and acceleration are zero. Determine the co-efficients of a cubic polynomial at each joint to accomplish the motion. [16] 13. Under what conditions a hydraulic motor is preferred, compared to stepper or DC servomotor. Briefly explain the functioning of a hydraulic motor. [16] 14. (a) Discuss robot trajectory planning? [8] (b) Explain the general guidelines for planning a joint interpolated motion trajectory. [8] 15. (a) Explain the control loops using current amplifier for the robot joint motions mentioning the response equations involved. [8] (b) What is path planning and explain why path planning is required for a robotic system. [8] 16. (a) Explain the Lagrange Eulers formulation for robot arm. [8] (b) Differentiate clearly with reference to 2- jointed manipulator of RR type and LL type. [8] 17. Trajectory planning and motion control determines the type of actuator required, explain three different systems, one with hydraulic, one with pneumatic and one with electrical actuator. Provide detailed justification. [16] 18. Explain a 3-5-3 trajectory plan to represent a pick and place movement for an assembly operation. [16] 19. Explain the different types of actuators that can be used for the robot joints. [16] 20. Distinguish clearly between forward Newton - Euler equations and Forward Newton-Euler equations and backward Newton euler Equations, with a simple example.[16] 21. (a) What is path planning? Explain the need for path planning. [6]

21

(b) Differentiate between path planning and trajectory planning. [4] (c) What are the drawbacks of incremental encoders? [6] 22. (a) Draw the figure of a hydraulic system of robot and show how the out put shaft velocity is proportional to the flow of the oil in motor-pump combination for a hydraulic system. [10] (b) Compare and contrast hydraulic and Electrical actuators. [6] 23. Define rotation transformation and explain how to represent the transformation for rotation of an angle about x , y and z-axis. 24. What is a forward kinematics problem? Explain Denavit-Hartenberg convention for selecting frames of reference in robotic application. [16] 25. Write and explain the algorithm for deriving the forward kinematics for any manipulator based on D-H convention. Perform the forward transformation for the five axis Microbot using the following data. Link a d 1. 0 -90 1 d1 2. a2 0 2 0 3. a3 0 3 0 4. a4 + 900 4 0 5. 0 0 5 d5

AUTOMATION IN MANUFACTURING

1. a) Draw the simple block diagram of pneumatic circuit and discuss it briefly. b) What are the different types automation? Discuss them briefly.

2. a) Discuss the general methods of transporting work pieces on flow lines. b) Discuss the advantages and limitations of the continuous transfer mechanisms.

3. a) Discuss the general terminology used in the analysis of an automated flow line. b) Discuss briefly about the following terms used in automated flow lines: (i) Buffer stock effectiveness (ii) Partial Automation

4. a) What are the various assembly systems used in industry to accomplish the assembly processes. b) Explain the steps used in solving the line balancing problem by using Largest Candidate Rule method.

5. a) Explain briefly the important principles of material handling. b) Describe the following conveyors used in material transport systems: (i) Roller and Skate wheel conveyors (ii) Belt conveyors.

6. a) Explain the various objectives for installing an automated storage system in a factory. b) Explain the various applications of carousal storage systems.

7. a) Explain the advantages of using adaptive control systems in turning operation. b) Discuss the comparisons between adaptive machining and non-adaptive machining.

8. a) What is stereo lithography? Describe the stereo lithography with the help of neat sketch. b) What is Concurrent Engineering and what are its important components?

1. a) Explain the following types of Automation: (i) Programmable Automation (ii) Fixed Automation b)What are the important pneumatic components used in automated system?Describe briefly.

22

2. a)With the help of neat sketches, explain the following linear transfer mechanisms: i) Powered Roller Conveyor System ii) Walking Beam Transfer System b) Explain the advantages and limitations of synchronous transfer mechanisms.

3. a) Explain how the efficiency of the flow line increases by adding one or more parts storage buffers between work stations along the line.b) Discuss the analysis of a two-stage automated flow line.

4. a) What is ranked positional weight value? Explain its importance in solving line balancing problems by using Ranked Positional Weights Method. b) Discuss any four methods that should be considered by the designer of a flow line for improving the efficiency of the assembly line.

5. a) Explain the advantages of implementing various principles of material handling. b) Describe the following conveyors used in material transport systems: (i) In-floor tow-line conveyor (ii) Overhead trolley conveyor.

6. Define AS/RS. Describe the various basic components of AS/RS.

7. a) Explain the advantages of using adaptive control systems in turning operation. b) Enumerate the differences between ACO and ACC types of adaptive control.

8. a) What are the advantages of various Rapid Prototyping techniques? b) Briefly explain the software configuration of Business Process Reengineering.

