1 MENG 464 COMPUTER INTEGRATED MANUFACTURING Material Handling System.

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MENG 464MENG 464COMPUTER INTEGRATED COMPUTER INTEGRATED

MANUFACTURINGMANUFACTURING

Material Handling Material Handling SystemSystem


Material HandlingMaterial Handling is the movement, is the movement, storage, control and protection of storage, control and protection of materials, goods and products materials, goods and products throughout the process of throughout the process of manufacturing, distribution, manufacturing, distribution, consumption and disposal.consumption and disposal.

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The Material Handling System (MHS) The Material Handling System (MHS) is a fundamental part of a Flexible is a fundamental part of a Flexible Manufacturing system since it Manufacturing system since it interconnects the different interconnects the different processes supplying and taking out processes supplying and taking out raw material, work-pieces, sub-raw material, work-pieces, sub-products, parts and final products. products, parts and final products.

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Components:Components: RobotsRobots ConveyorsConveyors Automated Guided Vehicles(AGVs)Automated Guided Vehicles(AGVs) Automated Storage/Retrieve System Automated Storage/Retrieve System

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Robots in Robots in ManufacturingManufacturing

Industrial robot is aIndustrial robot is a ProgrammableProgrammable Multi-functionalMulti-functional Designed to move materials, parts, Designed to move materials, parts,

tools or special devicestools or special devices Through programmed motionsThrough programmed motions To perform many different tasksTo perform many different tasks

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Robots in ManufacturingRobots in Manufacturing First industrial robot was developed in the First industrial robot was developed in the

1950s1950s Further advancements enable to utilize robots Further advancements enable to utilize robots

inin Variety of typesVariety of types StyleStyle SizeSize

Their functionalities may include but not Their functionalities may include but not restricted torestricted to WeldingWelding DrillingDrilling PaintingPainting Military applicationsMilitary applications AssemblyAssembly Explosive material removalExplosive material removal Pick-and-placePick-and-place Material handlingMaterial handling

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A typical robot consists of many A typical robot consists of many different part connected to each otherdifferent part connected to each other

Most robots resembles a human armMost robots resembles a human arm Its motions are controlled by a Its motions are controlled by a

computer programcomputer program Depends on the type of robot, Depends on the type of robot,

movement capabilities of them are movement capabilities of them are measured by the term degrees of measured by the term degrees of freedomfreedom

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Robots with different degrees of Robots with different degrees of freedomsfreedoms2-3 dof

Robots used in surgery

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Robots in ManufacturingRobots in Manufacturing How do robots work:How do robots work: there are 3 power sources there are 3 power sources

Hydraulic Hydraulic drivedrive

Joints are actuated by hydraulic driversJoints are actuated by hydraulic drivers

The major disadvantages are:The major disadvantages are: Floor is used by the installation of hydraulic systemFloor is used by the installation of hydraulic system Leaks may seen often and cause messy floorLeaks may seen often and cause messy floor

AdvantagesAdvantages Due to the speed and power, they are used in large Due to the speed and power, they are used in large industrial robotsindustrial robots Also desired to use in the environments where electric-Also desired to use in the environments where electric-driven robots might cause fire etc.driven robots might cause fire etc.

Electric Electric DriveDrive

Comparison to Hydraulic systems, less power and slower Comparison to Hydraulic systems, less power and slower speedspeed

Most common robot types in the industryMost common robot types in the industry

There are two distinct group: Stepper motors and Direct There are two distinct group: Stepper motors and Direct current (DC) servo-motor drivencurrent (DC) servo-motor driven

PneumatiPneumatic Drivec Drive

Usually installed to small robotsUsually installed to small robots

Tends to have less degrees of freedomTends to have less degrees of freedom

Operations are simple and less cycle timesOperations are simple and less cycle times

Less expensive, Since most of the robot parts are Less expensive, Since most of the robot parts are commercially available, small institution can build commercially available, small institution can build their own robotstheir own robots

10IE 447 - CIM Lecture Notes - Chapter 9

MHS


How do we know the location of robot How do we know the location of robot arms?arms? Sensors are usedSensors are used to monitor the motion of to monitor the motion of

robotsrobots Motion of robots is sustained by the power Motion of robots is sustained by the power

based on the given input (computer algorithm)based on the given input (computer algorithm) Once the order is given, it is important to know Once the order is given, it is important to know

the location of robot’s arm/partsthe location of robot’s arm/parts Its movements should be controlled during the Its movements should be controlled during the

entire motionentire motion Robot should also be capable of sensing their Robot should also be capable of sensing their

environmentsenvironments Sensors provides feedback to the controller and Sensors provides feedback to the controller and

give flexibility to robotsgive flexibility to robots

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Robots in Robots in ManufacturingManufacturingType of sensors being used in roboticsType of sensors being used in robotics

