automated material handling org pec university technology

AUTOMATED MATERIAL HANDLING

SUMITTTED BY

MANMEET SINGH

13209015

M.E (MECHANICAL)

FIRST YEAR

SUBMITTED TO

Dr. SANJEEV KUMAR

MATERIALHANDLING

WHAT IS MATERIAL HANDLING

Movement Storage Protection Control (Of material throughout

manufacturing) And distribution process including

consumption and disposal. Includes (raw material ,work in progress ,sub

assemblies ,finished assemblies)

MATERİAL HANDLİNG ACCOUNTS FOR:

25% of all employees, 55% of all factory space, 87% of production time 15-70% of the total cost of a manufactured product

PRINCIPLES OF MATERIAL HANDLING1) Planning Principle

(needs, desirable option ,consultation, performance)

2) Standardization Principle3) Work Principle

(minimized without sacrificing productivity)

4) Ergonomic Principle (safety, eliminate repetitive jobs )

5) Unit Load Principle6) Space Utilization Principle7) System Integration Principle8) Automation Principle9) Environment Principle (energy, impact, hazard)

10) Life Cycle Cost Principle

OBJECTIVES OF MATERIAL HANDLING

Reduce manufacturing cycle time Reduce delays, and damage Promote safety and improve working conditions Maintain or improve product quality Promote productivity Material should move as short a distance as possible Use gravity Move more material at one time Automate material handling Promote increased use of facilities Promote the use of building cube Purchase versatile equipment Develop a preventive maintenance program Maximize the equipment utilization etc.

CONSIDERATIONS IN MATERIAL HANDLING SYSTEM DESIGN

Material characteristics Flow rate Routing Scheduling Plant layout

MATERIAL CHARACTERISTICS

Category Measures

1. Physical state2. Size3. Weight4. Shape5. Condition6. Safety risk and risk

of damage

Solid, liquid, or gasVolume; length, width, heightWeight /piece, weight/unit volumeLong and flat, round, square, etc.Hot, cold, wet, etc.Explosive, flammable, toxic; fragile, etc.

FLOW RATE

Manual handlingHand trucks

Powered trucksUnit load AGV

ConveyorsAGV train

High

Low

LongShort Move Distance

Quantity of material moved

Conveyors

PLANT LAYOUT

Layout Type Characteristics Typical MH Equipment

Fixed – position

Process

Product

Large product size, low production rate

Variation in product and processing, low and medium production rates

Limited product variety, high production rate

Cranes, hoists, industrial trucks

Hand trucks, forklift trucks, AGVs

Conveyors for product flow, trucks to deliver components to stations.

ROUTING AND SCHEDULING

Routing - pick-up and drop-off locations, move distances, routing variations, conditions along the route (surface, traffic, elevation)

Scheduling - timing of each delivery Prompt delivery when required Use of buffer stocks to mitigate against late

deliveries

CATEGORIES OF MATERIAL HANDLING EQUIPMENT

1. Material transport equipment - to move materials inside a factory, warehouse, or other facility

2. Storage - to store materials and provide access to those materials when required

3. Unitizing equipment - refers to (1) containers to hold materials, and (2) equipment used to load and package the containers

4. Identification and tracking systems - to identify and keep track of the materials being moved and stored

UNIT LOAD PRINCIPLE (UNİTİZİNG)

In general, the unit load should be as large as practical for the material handling system that will move and store it A unit load is the mass that is to be moved or

otherwise handled at one time Reasons for using unit loads in material

handling: Multiple items handled simultaneously Required number of trips is reduced Loading/unloading times are reduced Product damage is decreased

UNIT LOAD CONTAINERS

(a) Wooden pallet, (b) pallet box, (c) tote box

MATERIAL TRANSPORT EQUIPMENT

Industrial trucks AGVs Robots Monorails and other rail guided vehicles Conveyors Cranes and hoists

AUTOMATION IN MATERIAL HANDLING

WHY USE AUTOMATION IN MATERIAL HANDLING

1. To increase labor productivity2. To reduce labor cost3. To mitigate the effects of labor shortages4. To reduce or remove routine manual and

clerical tasks5. To improve worker safety6. To improve product quality7. To reduce manufacturing lead time8. To accomplish what cannot be done

manually9. To avoid the high cost of not automating

AUTOMATED GUIDED VEHICLES

1. AUTOMATED GUIDED VEHICLE

What is AGV ?Material handling system that uses independently operated, Self-propelled vehicles, Guided along defined pathways. Increase efficiency and reduce costs by helping

to automate a manufacturing facility or warehouse.