1. a) Explain the following types of automation: (i) Fixed Automation (ii) Flexible Automation. b) Describe the function and working of the following automated machine tools: (i) Transfer Machine (ii) Single Station Machine. 2. a) With the help of neat sketches, explain the following linear transfer mechanisms: (i) Walking Beam Transfer System (ii) Chain Drive Conveyor System b) Enumerate the differences between synchronous and asynchronous transfer mechanisms. 3. a) What is partial automation and what are the reasons for the existence of partially automated production lines in the shop floors? b) Discuss the following terms used in the automated flow lines: (i) Starving of stations (ii) Blocking of stations. 4. a) Explain the different ways in which the work is moved on the line between operator workstations in Manual Assembly Line. b) What is Flexible Assembly Line? Discuss its important features. 5. What are the different types of material handling equipment associated with the different plant layouts? Discuss them briefly. 6. a)Explain the various applications of AS/RS technology. b)Describe the use of the following components of an AS/RS: (i) Pickup and deposit stations (ii) Storage structure 7. a) Explain the advantages of using adaptive control systems in turning operation. b) What is adaptive control? Under what conditions adaptive control is recommended? 8. a) Explain the solid based Rapid Prototyping process with the help of neat sketch. b) Explain the objectives of Concurrent Engineering 1. a) Define Fixed Automation and Flexible Automation. Enumerate the differences between them. b) What are the important mechanical feeding devices used in automated systems? Discuss them briefly. 2. Draw the neat sketches of the following mechanisms and discuss briefly: a) Rachet and Pawl mechanism

23

b) Over and Under type chain drive mechanism c) Cam mechanism d) Walking Beam mechanism. 3. a)Discuss the important general terminology used in the analysis of the automated flow lines. b) What are the two basic approaches used in the analysis of transfer lines without storage? Explain them briefly.

4. a) Briefly discuss the following assembly processes: (i) Adhesive bonding (ii) Joining Methods b) With the help of suitable example explain the procedure to solve the line balancing problem by Kilbridge and Westers Method.

5. a) When are the Conveyors used in Automated Material Handling System? What are the different types of conveyor systems? b) Discuss them briefly with the help of simple sketches, wherever possible.

6. a) Discuss the advantages of using Automated storage systems in a warehouse. b) What are the various problems encountered in interfacing handling and storage systems with manufacturing units? Discuss them briefly. 7. a) Explain the advantages of using adaptive control systems in turning operation. b) Enumerate the differences between ACO and ACC types of adaptive control. 8. a) Discuss the applications of Rapid Prototyping. b) Discuss the reasons for implementation of Business Process Reengineering concepts in various companies

ROBOTICS

1. A single cubic trajectory given by q(t) = 30 + t2 6t3 is used for a period of 3 seconds. Determine starting and goal position, velocity, and accelerations of the end-effector. [16] 2.a) Explain the working of Pneumatic actuator. Develop the relationship in case of cylinder type and rotary vane type actuator. b) What is the velocity of the piston and the force generated by the piston if the fluid pressure is 12 N/mm2 inside the cylinder, the piston is 50 mm in diameter and the flow rate is 2.5 cm3/sec? [8+8] 3.a) What are the sequence of operations of robot in the manufacturing cell? Explain. b) What are the various components of the manufacturing cell? Explain the function of the components in the cell. [6+10] 4. What are the basic components of Industrial robots? Explain the functional of the components briefly. [4+12] 5.a) What is an end effector? b) Give the classification of grippers. c) What is a mechanical gripper? What are the two ways of constraining the part in the mechanical gripper? [4+4+8] 6.a) Find the rotation matrix correspondent to the set of Euler angles ZXZ. b) What do you mean by equivalent angle and axis? Explain. [8+8] 7. Explain the method of Assignment of DH frames with the help of an example and define the link parameters. [16] 8.a) Differentiate between geometric Jacobian & analytical Jacobian. b) Compute the Jacobian matrix for a spherical robotic manipulator. [6+10]

1. Explain the method of Assignment of DH frames with the help of an example and define the link parameters. [16] 2.a) Differentiate between geometric Jacobian & analytical Jacobian. b) Compute the Jacobian matrix for a spherical robotic manipulator. [6+10] 3. A single cubic trajectory given by q(t) = 30 + t2 6t3 is used for a period of 3 seconds. Determine starting and goal position, velocity, and accelerations of the end-effector. [16] 4.a) Explain the working of Pneumatic actuator. Develop the relationship in case of cylinder type and rotary vane type actuator. b) What is the velocity of the piston and the force generated by the piston if the fluid pressure is 12 N/mm2 inside the cylinder, the piston is 50 mm in diameter and the flow rate is 2.5 cm3/sec? [8+8] 5.a) What are the sequence of operations of robot in the manufacturing cell? Explain. b) What are the various components of the manufacturing cell? Explain the function of the components in the cell.