1. 1. Position Position SensorsSensors

Monitors the location of jointsMonitors the location of joints

Coordinate information is feedback to controllerCoordinate information is feedback to controller

This communication gives the system the capability of location This communication gives the system the capability of location the end-effectors, which is the part usually performs the tasks.the end-effectors, which is the part usually performs the tasks.

2. Range 2. Range sensorssensors

Measures the distance between a point in the robot and interest Measures the distance between a point in the robot and interest point that surrounds the robotspoint that surrounds the robots

The task is usually performed by television cameras or sonar The task is usually performed by television cameras or sonar transmitter and receiverstransmitter and receivers

If the sonar or camera misses a point, undesired coincidences If the sonar or camera misses a point, undesired coincidences may occurmay occur

3. 3. Velocity Velocity sensorssensors

Estimates the speed using a moving manipulatorEstimates the speed using a moving manipulator

Due the the effects caused by, mechanical force, gravity, weight Due the the effects caused by, mechanical force, gravity, weight of load etc, desired speed and required force to reach the speed of load etc, desired speed and required force to reach the speed should be computed continuouslyshould be computed continuously

4. 4. Proximity Proximity sensorssensors

Sense and indication of presence of another object within Sense and indication of presence of another object within specified distancesspecified distances

Prevents accidents and locate the existence of work-piecePrevents accidents and locate the existence of work-piece


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Robot movements:Robot movements: Robots are feasible when they are Robots are feasible when they are fastfast

but also the but also the stability is highstability is high The trade-off between speed and stability The trade-off between speed and stability

is sustained by a powerful control systemis sustained by a powerful control system Robotics and Control are two joint Robotics and Control are two joint

disciplinesdisciplines


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Robotic movements and jointsRobotic movements and joints Robots required to performRobots required to perform

1.1. Rotational movementsRotational movements

2.2. Radial movementsRadial movements

3.3. Vertical movementsVertical movements Type of jointsType of joints

1.1. Rotational jointsRotational joints

2.2. Twisting jointsTwisting joints

3.3. Revolving jointsRevolving joints

4.4. Linear jointsLinear joints


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Analysis of robot motions:Analysis of robot motions:

Forward and Backward Kinematics conceptsForward and Backward Kinematics concepts Forward Kinematics:Forward Kinematics: Transformation of Transformation of

coordinate of the end-effectors point from the coordinate of the end-effectors point from the joint space to the world spacejoint space to the world space

Position of end-effectors is computed based on Position of end-effectors is computed based on the joints locationsthe joints locations

Backward Kinematics:Backward Kinematics: Transformation of Transformation of coordinates from world space to joint spacecoordinates from world space to joint space

In this concept the position of end-effectors is In this concept the position of end-effectors is known in world coordinate systemknown in world coordinate system

Required motion is computed based on this Required motion is computed based on this informationinformation


MHS

Robot ConfigurationsRobot Configurations

LL Robot: Base is static, arms are linear joints

RRR Robot: Base is static, arms are rotational

joints

TL Robot: Base is rotational and the arm is

linear joint

(x1, y1) (x2, y2)

(x, y)

L2

L1

L3

(x, y)

(x, y)


MHS


Essentials of robot programmingEssentials of robot programming RequiresRequires

The path robot should followThe path robot should follow The points it should reachThe points it should reach Details about how to interpret the Details about how to interpret the

sensor datasensor data How and when the end-effectors should How and when the end-effectors should

be activatedbe activated How to move parts between given How to move parts between given

locationslocations


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Essentials of robot programmingEssentials of robot programming Programming techniquesProgramming techniques

Teach-by showing:Teach-by showing: Robot can repeat the motion already been Robot can repeat the motion already been

done by the programmerdone by the programmer Textual language programmingTextual language programming

A computer programming is written using A computer programming is written using logical statementslogical statements

Some of the languages are:Some of the languages are: Wave, VAL, AML, RAIL, MCL, TL-10, Wave, VAL, AML, RAIL, MCL, TL-10,

IRL, PLAW, SINGLA and IRL, PLAW, SINGLA and ACLACL


MHS

Robots of IE CIM LABRobots of IE CIM LAB


MHS


SCORA ER14

A four-axis, table-top mounted SCARA robot, the SCORA-ER 14 is designed for work in industrial training facilities. This rugged and reliable robot performs light-payload assembly, handling and packaging applications with impressive speed and accuracy.