Carry loads or tow objects behind them in trailers. The trailers can be used to move raw materials or finished product.

The AGV can also store objects on a bed. some AGVs use fork lifts to lift objects for storage.

AGVs are employed in nearly every industry, including, paper, metals, newspaper and general manufacturing.

HISTORY Developed by AM Barrett Jr in 1954

(overhead wire to guide a modified towing truck pulley in a grocery warehouse)

1973,Volvo developed AGV to serve assembly platforms for moving car bodies through its final assembly plants.

Today the AGV plays an important role in the design of new factories and warehouses.

COMPONENTS OF AGV Vehicle Guided path Control unit Computer interface

AGV TYPES

Driver less trains Pallet trucks Unit load carriers

DRIVER LESS TRAINS Consists of towing vehicle, which is the AGV that pulls. One or more trailers forming a train. Heavy payloads. Large distances like in a warehouse. With or without intermediate pick-up and drop-off points

along its path.

DRIVER LESS TRAIN

PALLET TRUCKS

shift palletized loads along programmed path.

the vehicle is backed into the loaded pallet by act of human operator that steers the truck and uses the forks to lift the load vaguely.

The human operator will then drive the pallet truck to its route, program its destination and the vehicle will then automatically travel to the preprogrammed destination for unloading.

Capacity -several thousand kilograms and some are capable of handling two pallets.

PALLET TRUCKS

UNIT LOAD CARRIER

These are used to move unit loads from one station to another.

Light load AGVs, up to 250 kg or less.

UNIT LOAD CARRIER

VEHICLE GUIDANCE TECHNOLOGY

Imbedded guide wires Paint strips (Optical navigation system) Magnetic tape navigation systems Self guided vehicles (Laser triangulation

navigation system)

1. IMBEDDED GUIDE WIRES

•Faster and safer•More accurate•Less costly•Simpler and less programming required

CHOOSING APPROPRIATE PATH IN WIRE GUIDED SYSTEM

Use different frequency generators for different paths.

Guide wires leading into the two separate paths at the switch have different frequency

At switch vehicle reads identification code of destination frequency and follows it.

Same frequency throughout

At switch power is turned off in all other branches except the one that the vehicle is to travel on.

Frequency select method

Path select method

Less costly More accurate and

safer Less programming

Energy consumption Embedded system Less flexible than

other types

Advantages Drawbacks

2. PAINT STRIPS (OPTICAL NAVIGATION SYSTEM)

Chemical or tape strip is fixed or painted to the floor which contain fluorescent particles that reflect UV light source from vehicle

Vehicle has an onboard sensor which allows it to detect the path.

Not typically used in plants or warehouses because floor line needs to be cleaned or reapplied as it deteriorates with time.

Useful in environment where guide wires in the floor surface is not practical.

can be easily removed and relocated if the course needs to change.

It also does not involve the expense of cutting the factory or warehouse floor for the entire travel route.

"passive" system since it does not require the guide medium to be energized as wire does.

less expensive

Repaint Cannot be used in

dirty conditions

Advantage Drawback

3. MAGNETIC TAPE/GRID NAVIGATION SYSTEMS

Magnetic tape is adhered on the surface of the floor

A sensor on underside of vehicle detects the magnetic tape

Can operate off tape path

Similar to wire guidance

4. SELF GUIDED (LASER TRIANGULATION NAVIGATION SYSTEM)

Most popular method of AGV navigation. Operate without continuously defined

pathways. Use combination of dead reckoning

(capability of a vehicle to follow a given route in the absence of a defined pathway) and beacons located throughout the plant, which can be identified by on board sensors.

Continuously verify position by comparing the calculated position with one or more known position

HOW ARE THE VEHICLES POWERED? TYPES OF BATTERIES, INDUCTIVE POWER AND FUEL CELLS

1. Most common batteries Flooded lead acid Sealed batteries NiCad Lithium ion 2. Inductive power – vehicle receives power from

plate(s) embedded in the floor. Used in some applications that require less flexibility

3. Fuel cells – performing well in limited scale use in AGVs.

The best choice of battery is based on your application. Talk to your AGV supplier to determine which battery is best for your application.

VEHICLE MANAGEMENT

Two aspects of vehicle management: Traffic control - to minimize interference

between vehicles and prevent collisions1. Forward (on-board vehicle) sensing2. Zone control

Vehicle dispatching1. On-board control panel2. Remote call stations3. Central computer control

1. ON BOARD SENSING

One or more sensors on vehicle Which detect presence of other vehicles ,

obstacle , or humans near by. More effective in straight path ,less effective

at turns, convergence points.