24

[6+10] 6. What are the basic components of Industrial robots? Explain the functional of the components briefly. [4+12] 7.a) What is an end effector? b) Give the classification of grippers. c) What is a mechanical gripper? What are the two ways of constraining the part in the mechanical gripper? [4+4+8] 8.a) Find the rotation matrix correspondent to the set of Euler angles ZXZ. b) What do you mean by equivalent angle and axis? Explain. [8+8]

1.a) What is an end effector? b) Give the classification of grippers. c) What is a mechanical gripper? What are the two ways of constraining the part in the mechanical gripper? [4+4+8] 2.a) Find the rotation matrix correspondent to the set of Euler angles ZXZ. b) What do you mean by equivalent angle and axis? Explain. [8+8] 3. Explain the method of Assignment of DH frames with the help of an example and define the link parameters. [16] 4.a) Differentiate between geometric Jacobian & analytical Jacobian. b) Compute the Jacobian matrix for a spherical robotic manipulator. [6+10] 5. A single cubic trajectory given by q(t) = 30 + t2 6t3 is used for a period of 3 seconds. Determine starting and goal position, velocity, and accelerations of the end-effector. [16] 6.a) Explain the working of Pneumatic actuator. Develop the relationship in case of cylinder type and rotary vane type actuator. b) What is the velocity of the piston and the force generated by the piston if the fluid pressure is 12 N/mm2 inside the cylinder, the piston is 50 mm in diameter and the flow rate is 2.5 cm3/sec? [8+8] 7.a) What are the sequence of operations of robot in the manufacturing cell? Explain. b) What are the various components of the manufacturing cell? Explain the function of the components in the cell. [6+10] 8. What are the basic components of Industrial robots? Explain the functional of the components briefly. [4+12]

1.a) What are the sequence of operations of robot in the manufacturing cell? Explain. b) What are the various components of the manufacturing cell? Explain the function of the components in the cell. [6+10] 2. What are the basic components of Industrial robots? Explain the functional of the components briefly. [4+12] 3.a) What is an end effector? b) Give the classification of grippers. c) What is a mechanical gripper? What are the two ways of constraining the part in the mechanical gripper? [4+4+8] 4.a) Find the rotation matrix correspondent to the set of Euler angles ZXZ. b) What do you mean by equivalent angle and axis? Explain. [8+8] 5. Explain the method of Assignment of DH frames with the help of an example and define the link parameters. [16] 6.a) Differentiate between geometric Jacobian & analytical Jacobian. b) Compute the Jacobian matrix for a spherical robotic manipulator. [6+10] 7. A single cubic trajectory given by q(t) = 30 + t2 6t3 is used for a period of 3 seconds. Determine starting and goal position, velocity, and accelerations of the end-effector. [16] 8.a) Explain the working of Pneumatic actuator. Develop the relationship in case of cylinder type and rotary vane type actuator. b) What is the velocity of the piston and the force generated by the piston if the fluid pressure is 12 N/mm2 inside the cylinder, the piston is 50 mm in diameter and the flow rate is 2.5 cm3/sec? [8+8]

25

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPUR

B.Tech. IV-I Sem (M.E) T P C

4 0 4

(9A03701) OPERATIONS RESEARCH

UNIT I

Development Definition Characteristics and Phases Types of models operation Research models applications. ALLOCATION : Linear Programming Problem Formulation Graphical solution Simplex method Artificial variables techniques -Twophase method, Big-M method Duality Principle-Economic interpretation of duality. UNIT II

TRANSPORTATION PROBLEM Formulation Optimal solution, unbalanced transportation problem Degeneracy. Assignment problem Formulation Optimal solution - Variants of Assignment Problem-Traveling Salesman problem. SEQUENCING Introduction Flow Shop sequencing n jobs through two machines n jobs through three machines Job shop sequencing two jobs through m machines. UNIT III

REPLACEMENT : Introduction Replacement of items that deteriorate with time when money value is not considered and considered Replacement of items that fail completely, group replacement. UNIT IV

THEORY OF GAMES : Introduction Minimax (maximin) Criterion and optimal strategy Solution of games with saddle points Rectangular games without saddle points 2 X 2 games dominance principle m X 2 & 2 X n games -graphical method. UNIT V

WAITING LINES : Introduction Single Channel Poisson arrivals exponential service times with finite queue length and non finite queue length models Multichannel Poisson arrivals exponential service times with finite queue length and queue length and non finite queue length models. UNIT VI INVENTORY : Introduction Single item Deterministic models Purchase inventory models with one price break and multiple price breaks shortages are not allowed Stochastic models demand may be discrete variable or continuous variable Instantaneous production. Instantaneous demand and continuous demand and no set up cost. UNIT VII

DYNAMIC PROGRAMMING : Introduction Bellmans Principle of optimality Applications of dynamic programming- capital budgeting problem shortest path problem linear programming problem. UNIT VIII

SIMULATION : Definition Types of simulation models phases of simulation applications of simulation Inventory and Queuing problems Advantages and Disadvantages Simulation Languages. TEXT BOOKS:

1. Introduction to Operations Research, Taha, PHI 2. Introduction to Operations Research, Hiller & Libermann, TMH. REFERENCES:

1. Operations Research, A.M. Natarajan, P.Balasubramani, A. Tamilarasi, Pearson Edu. 2. Operations Research: Methods & Problems, Maurice Saseini, Arhur Yaspan & Lawrence Friedman 3. Operations Research, R.Panneerselvam, PHI Publ. 4. Operations Research, wagner, PHI Publ. 5. Operations Research, J.K. Sharma, Mac Milan. 6. Operations Research, Wayne L. Winston, Thomson Brooks, Cole 7. Operations Research, R. Veerachari and V. Ravi Kumar, I.K. International Question Paper Pattern: 5 questions to be answered out of 8 questions Each question should not have more than 3 bits.