• Handling and packaging operations with palletizing and storage devices• Assembly operations with automatic screw driving and gluing devices• Quality control operations with machine vision and high-precision measurementdevices


MHS


SCORBOT ER9

The SCORBOT-ER 9 is a five-axis vertically articulated robot designed for work inindustrial training facilities.With a multi-tasking controller that provides real-time control and synchronization of up to 12 axes, 16 inputs and 16 outputs, the SCORBOT-ER 9 supports both stand-alone applications as well as sophisticated automated work cells.


MHS

Steps in Robot Steps in Robot ProgrammingProgramming

Programming of an Industrial TaskProgramming of an Industrial Task

1. Teach Pendant 1. Teach Pendant OperationOperation

move the robot arm inmove the robot arm in JointsJoints CartesianCartesian Tool coordinatesTool coordinates

Control robot grippers Control robot grippers and the speed of motionand the speed of motion

Record positions to the Record positions to the robot controller’s robot controller’s memorymemory

Move robot arm to Move robot arm to recorded positionsrecorded positions

1AXIS 1 X

2AXIS 2 Y

3AXIS 3 Z

4AXIS 4

5AXIS 5

6AXIS 6

7AXIS 7

8AXIS 8

9AXIS 9

0SELEC T

AXIS

S IN G LE STE P

SPLIN E

M O VE C

IN SERT

D ELETE

R EC O R DPO SITIO N

ABO RTSPEED (% )

S P EE D L(% )

M O VE

M O VE L

EN TER

EXEC UTE

O PEN

C LO SE

CO N TR O LO N/O FF

R U N

C LR

G RO U PSELEC T

AU TO M ODE


MHS



2. Writing robot programs2. Writing robot programs Use ACL (Automatic Control Language) to edit Use ACL (Automatic Control Language) to edit

robot programs.robot programs. Commonly used robot program statements.Commonly used robot program statements.

MOVE:MOVE:

MOVED: MOVED:

OPEN:OPEN:

CLOSE:CLOSE:

SPEED:SPEED:


MHS



3. Executing Robot Programs3. Executing Robot Programs Use ATS DIRECT Mode;Use ATS DIRECT Mode;

Statements to execute;Statements to execute;

RUN RUN prgname prgname : To execute the program : To execute the program prgnameprgname

ABORT: To abort the current running robot ABORT: To abort the current running robot program.program.

Conveyors In CIMConveyors In CIM

Conveyors type:Conveyors type:Belt ConveyorsBelt ConveyorsRoller ConveyorsRoller ConveyorsCrane ConveyorsCrane ConveyorsScrew ConveyorsScrew Conveyors……


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The package conveyor business has been in The package conveyor business has been in existence for almost one hundred years.existence for almost one hundred years.

Material handling engineering, in an over-Material handling engineering, in an over-simplified, basically, consists of simplified, basically, consists of determining "how a product should be determining "how a product should be moved from one place to another, within moved from one place to another, within the shortest allowable period of time, for the shortest allowable period of time, for the least cost and with the least amount of the least cost and with the least amount of manual effort".manual effort".


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Classification of conveyors:Classification of conveyors:ActiveActive; Energy is supplied to the ; Energy is supplied to the component for the movement of the component for the movement of the materials, upward movements.materials, upward movements.PassivePassive; No energy is supplied to the ; No energy is supplied to the component and gravity force is component and gravity force is utilized for the movement of the utilized for the movement of the materials, mostly downward materials, mostly downward movements. movements.


MHS


Classification of conveyorsClassification of conveyorsContinuous movementContinuous movement; Applicable ; Applicable for the movement of continuous for the movement of continuous materialmaterial such as liquids, sand, soil and such as liquids, sand, soil and cereals. cereals. District movementDistrict movement; Applicable for ; Applicable for the movement of district materialthe movement of district material such such as boxes, parts, cans and…as boxes, parts, cans and…


MHS

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Material Material Handling Handling Systems Systems Automatic Guided Vehicle Automatic Guided Vehicle

SystemsSystemsAGVSAGVS

IE 447 - CIM Lecture Notes - Chapter 9 MHS

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Understanding Understanding AGVSAGVS