2. ZONE CONTROL

Zone control to implement blocking system. Zones A, B, and D are blocked. Zone C is free. Vehicle 2 is blocked from entering Zone A by vehicle 1. Vehicle 3 is free to enter Zone C.

VEHICLE DISPATCHING

1. On board control panel Manual vehicle control and programming Lowest level of sophistication Flexibility

2. Remote call station Press button at load unload stations Programmed destination with on board panel

3. Central computer control Automatic dispatching Central computer issues commands Current location information of each AGV Radio frequency commonly used for

communication

VEHICLE SAFETY FEATURES

Travelling speed(< human normal walking speed) Automatic stopping of vehicle if it strays more

than a short distance(50-150mm) –ACQUISITION DISTANCE

Obstacle detection Emergency bumper Warning lights ,bells , alarms etc

bumper

APPLICATIONS

Material transport Storage application: Integration with AS/RS Assembly line application Flexible manufacturing system Office mail delivery Hospital material transport: meal tray,

medical supplies

ROBOTS

2. INDUSTRIAL ROBOT DEFINED

A general-purpose, programmable machine possessing certain human like characteristics

Hazardous work environments Repetitive work cycle Consistency and accuracy Difficult handling task for humans Multi shift operations Reprogrammable, flexible Interfaced to other computer systems

INDUSTRIAL ROBOT APPLICATIONS

1. Material handling applications Material transfer – pick-and-place, palletizing Machine loading and/or unloading

2. Processing operations Welding Spray coating Cutting and grinding

3. Assembly and inspection

MATERIAL HANDLING APPLICATIONS This category includes the following:

Part Placement Palletizing and/or depalletizing Machine loading and/or unloading Stacking and insertion operations

The robot must have following features to facilitate material handling: The manipulator must be able to lift the parts safely. The robot must have the reach needed. The robot’s controller must have a large enough memory

to store all the programmed points so that the robot can move from one location to another.

The robot must have the speed necessary for meeting the transfer cycle of the operation.

1. PART PLACEMENT

o The basic operation in this category is the relatively simple pick-and-place operation.

o This application needs a low-technology robot of the cylindrical coordinate type.

o Only two, three, or four joints are required for most of the applications.

o Pneumatically powered robots are often utilized

2. PALLETIZING AND/OR DEPALLETIZING

o The applications require robot to stack parts one on top of the other, that is to palletize them, or to unstack parts by removing from the top one by one, that is depalletize them.

o Example: process of taking parts from the assembly line and stacking them on a pallet or vice versa.

3. MACHINE LOADING AND/OR UNLOADING:

Robot transfers parts into and/or from a production machine. There are three possible cases:1. Machine loading in which the robot loads parts into a

production machine, but the parts are unloaded by some other means.

Example: a press working operation, where the robot feeds sheet blanks into the press, but the finished parts drop out of the press by gravity.

2. Machine loading in which the raw materials are fed into the machine without robot assistance. The robot unloads the part from the machine assisted by vision or no vision.

Example: bin picking, die casting, and plastic molding 3. Machine loading and unloading that involves both loading

and unloading of the work parts by the robot. The robot loads a raw work part into the process ad unloads a finished part. Example: Machine operation

4. STACKING AND INSERTION OPERATION

In the stacking process the robot places flat parts on top of each other, where the vertical location of the drop-off position is continuously changing with cycle time.

In the insertion process robot inserts parts into the compartments of a divided carton.

RAIL GUIDED VEHICLES

3. RAIL-GUIDED VEHICLES

Self-propelled vehicles that ride on a fixed-rail system

Vehicles operate independently and are driven by electric motors that pick up power from an electrified rail

Fixed rail system Overhead monorail - suspended overhead

from the ceiling On-floor - parallel fixed rails, tracks generally

protrude up from the floor Routing variations are possible: switches,

turntables, and other special track sections

OVERHEAD MONORAIL

CONVEYORS

4. CONVEYOR SYSTEMS

Large family of material transport equipment designed to move materials over fixed paths, usually in large quantities or volumes

1. Non ‑ powered Materials moved by human workers or by

gravity

2. Powered Power mechanism for transporting materials is

contained in the fixed path, using chains, belts, rollers or other mechanical devices