26

P.B.R.VISVODAYA INSTITUTE OF TECHNOLOGY & SCIENCE, KAVALI

Department of MECHANICAL ENGINEERING

CLASS/BRANCH: IV B.Tech/ME SUBJECT: OPERATIONS RESEARCH

Semester : I Name of the faculty: B. Konda reddy

COURSE OBJECTIVE

At end of the course , the learner will be able to----------- 1. Industrial and business applications can be formulated as mathematical equations and solve these equations. 2. Transportation costs can be calculate with simple techniques. 3. Assigning the jobs to machines, operators to the machines, salesmen assigning to various regions. 4. Scheduling the jobs on various machines to minimize the time of completing the jobs. 5. Machines replacement period can be optimized. 6. In competitive situations better decision can be made. 7. Calculate optimum inventory period and costs. 8. Waiting time of customers or jobs can be reduced.

27


DEPARTMENT OF MECHANICAL ENGINEERING

LESSON PLAN FOR THE ACADEMIC YEAR 2012-2013

Class / Semester: IV B.Tech. I Semester Subject: Operations Research

Unit Week No. of

Hours

Topic to be covered No. of

Hours per

Week

No. of

Hours per

Unit

I

2-7-12 TO 7-7-12

2 3

Overall introduction of the subject, Development of OR Definitions of OR, Characteristics of OR, Phases in OR, Types of models, Applications

5

20

9-7-12 TO 14-7-12

2 3

LP formulation Graphical solution

5

16-7-12 to 21-7-12

3 2

Simplex Method Artificial Variables Technique (Big M Method)

5

23-7-12 to 28-7-12

2 3

Two Phase Method, Duality Principle, Economic interpretation of duality

5

II

30-7-12 TO 04-08-12

2

3

Transportation Problem: Formulation, Balanced T.P. and Unbalanced T.P. Optimal solution By MODI and Stepping stone method 5

13 06-8-12 TO

11-8-12

2 2

Degeneracy in transportation problem Assignment Problem: Formulation, Optimal solution, Variations in Assignment problem Traveling Salesman Problem

4

13-8-12 TO

18-8-12

2

2

Sequencing: Flow shop Scheduling : n jobs through 2 machines, n jobs through 3 machines Job Shop Scheduling : 2 jobs trough m machines

4

III 21-8-12 TO

25-8-12

3

2

Replacement of items that deteriorate with time when money value is counted and not counted Replacement of items that fail completely, Group replacement

5 5

IV

27-8-12 TO 01-9-12

3

2

Maximin and Minimax Criterion, Optimal strategy, Solution of games with saddle points, Dominance Principle Rectangular games without saddle points

5 7

06-09-12 to 08-09-12

2 Solution to mx2 and 2xn games Graphical Method

2

V

10-9-12 TO

15-9-12 5

Waiting Lines : Introduction, Single Channel Poisson Arrivals Exponential service times with infinite population models 5

9

17-9-12 TO 22-9-12

2

2

Single Channel Poisson Arrivals Exponential service times with finite population models Multi channel Poisson arrivals exponential service times with infinite population

4

VI

24-9-12 to 29-9-12

3

2

Inventory : Introduction, Single Item Deterministic Models Shortages allowed and not allowed Purchase inventory models with one price break

5

10

01-10-12 TO 06-10-12

2

3

Purchase inventory models with multiple price break Stochastic models

5

VII 08-10-12 TO

13-10-12 2

Dynamic Programming : Introduction, Characteristics, Bellmans Principle of optimality, Applications

5 9

28

3 Capital budgeting problem

15-10-12 to 20-10-12

2 2

Shortest Path Problem Linear Programming Problem 4

VIII

22-10-12 to 27-10-12

2

Simulation: Definition, Types of simulation models, Phases of simulation 2

6 29-10-12 to

31-10-12

2 2

Inventory Problems Queuing Problems Advantages, Disadvantages, Simulation languages 4

Total Expected Hours 79

TEXT BOOKS:

1. Introduction to OR / Hamdy Taha / PHI Publications 2. Introduction to OR / Hiller & Libermann

REFERENCES: 1. Operations Research / R. Panner Selvam / PHI Publications 2. Operations Research / P.K.Gupta & D.S.Hira / S. Chand Publications 3. Operations Research / Mahajan / Dhanpat Rai Publications 4. Operations Research / S.D.Sharma / Kedarnath Publications

29



MID EXAM-I/DESCRIPTIVE TYPE

SUBJECT: OPERATIONS RESEARCH DATE: 03/08/2012 (FN)

CLASS/BRANCH: IV B.Tech/ME DURATION: 90 min

************************************************************************************* Answer any three of the following

1. (a) Explain the following (i) Slack variables (ii) Surplus variables (iii)Artificial variables with respect to LPP. (b) Solve the following LPP Max Z = 50x1+ 60 x2