History of AGVSHistory of AGVS


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History of AGVSHistory of AGVS1953 First AGV1953 First AGV

The first AGV system The first AGV system was built and was built and introduced in 1953introduced in 1953( A( A modified modified towing towing tractortractor that was used that was used to pull a trailer and to pull a trailer and follow an overhead follow an overhead wire in a grocery wire in a grocery warehousewarehouse))


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History of AGVSHistory of AGVS1973 Volvo Assembly 1973 Volvo Assembly

PlantPlant In 1973, Volvo in In 1973, Volvo in

Kalmar, Sweden set Kalmar, Sweden set out to develop non-out to develop non-synchronous synchronous assembly assembly equipment as an equipment as an alternative to the alternative to the conventional conventional conveyor assembly conveyor assembly line. The result line. The result was was 280280 computer-computer-controlled controlled assembly AGVsassembly AGVs..


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History of AGVSHistory of AGVS1970s First Unit Load1970s First Unit Load

IIntroduction of a ntroduction of a unit load vehicleunit load vehicle

They have the ability to serve several functions;

a work platform,

a transportation device, and

a link in the control and information system

They transport material in warehouses, factories, mills, hospitals, and other industrial and commercial settings.


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History of AGVSHistory of AGVSSmart Floors and Dumb VehiclesSmart Floors and Dumb Vehicles

In the 1970’s the In the 1970’s the principal guidance principal guidance technology was to technology was to induce an electronic induce an electronic frequency through a frequency through a wire that was buried in wire that was buried in the floor.the floor.

‘‘floor controller’floor controller’

•These first generation navigation schemes were expensive to install.

•All floor cuts needed to follow the exact path of the AGV.


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History of AGVSHistory of AGVSDead Reckoning CapabilityDead Reckoning Capability

As the vehicles became As the vehicles became more intelligent, the more intelligent, the path became less path became less sophisticatedsophisticated

Dead reckoningDead reckoning is a is a term that describes the term that describes the ability of a vehicle ability of a vehicle to to traverse steel expansion traverse steel expansion joints on the factory joints on the factory floor orfloor or to cross a steel to cross a steel grategrate

The biggest advantage was that dead reckoning eliminated the need to make the cut radius turns at intersections. (Installation was greatly simplified).


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History of AGVSHistory of AGVS1980s Non-Wire Guidance1980s Non-Wire Guidance

The introduction of The introduction of llaser aser andand inertia inertia

guidanceguidance..

AAllow for increased system flexibility and llow for increased system flexibility and accuracyaccuracy

NNo need for floor alterations or production o need for floor alterations or production interruptioninterruption


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AGV NAVIGATIONAGV NAVIGATION

The principles which make it possible for an The principles which make it possible for an AGV to navigate its way between any two AGV to navigate its way between any two locations are really quite simple. All navigation locations are really quite simple. All navigation methods use a path. The vehicle is instructed to methods use a path. The vehicle is instructed to FollowFollow a Fixed Path a Fixed Path or or TakeTake an Open Path an Open Path..


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Fixed Path NavigationFixed Path NavigationFollowing a PathFollowing a Path

The paths are well The paths are well marked on the floormarked on the floor

The paths are The paths are continuouscontinuous

The paths are fixed, but The paths are fixed, but can be changedcan be changed


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Fixed Path Navigation: Fixed Path Navigation: Creating a PathCreating a Path

The principle techniques for creating paths are to:The principle techniques for creating paths are to: Apply a narrow Apply a narrow magnetic tapemagnetic tape on the surface of the floor on the surface of the floor Apply a narrow Apply a narrow photo sensitive chemical stripphoto sensitive chemical strip on the on the

surface of the floorsurface of the floor Apply a narrow Apply a narrow photo reflective tapephoto reflective tape on the surface of the on the surface of the

floorfloor Bury a wireBury a wire just below the surface of the floor just below the surface of the floor


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Fixed Path Navigation: Fixed Path Navigation: Buried Wire PathBuried Wire Path

Bury a Bury a current-carrying current-carrying wire just below the wire just below the surface of the floorsurface of the floor


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Fixed Path Navigation: Fixed Path Navigation: Steering Correction CoilsSteering Correction Coils

TThe vehicle steers itself to he vehicle steers itself to FOLLOWFOLLOW the magnetic field the magnetic field surrounding the buried wire.surrounding the buried wire.