CONVEYOR TYPES

1. Roller2. Skate ‑ wheel 3. Belt4. In‑ floor towline

1. ROLLER CONVEYOR

Pathway consists of a series of rollers that are perpendicular to direction of travel

Loads must possess a flat bottom to span several rollers

Powered rollers rotate to drive the loads forward

Un-powered roller conveyors also available

2. SKATE-WHEEL CONVEYOR

Similar in operation to roller conveyor but use skate wheels instead of rollers

Lighter weight and unpowered

Sometimes built as portable units that can be used for loading and unloading truck trailers in shipping and receiving

3. BELT CONVEYOR Continuous loop

with forward path to move loads

Belt is made of reinforced elastomer

Support slider or rollers used to support forward loop

Two common forms: Flat belt (shown) V-shaped for bulk

materials

4. IN-FLOOR TOW-LINE CONVEYOR

Four-wheel carts powered by moving chains or cables in trenches in the floor

Carts use steel pins (or grippers) to project below floor level and engage the chain (or pulley) for towing

This allows the carts to be disengaged from towline for loading and unloading

POWERED CONVEYOR OPERATIONS AND FEATURES

Types of motions1. Continuous - conveyor moves at constant

velocity2. Asynchronous - conveyor moves with stop-

and-go motion They stop at stations, move between stations

Another classification of conveyors:1. Single direction2. Continuous loop3. Recirculating

(a) Single direction conveyor

(b) Continuous loop conveyor

CRANES AND HOISTS

5. CRANES AND HOISTS

Handling devices for lifting, lowering and transporting materials, often as heavy loads

Cranes Used for horizontal movement of materials

Hoists Used for vertical lifting of materials

Cranes usually include hoists so that the crane-and-hoist combination provides Horizontal transport Vertical lifting and lowering

BRIDGE CRANE

GANTRY CRANE------TYPES---- Double gantry Half gantry Cantilever

gantry

Half gantry

JIB CRANE

ANALYSIS OF MATERIAL TRANSPORT SYSTEMS

1. Charting techniques in material handling2. Vehicle based system3. Conveyor analysis

ANALYSIS OF MATERIAL TRANSPORT SYSTEMS

Analysis of vehicle-based systems From-to charts and network diagrams Types of systems: industrial trucks, AGVS, rail-

guided vehicles, and asynchronous conveyor operations

CHARTING TECHNIQUES IN MATERIAL HANDLING (FROM –TO CHART)

FROM

TO 1 2 3 4 5

1 0 9/50 5/120 6/205 0

2 0 0 0 0 9/80

3 0 0 0 2/85 3/170

4 0 0 0 0 8/85

5 0 0 0 0 0

FROM –TO CHART showing flow rates, (loads per hr/travel distance)

Flow diagram showing material deliveries between load/unload stations

ANALYSIS VEHICLE BASED SYSTEM

Tc = delivery cycle time (min/del) TL = time to load (min)—0.75 min Tu = time to unload (min)---0,5 min Ld = distance b/w load to unload

(110m) Le = distance b/w unload to load

(80 m) v = vehicle velocity (50 m/min)

Tc ideal value because it ignores Traffic congestion Reliability problems etc

LOAD

UNLOAD

5540

20

20

Direction of AGV

Guide path

AGV

Tc = TL +[Ld/v ]+ [Le/v] + Tu

Tc= 0.75 + [110/50]+[80/50]+ 0.5Tc= 5.05 min

1. RATE OF DELIVERIES PER VEHICLE Possible time loss include1) Availability ( A) -proportion of total shift time that te

vehicle is operational and not broken down or being repaired)

2) Traffic congestion ( Tf)- blocking, waiting in queue etc

Many vehicles Tf decreases ,value ranges from 0.85 to 1

3) Efficiency (E)-of manual drivers if any(worker efficiency)

if not apply is taken as unity (1) AT = available time (min/hr per vehicle)

Rdv = rate of deliveries per vehicle (del/hr per

vehicle)

AT = 60× A × Tf × E

Rdv = AT Tc 1

2. NUMBER OF VEHICLES REQUIRED

Rf = specified delivery schedule or total delivery requirements (del/ hr per vehicle)

WL = Work load(min/hr) n = number of vehicle required

n = WL AT

n = Rf Rdv

2

From 1 and 2

LIMITATIONS OF AUTOMATED MATERIAL HANDLING SYSTEMS

Additional investment Lack of flexibility Vulnerability to downtime whenever there is

breakdown Additional maintenance staff and cost Cost of auxiliary equipment. Space and other requirements

ENDTHANK YOU