Subjected to 2 x1 + x2 30 3x1 +4 x2 60 x1 10

x1 0, x2 0, 2. Four engineers are available to design four projects. Engineer 2 is not competent to design the project B. Given the following

time estimates needed by each engineer to design a given project, find how the engineers should be assigned to projects so as to minimize the total design of four projects. Projects A B C D 1 12 10 10 8 2 14 not suitable 15 11 Designer 3 6 10 16 4 4 8 10 9 7

3. ABC Limited has three production shops which supply a product to five warehouses. The cost of production varies from shop to shop and cost of transportation from one shop to a warehouse also varies. Each shop has a specific production capacity and each warehouse has certain amount of requirement. The costs of transportation are given below. I I II III IV V supply A 6 4 4 7 5 100 B 5 3 7 4 8 125 C 3 4 6 3 4 175 Demand 60 80 85 105 70 The cost of manufacturing the product at different production shops is Shop Variable Fixed cost A 14 7000 B 16 4000 C 15 5000

Find the optimum quantity to be supplied from each shop to different warehouses at minimum total cost. 4. A transport company owns three mini buses each of which was purchased for Rs 80000. The costs of running a bus together

with resale value are as follows.

Year 1 2 3 4 5 6 7 8 Running cost 3000 3600 4800 5000 8000 11200 15000 20000 Resale value 70000 61000 55000 49000 32000 20000 10000 5000

Two of these buses are two years old while the third one is one year old. The company contemplates replaces the buses by two full sized buses, each such bus containing 50% more seating capacity than a mini bus. Estimates of running costs and resale value of each of new buses are given below. While each such bus would cost Rs 120000.

Year 1 2 3 4 5 6 7 8 Running cost 3400 3900 4700 5800 7200 9000 12000 16000 Resale value 100000 92000 86000 81000 76000 66000 54000 40000 Should the mini buses be replaced with new full sized buses? If not why ? If yes, when?

5. (a) Briefly explain (i) pure strategy (ii) mixed strategy (iii) optimal strategy (b) For the following pay off matrix , determine the best strategies and the value of the game.

30

Player Y J K L P 60 50 40

Player X Q 70 70 50 R 80 60 75



MID EXAM-I/OBJECTIVE TYPE



************************************************************************************* 1. In the optimal table artificial variable is present in the basis column then the problem has ____solution.

(a) Unique (b) Unbounded (c) infeasible (d) multiple [ ] 2. In the key column all the elements are negative or zero then the problem has _________solution.

(a) Unique (b) Unbounded (c) infeasible (d) multiple [ ] 3. Assignment models are solved by [ ]

(a) Johnsons method (b) MODI method (c) Hungarian method (d) Least cost method 4. Sequencing models are solved by [ ]

(a) Johnsons method (b) MODI method (c) Hungarian method (d)Stepping stone method 5. If the probability of failure of a resistor in the first month is 0.2 and total number of resistors in the system 100 , then the

number of resistors failed in the first month is ___ (a) 100 (b) 200 (c) 50 (d) none [ ]

6. Write the sequence for the following problem [ ] Job 1 2 3 Time on m/c A 7 3 8 Time on m/c B 4 9 3 (a) 2,3,1 (b) 1,3,2 (c) 1,2,3 (d) none

7. Find the saddle point for the following game [ ] B

I II III I 5 7 3 A II 8 9 1 III 6 4 2 (a) I, II (b) II, III (c) I, III (d) III, I

8. The depreciation cost __________ (increases / decreases) with the age of the equipment. 9. What is meant by fair game? 10. If the game is reduced to 3X3 by dominance principle , then the problem is solved by ______method. 11. What is meant by degeneracy in transportation problem?

31

12. Name the methods to find initial feasible solution for transportation problems? 13. Write the dual for the following problem

Max Z = 50x1+ 60 x2 Subjected to 2 x1 + x2 30, 3x1 +4 x2 60, x1 0, x2 0, 14. In 2 jobs m machines problem, a line at 450represents [ ]

(a) Job 1 is idle (b) Job 2 is idle (c) both Jobs are idle (d) no Job is idle 15. Group replacement is applicable for [ ]

(a) Repairable items (b) Items fail partially (c) Items that fail completely (d) Dissimilar items 16. While sequencing a job , No passing rule is allowed. TRUE/FALSE 17. Initial basic feasible solution for a transportation problem can be found by MODI method. TRUE/FALSE 18. When money value is changing with time at 10% the discount factor for 2ndyear is _________ 19. Operations research is the art of giving bad answers to problems to which otherwise worse answers are given.

TRUE/FALSE 20. The travelling salesman problem is said to be ____________, if the distance between every pair of cities is independent of

the direction of his journey.



MID EXAM-II/DESCRIPTIVE TYPE



Answer any three of the following

1. A computer shop has a laser printer. The jobs for laser printing are randomly distributed approximating a Poisson distribution with mean service rate of 10 jobs per hour, since job pages vary in length (pages to be typed). The jobs arrive at a rate of 6perhour during the entire 8 hours work day. If the laser printer is valued Rs30/- per hour, determine (a) the percent time an arriving job has to wait (b) average system time (c) average idle time cost of the printer per day. 2. (a) Derive an expression for basic EOQ model.