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Fixed Path Navigation: Fixed Path Navigation: Path SelectionPath Selection

In this illustration, a In this illustration, a vehicle at “A” has two vehicle at “A” has two choices on how to get to choices on how to get to “B”. A computer either on “B”. A computer either on board the vehicle or at board the vehicle or at some central location some central location selects a path based on selects a path based on established criteria.established criteria.

Criteria: Criteria: TThe shortest distancehe shortest distance TThe path with the least he path with the least

traffic at the present traffic at the present timetime

All of the “PATH All of the “PATH FOLLOWING” methods FOLLOWING” methods permit routing options permit routing options that include guide path that include guide path switching and merging.switching and merging.


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Open Path Navigation: Open Path Navigation: Taking a PathTaking a Path

Unlike “Unlike “path following path following navigationnavigation,” where the ,” where the guide paths are fixed, guide paths are fixed, and more or less and more or less permanent, vehicles permanent, vehicles operating in the “operating in the “Take a Take a PathPath” category are ” category are actually offered more actually offered more variation if not an variation if not an infinite number of ways infinite number of ways to navigate the open to navigate the open space between two space between two points.points.


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Open Path Navigation: Open Path Navigation: Navigation MethodsNavigation Methods

The three most common open space The three most common open space navigation methods arenavigation methods are:: Laser GuidanceLaser Guidance Inertial GuidanceInertial Guidance Cartesian GuidanceCartesian Guidance

The choice of navigation method for aThe choice of navigation method for a particular particular application is often a simple matter of preferenceapplication is often a simple matter of preference..


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Navigation Methods - Laser Navigation Methods - Laser GuidanceGuidance

RReference points are eference points are strategically located strategically located targetstargets

A beacon on top of the A beacon on top of the vehicle emits a vehicle emits a rotating laser beam rotating laser beam which is reflected back which is reflected back to the vehicle when it to the vehicle when it strikes (sees) a target.strikes (sees) a target.


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Navigation Methods - Inertial Navigation Methods - Inertial GuidanceGuidance

AAn n on board gyroscopeon board gyroscope establishes and maintains a vehicle’s heading establishes and maintains a vehicle’s heading.. Distance traveled is calculated by an Distance traveled is calculated by an on board encoderon board encoder which counts wheel rotations. which counts wheel rotations.


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Navigation Methods – Navigation Methods – Cartesian GuidanceCartesian Guidance

LLocation precision is ocation precision is accomplished by way of a accomplished by way of a fixed grid pattern that fixed grid pattern that covers the entire floor covers the entire floor area.area.

The possible travel paths The possible travel paths in a given, unrestricted in a given, unrestricted operating area for a grid operating area for a grid based system are infinite based system are infinite and most like that and most like that provided by laser provided by laser guidanceguidance


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AGVS DispatchingAGVS Dispatching

Dispatching AGVS is much the same as dispatching Dispatching AGVS is much the same as dispatching taxi taxi cabscabs..

The dispatch function makes sure that all The dispatch function makes sure that all customers get customers get timely services from the vehicle best able to service a timely services from the vehicle best able to service a requestrequest..

RemoteRemote and and local dispatchlocal dispatch are most commonly described as are most commonly described as offboardoffboard and and onboard dispatchersonboard dispatchers respectively. respectively.


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AGVS CommunicationsAGVS Communications

Communications include message Communications include message ccommandsommands such assuch as:: where to go,where to go, when to start,when to start, when to slow downwhen to slow down,, when to stop.when to stop.

FFour types of basic communication mediaour types of basic communication media:: Radio CommunicationRadio Communication Infrared CommunicationInfrared Communication Guide Wire Data CommunicationGuide Wire Data Communication Inductive Loops CommunicationInductive Loops Communication


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AGVS Communications AGVS Communications Radio CommunicationRadio Communication

MMaximum flexibility in aximum flexibility in system controlsystem control

Vehicles can be Vehicles can be programmed “on the programmed “on the fly”fly”

system speed of system speed of response to changing response to changing load movement load movement demands is improveddemands is improved


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AGVS Communications AGVS Communications Infrared CommunicationInfrared Communication

Optical infrared communication Optical infrared communication is is highly reliablehighly reliable but has the but has the disadvantage of not being disadvantage of not being continuouscontinuous; it is point to point. ; it is point to point.

Vehicles may be stopped during Vehicles may be stopped during this data exchange which usually this data exchange which usually occurs at load stations where the occurs at load stations where the fixed and mobile units are fixed and mobile units are aligned and in close proximity. aligned and in close proximity.