(b) Contract has to supply 10000 bearings per day with an automobile manufacturer and he finds that when he starts a production run he can produce 20000 bearings / day. A cost of holding a bearing in stock per one year is 30 paise and setup cost of production run is Rs 280/-. How frequently should production run be made?

3. An organization is planning to diversity its business with a maximum utility of Rs 5crores. It has identified three different locations to install plants. The organization can invest one or more of these plants subjected to the availability of the fund. The different possible alternatives and their investment (in crores of rupees) and present worth of returns during the useful life (in crores of rupees) of each these plants are summarized in table. The first row of table has zero cost and zero returns for all the plants. It is known as do-nothing alternative. Find the optimal allocation of the capital to different plants which will maximize the corresponding sum of the present worth of returns.

plant 1 plant 2 plant 3

Alternative cost return cost return cost return

1 0 0 0 0 0 0

2 1 15 2 14 1 3

3 2 18 3 18 2 7

4 4 28 4 21 - -

4.(a) Define simulation?

(b) Briefly explain about different simulation languages?

5. Find the optimal order quantity for a product when the annual demand for the products is 5000 units. The cost of storage per unit per year is 10% of the unit cost and ordering cost per order is Rs 180/-. The unit costs are given below.

Quantity unit cost

0q1500 Rs 25.00

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500q21500 RS 24.80

1500q33000 Rs 24.60

3000q4 Rs 24.40



MID EXAM-II/OBJECTIVE TYPE



Name:_______________ Roll no : ____________

______________________________________________________________________________

1. Dynamic programming technique is developed by [ ] a) Johnson b) Richard Bellman c) Hungarian d) none 2. The cost involved in inventory are [ ] a) carrying cost b) ordering cost c) shortage cost d) all of the above 3. Which of the following is not a simulation language [ ] a) GPSS b) GPRS c) SIMULA d) SIMSCRIPT 4. FORTRAN was the intermediate language in the initial day for [ ] a) GPSS b) GPRS c) SIMULA d) SIMSCRIPT 5. SIMULA resembles with [ ] a) COBOL b) BASIC c) ALGOR d) FORTRAN 6. For the basic EOQ model the minimum inventory cost is [ ] a) 2RC3/C1 b) 2RC1/C3 c) 2RC3C1 d)none 7. In model (M/M/1) (FCFS//) the average length of queue [ ] a) /(- ) b) 2/(- ) c) /(- ) d)none 8. In model (M/M/1) (FCFS//) the average waiting time in system [ ] a) /(- ) b) 2/(- ) c) 1/(- ) d)none 9. Dynamic programming is also called ___________ optimization. [ ] a) Bell man's b) Johnson's c) recursive d) none 10. State Bellman's principle of optimality? 11. Name the assumptions for production model with shortage? 12. Write the Kendal's notation for first come first serve, Poisson arrival exponential distribution multi channel with infinite population queuing problem? 13. Ordering quantity increases ordering cost value is decreases. TRUE/FALSE 14. Define service rate? 15.The numbers generated by mid square method are called ___ random numbers. 16. Which costs can vary with order quantity? [ ] a) unit cost only b) Reorder cost only c) holding cost only d) all of these 17. Which of the following is not a key operating characteristic for a queuing system? [ ] a) Utilization factor b) percent idle time c) average time spent for waiting in system and queue. d) None of the above. 18. A calling population is considered to be infinite when _________________. 19. Define lead time? 20. LPP can be solved by using Dynamic programming technique. TRUE / FALSE

QUESTION BANK UNIT-I

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1. A confectioner sells two products A and B. The selling price of A is Rs 60 and B is Rs 40. The unit cost of product A is Rs 30 and of B Rs 10. The two products are produced in a common production process. The production process has a capacity of 30000 man hours. It takes three hours to produce a unit of A and one hour to produce unit of B. The market for the product has been surveyed and confectioner knows that the maximum number of units of A that can be sold is 8000 and B is 12000. Formulate and solve the equation graphically to maximize contribution.

2. (a) Explain the following (i) Slack variables (ii) Surplus variables (iii) Artificial variables with respect to LPP. (b) Solve the following LPP Max Z = 50x1+ 60 x2

Subjected to 2 x1 + x2 30 3x1 +4 x2 60 x1 10

x1 0, x2 0, 3. a) Define operations research?

b) Enumerate the main characteristics of operations research? c) Describe the phases of scientific method in operations research?

4. Find the dual of the following problem and hence or otherwise solve the given problem. Min Z = 3x1+ 4 x2+ 6 x3

Subjected to x1 + 4x2+ 3x3 2 x1 -2 x2- 6 x3 3 x1+ x2+ x3 1

x1 0, x2 0,x3 0 5. a) How are the following detected in simplex method?

i) Alternate solution ii) unbounded solution iii) Infeasible solution b) Use simplex method to solve the following LPP Min Z = 5x+ 6y

Subjected to 2 x + 5y 1500 3x +y 1200 x 0,y 0,

UNIT-II 1. Solve the following transportation problem.

TO Supply 10 7 3 6 3 From 1 6 8 3 5 7 4 5 3 7

Demand 3 2 6 4 2. The owner of a small machine shop has four machinists available to assign to jobs for the day. Five jobs are offered with

expected profit for each machinist on each job as follows. Jobs A B C D E M/C s M1 12 28 0 51 32

M2 12 34 11 23 9 M3 37 42 61 21 31 M4 0 14 37 27 30 Assign machinist to jobs which results in overall maximum profit.

3. A machine operator has to perform three operations, turning, threading, and knurling on different jobs. The time required to perform these operations (in minutes) for each job is known. Determine the order in which the jobs should be processed in order to minimize the total time required to work out all the jobs. Also find the minimum elapsed time. Jobs 1 2 3 4 5 6

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M/C Turning 3 12 5 2 9 11 Threading 8 6 4 6 3 1 Knurling 13 14 9 12 8 13

4. Four engineers are available to design four projects.Engineer2 is not competent to design the project B. Given the following estimates needed by each engineer to design a given project, find how should the engineers be assigned to projects so as to minimize the total design of four projects. Projcects A B C D 1 12 10 10 8 2 14 not suitable 15 11 3 6 10 16 4 4 8 10 9 7 5. ABC Limited has three production shops which supply a product to five warehouses. The cost of production varies from shop to shop and cost of transportation from one shop to a warehouse also varies. Each shop has a specific production capacity and each warehouse has certain amount of requirement. The costs of transportation are given below. I I II III IV V supply A 6 4 4 7 5 100 B 5 3 7 4 8 125 C 3 4 6 3 4 175 Demand 60 80 85 105 70 The cost of manufacturing the product at different production shops is Shop Variable Fixed cost A 14 7000 B 16 4000 C 15 5000

Find the optimum quantity to be supplied from each shop to different warehouses at minimum total cost.

UNIT-III

1. A transport company owns three mini buses each of which was purchased for Rs 80000. The costs of running a bus together with resale value are as follows.

Year 1 2 3 4 5 6 7 8 Running cost 3000 3600 4800 5000 8000 11200 15000 20000 Resale value 70000 61000 55000 49000 32000 20000 10000 5000

Two of these buses are two years old while the third one is one year old. The company contemplates replaces the buses by two full sized buses, each such bus containing 50% more seating capacity than a mini bus. Estimates of running costs and resale value of each of new buses are given below. While each such bus would cost Rs 120000.

Year 1 2 3 4 5 6 7 8 Running cost 3400 3900 4700 5800 7200 9000 12000 16000 Resale value 100000 92000 86000 81000 76000 66000 54000 40000 Should the mini buses be replaced with new full sized buses? If not why ? If yes, when?

2. a) Write a note on replacement of capital items when money value is considered. b) The following table gives the running costs per year and resale price of a certain equipment whose purchase price is Rs 5000. Year 1 2 3 4 5 6 7 8

Running cost(Rs) 1500 1600 1800 2100 2500 2900 3400 4000 Resale value (Rs) 3500 200 1700 1200 800 500 500 500 At what year is replacement due?

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3. a) Explain briefly how the replacement problems are classified? b) Fleet of cars have increased their costs as they continue in service due to increased direct operating cost and increased maintenance cost . The initial cost is Rs 350000 and the trade in value drop as time passes until it reaches a constant value of Rs 40000. Given the cost of operating, maintaining, and the trade in value , determine the proper length of service before cars should be replaced. Year of service 1 2 3 4 5

Year end trade in value (Rs) 290000 210000 150000 110000 40000 Annual operating cost (Rs) 11500 12800 13600 14000 15000 Annual maintaining 3000 5000 8000 12000 15000

4. A machine has initial investment of Rs 30000 and its salvage value at the end of i years of its use is estimated as Rs 30000 (i+1). The annual operating and maintenance cost in the first year is Rs 15000 and increases by Rs 5000 in each year thereafter. Replacement policy is to be planned over a period of seven years. During this period cost of capital may be taken as 10% per year. Solve the problem for optimal replacement.

5. A series lamp circuit contains 10000 bulbs. When any bulb fails it is replaced. The cost of replacing a bulb individually is Re 1only. If all the bulbs are replaced simultaneously, the cost per bulb would be Rs 0.35. The percent of surviving, say S(t) at the end of month t and P(t) probabilities of failures during the month are given below: T 0 1 2 3 4 5 6 S(t) 100 97 90 70 30 15 0 P(t) - 0.03 0.07 0.2 0.4 0.15 0.15 What is the optimal replacement? UNIT-IV

1. (a) Briefly explain (i) pure strategy (ii) mixed strategy (iii) optimal strategy (b) For the following pay off matrix, determine the best strategies and the value of the game.

Player Y J K L P 60 50 40

Player X Q 70 70 50 R 80 60 75 2. a) Briefly explain limitations of game theory. b) Find the solution of the following B I II III A I 1 3 11 II 8 5 2

3. Solve the following game by LPP B 1 2 3 1 0 2 2

A 2 3 -1 3 3 4 4 -2 4. a) Briefly explain the properties found in competitive games. b) Reduce the following game by dominance and find the game value. Player B I II III IV I 3 2 4 0 Player A II 3 4 2 4 III 4 2 4 0 IV 0 4 0 8

5. Player A is paid Rs 8 if two coins turn both heads and Rs 10 if two coins turn both tails. Player B is paid Rs 3 when the two coins do not match. Given the choice of being A or B. Which one would you choose and what would be your strategy.