Or, the vehicle communicates at fixed points along its guide path as the vehicle travels through a given zone.

Infrared communication is best suited for small systems with few vehicles and load stations.


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Remote DispatchingRemote DispatchingThe DispatcherThe Dispatcher

The remote dispatch function generally resides in a The remote dispatch function generally resides in a

computer (PC),computer (PC), Programmable Controller (PLC),Programmable Controller (PLC), or other microprocessor, known as the Dispatcheror other microprocessor, known as the Dispatcher..

The Dispatcher accepts input from the various system Components (generally transport requests) and directs the AGVS to fulfill the command in the most efficient manner.

Remote dispatch can occur with vehicles at single or various dispatch points.


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AGVS MonitoringAGVS Monitoring

TTypes of monitoringypes of monitoring : : System monitoringSystem monitoring Vehicle monitoringVehicle monitoring

The functions and The functions and reporting capabilities of reporting capabilities of each are important to each are important to the safe operation of the the safe operation of the AGVs.AGVs.


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Material Material Handling Handling SystemsSystems

Automatic Storage Retrieve Automatic Storage Retrieve SystemsSystems

AS/RSAS/RS



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Principles of Materials Principles of Materials HandlingHandling

Introduction:Introduction:

Certain fundamental principles for analyzing and designing solutions to Certain fundamental principles for analyzing and designing solutions to materials handling problems have been developed over a period of time materials handling problems have been developed over a period of time based on experience of many materials handling experts. These can be based on experience of many materials handling experts. These can be used as general guide by any fresh materials handling practitioner, for used as general guide by any fresh materials handling practitioner, for analyzing a materials handling problem and arriving at a solution to same. analyzing a materials handling problem and arriving at a solution to same. Many of the materials handling problems may be initially treated by these Many of the materials handling problems may be initially treated by these principles before undertaking detailed technical analysis. In certain principles before undertaking detailed technical analysis. In certain materials handling problems, these principles may become the only resort materials handling problems, these principles may become the only resort to an acceptable solution where the exact analysis is too costly or difficult.to an acceptable solution where the exact analysis is too costly or difficult.

59MENG 464 - CIM Lecture Notes -

Chapter 9 MHS

PLANNING PRINCIPLEPLANNING PRINCIPLE All handling activities should be planned. This is the most basic All handling activities should be planned. This is the most basic

principle which is in line withprinciple which is in line withthe Materials Handling Equation (see the Materials Handling Equation (see block below).Suggestions for carrying out planning principles are:block below).Suggestions for carrying out planning principles are:

• • Consider the plant layout before equipment / system design.Consider the plant layout before equipment / system design. • • Plan correct location for materials supply and disposal. Plan for scrap Plan correct location for materials supply and disposal. Plan for scrap

removal.removal. • • Assure adequate storage space at the workplace.Assure adequate storage space at the workplace. • • Avoid placing materials directly on the floor. Place product on a pallet, Avoid placing materials directly on the floor. Place product on a pallet,

skid etc. at the beginningskid etc. at the beginning of the process.of the process. • • Use same container throughout the materials movement, as far as Use same container throughout the materials movement, as far as

practicable.practicable. • • Observe principles of motions economy.Observe principles of motions economy. • • Plan productive operations and inspections during material movement, if Plan productive operations and inspections during material movement, if

possible.possible. • • Use judicious amount of manual handling.Use judicious amount of manual handling.


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SYSTEMS PRINCIPLESYSTEMS PRINCIPLE Integrate as many handling activities as possible encompassing full scope of Integrate as many handling activities as possible encompassing full scope of

operations like receiving, storage, production, inspection, packaging, operations like receiving, storage, production, inspection, packaging, warehousing, shipping/transportation.warehousing, shipping/transportation.

Suggestions:Suggestions: • • Consider the entire scope of the handling activities, beyond the scope of Consider the entire scope of the handling activities, beyond the scope of

immediate concern.immediate concern. • • Integrate operations into handling systems like processing, inspection, packaging Integrate operations into handling systems like processing, inspection, packaging

etc.etc. • • Avoid/ minimize intermediate storage.Avoid/ minimize intermediate storage. • • While designing a materials handling system, the practices/requirements of the While designing a materials handling system, the practices/requirements of the

suppliers, clientssuppliers, clients and transporters are to be considered.and transporters are to be considered. • • Allow necessary flexibility considering future requirements/emergencies.Allow necessary flexibility considering future requirements/emergencies.