UNIT- V

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1. A computer shop has a laser printer. The jobs for laser printing are randomly distributed approximating a Poisson distribution with mean service rate of 10 jobs per hour, since job pages vary in length (pages to be printed). The jobs arrive at a rate of 6 per hour during the entire 8 hours working day. If the laser printer is valued Rs 30 per hour, determine (a) the percent time an arriving job has to wait. (b) average system time. (c) Average idle time cost of the printer per day.

2. Assume in a hotel a server is to look after supply of three tables, which would accommodate in total 6 customers. Assume customers who arrive when all the six seats of the three tables are full. Customers arrive at the average rate of 4 per hour and spend an average of 15 minutes in the hotel. Find (a) the probability a customer can directly sit in a seat up on his arrival. (b) Expected number of customers waiting for a seat. (c) The time a customer can expect to spend in the hotel.

3. In a bank 4 cash counters are operated for drawing money. On average 40 persons arrive in a 4hour day. Each cashier is to spend 10 minutes on the average on an arrival. If the arrivals are Poisson ally distributed and service times are according to exponential distribution. Determine (a) average number of customers in the system. (b) average number of customers waiting in the system. (c) average time a customer spends in the system. (d) the probability that a customer has to wait before he gets service.

4. Customers arrive at one teller counter in a bank according to a Poisson distribution with mean 12 per hour. Service time per customer is exponential with mean 6 minutes. The space in front of the counter can accommodate a maximum of 10 customers. Other customers can wait out side the space. (a) What is the probability that an arriving customer can come directly to the counter. (b) What is the probability that an arriving customer will have to wait outside the indicate space. (c) How long an arriving customer is expected to wait before starting service.

UNIT-VI 1. (a)Write advantages and disadvantages of inventory.

(b) Certain item costs Rs 235 per ton , the monthly requirement is 5 tons and each time the stock is replenished. There is a setup cost of Rs 1000. The cost of carrying inventory has been estimated at 10 % of value of stock per year. What is the optimum order quantity.

2. Find the optimal order quantity for a product when the annual demand for the products is 500 units. The cost of storage per unit per year is 10% of the unit cost, and ordering cost per order is Rs 180. The unit costs are given below. Quantity unit cost 0 q1 500 Rs 25.00 500 q2 1500 Rs 24.80 1500 q3 3000 Rs 24.60 3000 q4 Rs 24.40

3. (a) Derive an expression for basic EOQ model. (b) Contract has to supply 10000 bearings per day with an automobile manufacturer and he finds that when he starts a production run he can produce 20000 bearings per day. A cost of holding a bearing in stock per one year is 30 paise and setup cost of production run is Rs 280 . How frequently should production run be made.

4. A shop keeper has to decide how much quantity of bread he should stock every week. The quantity of bread demand is assumed to be continuous random variable with a given probability function f(x) . Let A is Rs 8be ultimate cost of purchasing the bread B is Rs 20. Unit sale price . C is Rs 2 refund on unit sale bread and D is Rs 5 is the unit penalty cost. Find the optimum quantity of bread to be stock. UNIT-VII 1. Solve the following linear programming problem by using dynamic programming technique.

Maximize Z =Z1 Z 2Z3 Z4 Subjected to constraints Z1+ Z 2 +Z3 +Z4 = 20

2. Solve the following LPP by using dynamic programming Maximize Z= 3x1 +8x2 Subjected to x1 +4 x2 8 X2 2 X1, x2 0

3. A man is engaged in buying and selling identical item. He operates from a ware house that can hold 500 items. Each month he can sell any quantity that he chooses up to the stock at the beginning of the month. Each month he can buy as much

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as he wishes for delivery at the end of the month. So long as his stock does not exceed 500 items. For the next four months he has the following error free forecasts of the cost sale prices.

Month I 1 2 3 4 Cost Ci 27 24 26 28 Sale price Pi 28 25 25 27

If he currently has a stock of 200 units, what quantity should he sell and buy next four months. Find the solution using dynamic programming.

4. An organization is planning to diversity its business with a maximum utility of Rs 5 crores. It has identified three different locations to install plants. The organization can invest one or more of these plants subjected to the availability of the fund. The different possible alternatives and their investment (in crores of rupees) and present worth of returns during the useful life (in crores of rupees) of each these plants are summarized in table. The first row of table has zero cost and zero return for all the plants. It is known as do nothing alternative. Find the optimal allocation of the capital to different plants which will maximize the corresponding sum of the present worth of returns. Plant 1 plant 2 plant 3 Alternative cost return cost return cost return 1 0 0 0 0 0 0 2 1 15 2 14 1 3 3 2 18 3 18 2 7 4 4 28 4 21 - - UNIT-VIII 1. (a) Write the advantages and disadvantages of simulation?

(b) Define simulation? 2. (a) Briefly explain about differ

robotics and automation

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