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MATERIAL FLOW MATERIAL FLOW PRINCIPLEPRINCIPLE

Plan operations sequence and equipment arrangement Plan operations sequence and equipment arrangement to optimize material flow.to optimize material flow.

Suggestions:Suggestions: • • Eliminate obstacles from material flow.Eliminate obstacles from material flow. • • Plan material movement in a direct path (avoid Plan material movement in a direct path (avoid

backtracking, zig-zag movements etc.)backtracking, zig-zag movements etc.) • • Use product layout whenever possible.Use product layout whenever possible. • • Keep related work areas close together.Keep related work areas close together. • • Combine operations to reduce material movement.Combine operations to reduce material movement. • • Minimize movement between floors.Minimize movement between floors. • • Move bulky / weighty materials the least distance.Move bulky / weighty materials the least distance. • • Process heavy / bulky materials close to receiving.Process heavy / bulky materials close to receiving.


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SIMPLIFICATION SIMPLIFICATION PRINCIPLEPRINCIPLE

Reduce, combine or eliminate unnecessary movement and/or equipment. It Reduce, combine or eliminate unnecessary movement and/or equipment. It increases efficiency of materials handling.increases efficiency of materials handling.

Suggestions:Suggestions:

• • Apply principles of motions economy. Avoid unnecessary handling. Eliminate re-Apply principles of motions economy. Avoid unnecessary handling. Eliminate re-handling ashandling as

much as possible.much as possible. • • Plan direct moves. Reduce or eliminate long, awkward or complicated moves.Plan direct moves. Reduce or eliminate long, awkward or complicated moves. • • Deliver materials at correct location first time.Deliver materials at correct location first time. • • Use material out of original container.Use material out of original container. • • Avoid use of variety of equipment types, sizes and makes.Avoid use of variety of equipment types, sizes and makes. • • Plan adequate material handling equipment capacity.Plan adequate material handling equipment capacity. • • Do not mechanize unnecessarily.Do not mechanize unnecessarily.


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GRAVITY PRINCIPLEGRAVITY PRINCIPLE

Utilize gravity to move material whenever practicable.Utilize gravity to move material whenever practicable.


• • Use roller conveyors, slides, chutes between equipment/processes.Use roller conveyors, slides, chutes between equipment/processes. • • Use ramps between varying work or floor levels.Use ramps between varying work or floor levels. • • Use sloping floor when materials movement by hand truck is mainly in Use sloping floor when materials movement by hand truck is mainly in

one direction.one direction. • • Use spiral chutes to feed machines at different floors.Use spiral chutes to feed machines at different floors.


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SPACE UTILIZATION SPACE UTILIZATION PRINCIPLEPRINCIPLE

Make optimum use of building volume.Make optimum use of building volume.


• • Space equipment/processes close together.Space equipment/processes close together. • • Eliminate or reduce temporary storage of materials.Eliminate or reduce temporary storage of materials. • • Stack materials to use building height.Stack materials to use building height. • • Use racks to permit higher stacking.Use racks to permit higher stacking. • • Use stacking containers to permit stacking.Use stacking containers to permit stacking. • • Exercise economic order quantities to reduce inventory.Exercise economic order quantities to reduce inventory. • • Clean storage areas and dispose scrap regularly.Clean storage areas and dispose scrap regularly. • • Use narrow aisle handling equipment to reduce aisle width.Use narrow aisle handling equipment to reduce aisle width.


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MECHANIZATION/MECHANIZATION/AUTOMATION AUTOMATION

PRINCIPLEPRINCIPLEWhen appropriate, use mechanized or automatic materials handling When appropriate, use mechanized or automatic materials handling

equipment.equipment.

Suggestions:Suggestions: • • Consider mechanized system in the following cases:Consider mechanized system in the following cases: ((a) Large quantities or volumes of materials, (b) Repetitive movement, (c) a) Large quantities or volumes of materials, (b) Repetitive movement, (c)

Long moves,Long moves, ((d) Hazardous move/materials, (e) Two man lifting, moving tasks, (f) d) Hazardous move/materials, (e) Two man lifting, moving tasks, (f)

Excess manual handling,Excess manual handling, ((g) Replacing large number of persons involved in handling, (h) Heavy g) Replacing large number of persons involved in handling, (h) Heavy

materials, (i) Scrapmaterials, (i) Scrap removal, (removal, (j) Feeding/unloading of high speed automated production j) Feeding/unloading of high speed automated production

machines.machines. • • Do not over mechanize.Do not over mechanize.


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EQUIPMENT SELECTION EQUIPMENT SELECTION PRINCIPLEPRINCIPLE

Before selecting materials handling equipment, consider all aspects of Before selecting materials handling equipment, consider all aspects of materials handling,e.g., materials to be handled, moves to be made, materials handling,e.g., materials to be handled, moves to be made, methods to be utilized.methods to be utilized.

PRINCIPLES OF MATERIALS HANDLING 13PRINCIPLES OF MATERIALS HANDLING 13 Suggestions:Suggestions: • • Select versatile equipment.Select versatile equipment. • • Select standardized equipment.Select standardized equipment. • • Consider unitization of load for handling.Consider unitization of load for handling. • • Select capacity judiciously. Provide additional capacity based on future Select capacity judiciously. Provide additional capacity based on future

plan.plan. • • Compare alternatives based on cost of handling.Compare alternatives based on cost of handling.


MHS

STANDARDIZATION STANDARDIZATION PRINCIPLEPRINCIPLE

Materials handling methods and equipment should be standardized to the Materials handling methods and equipment should be standardized to the extent possible.extent possible.


• • Use standardized containers.Use standardized containers. • • Purchase standard types and sizes of equipment.Purchase standard types and sizes of equipment. • • Use standard sizes of pallets to fit products, bay sizes, equipment and Use standard sizes of pallets to fit products, bay sizes, equipment and

transport trucks.transport trucks.


MHS

FLEXIBILITY PRINCIPLEFLEXIBILITY PRINCIPLE

Use methods and equipment, which can perform different tasks and Use methods and equipment, which can perform different tasks and applications.applications.


• • Buy flexible equipment like Fork Lift Truck, Conveyor etc.Buy flexible equipment like Fork Lift Truck, Conveyor etc. • • Use variable speed drives.Use variable speed drives. • • Make use of attachment & accessories.Make use of attachment & accessories. • • Use four ways pallets, skids and containers.Use four ways pallets, skids and containers. • • Utilize mobile in favour of fixed equipment (e.g. trucks in favour of fixed Utilize mobile in favour of fixed equipment (e.g. trucks in favour of fixed

conveyors)conveyors)


MHS

MOTION PRINCIPLEMOTION PRINCIPLEStoppage of mobile equipment should be minimum.Stoppage of mobile equipment should be minimum.


• • Reduce loading/unloading time.Reduce loading/unloading time. • • Load/unload while materials handling equipment is in motion, if Load/unload while materials handling equipment is in motion, if

possible.possible. • • Use mechanized loading/unloading equipment.Use mechanized loading/unloading equipment. 14 INTRODUCTION TO MATERIALS HANDLING14 INTRODUCTION TO MATERIALS HANDLING • • Use self-loading/unloading equipment like lift truck.Use self-loading/unloading equipment like lift truck. • • Plan materials movement on both ways movement of materials Plan materials movement on both ways movement of materials

handling equipment.handling equipment. • • Use equipment where carrying device is attached to motive unit like Use equipment where carrying device is attached to motive unit like

platform-type trucks, trailersplatform-type trucks, trailers etc.etc. • • Use pallets, skids etc. to hasten loading/unloading.Use pallets, skids etc. to hasten loading/unloading. • • Use devices like tipplers, bottom discharge containers etc.Use devices like tipplers, bottom discharge containers etc.


MHS

IDLE TIME PRINCIPLEIDLE TIME PRINCIPLE

Reduce idle or unproductive time of both materials handling equipment Reduce idle or unproductive time of both materials handling equipment and manpower.and manpower.

This principle is similar to motion principle, so far as materials handling This principle is similar to motion principle, so far as materials handling equipment are concerned,equipment are concerned,

hence same suggestions are applicable. Additional suggestions for hence same suggestions are applicable. Additional suggestions for ‘‘manpower’’ are:‘‘manpower’’ are:

• • Deliver materials at proper rate so that operators are not idle for Deliver materials at proper rate so that operators are not idle for materials.materials.

• • Use indirect labour for materials handling.Use indirect labour for materials handling. • • Install handling equipment to reduce labour.Install handling equipment to reduce labour. • • Combine jobs i.e. one man handles two or more machines or jobs.Combine jobs i.e. one man handles two or more machines or jobs.


MHS

1 MENG 464 COMPUTER INTEGRATED MANUFACTURING Material Handling System.

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