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ME
ME 486
486 - Automation
Automation
Ed Red
Objectives
To review modern technologies for material handling:
- Part handling
- AGVs
- AS/RS
- conveyors
To consider application conditions (student presentations)
To introduce assessment criteria
To test understanding of the material presented
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
Principle 5 - UNIT LOAD PRINCIPLE: Unit loads shall be appropriately sized and
configured in a way which achieves the material flow and inventory objectives at each
stage in the supply chain.
A unit load is one that can be stored or moved as a single entity at one time, such as a
pallet, container, or tote, regardless of the number of individual items that make up the
load.
Less effort and work are required to collect and move many individual items as a
single load than to move many items one at a time.
Large unit loads are common in both pre- and post-manufacturing in the form of raw
materials and finished goods.
Smaller unit loads are consistent with manufacturing strategies that embrace operating
objectives such as flexibility, continuous flow and just-in-time delivery. Smaller unit
loads (as few as one item) yield less in-process inventory and shorter item throughput
times.
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
( from Groover )
ME
ME 486
486 - Automation
Automation
AGV classification
Driverless trains - AGV is a towing vehicle used to tow one or more trailers
forming a train between stations.
Pallet trucks - Used to move palletized loads along predetermined routes.
Typically, personnel will steer the AGV to the pallet, acquire the pallet, then
steer it to the guide-path where the automated guidance system will then
move it to its destination. In a sense, it can be thought of as an automated
forklift.
Unit load carriers - Move unit loads from from one station to another
station. A unit load is a collection of items that is delivered repetitively as a
unit.
ME
ME 486
486 - Automation
Automation
AGV applications
Driverless train operations - Movement of large material quantity over large distances
(between buildings, warehouses).
Storage/distribution systems - Uses unit load carriers and pallet trucks to transfer material
between stations, sometimes interfacing with other automated systems such as an AS/RS
(Automated Storage and Retrieval System). Works well in assembly operations where the
unit loads (or kits) can be transferred from a central storage area to assembly sites.
Assembly line operations - AGVs become part of the assembly operation by transferring
material along an assembly line (such as moving an engine block between operational
stations)
Flexible manufacturing systems (FMS) - AGVs are used to transfer parts, materials and
tooling between the FMS process stations.
Miscellaneous applications - Non-manufacturing applications include the handling of
sensitive waste, transportation of material at hospitals, mail transportation.
ME
ME 486
486 - Automation
Automation
ME
ME 486
486 - Automation
Automation
ME
ME 486
486 - Automation
Automation
Tc = TL + TU + Ld / vc + Le / ve
available time
AT = 60 A Tf E
(min/hr/veh)
Rdv = AT / Tc
(num del/hr/veh)
WL = Rf Tc
(min/hr)
nc = WL/AT = Rf / Rdv
ME
ME 486
486 - Automation
Automation
(min)
ME
ME 486
486 - Automation
Automation
AGV questions
Who are major vendors of AGVs?
Describe their components (power source, transmission system,
communication system, etc.)?
What are typical costs?
What type of interfaces do they have? How are they programmed?
How fast do they move?
What are load to weight ratios?
Unusual maintenance requirements?
How do they avoid collisions?
How are they scheduled?
ME
ME 486
486 - Automation
Automation
Definition - An AS/RS is a
combination of equipment and
controls which handles, stores,
and retrieves materials with
precision, accuracy, and speed
under a defined degree of
automation. (Materials Handling Institute)
ME
ME 486
486 - Automation
Automation
AS/RS classification
Unit load AS/RS - Large automated system designed to use S/R machines to
move unit loads on pallets into and out of storage racks.
Mini-load AS/RS - Smaller automated system designed to move smaller
loads into and out of storage bins or drawers.
Man-on-board AS/RS - Uses personnel to pick items from racks or bins,
reducing transaction time.
Automated item retrieval system - Items to be moved are stored in single
file lanes, rather than in bins or drawers.
ME
ME 486
486 - Automation
Automation
AS/RS applications
ME
ME 486
486 - Automation
Automation
AS/RS control
The S/R is a large Cartesian type robot that integrates
modern control technology, I/O, and sensors
(compartment identification) to move between storage
compartments. AS/RS control is integrated with modern
material management software for real-time inventory
control, storage transactions, and material delivery.
ME
ME 486
486 - Automation
Automation
ME
ME 486
486 - Automation
Automation
W = 3 (x + a)
L = ny (y + b)
H = nz (z + c)
a = 6 in
b = 8 in
c = 10 in
C = 2 ny nz
uniform racks,
random storage
utilization
Rc = Rcs + Rcd
Rt = Rcs + 2 Rcd
ME
ME 486
486 - Automation
Automation
ME
ME 486
486 - Automation
Automation
Utilization = 0.9:
ME
ME 486
486 - Automation
Automation
AS/RS questions
1.
2.
3.
4.
5.
6.
7.
8.
9.
ME
ME 486
486 - Automation
Automation
Conveyors
Definition - A conveyor is a
mechanized device to move
materials in relatively large
quantities between specific
locations over a fixed path.
ME
ME 486
486 - Automation
Automation
Conveyors
Roller conveyors - Series of tube rollers perpendicular to motion direction, which can be
powered or use gravity for motion.
Skate-wheel conveyors - Similar to rollers but use skate wheels parallel to motion direction.
Belt conveyors - Drives move flat or belts shaped into a trough.
Belt
Skate
wheel
ME
ME 486
486 - Automation
Automation
Conveyors
Trolley
Chain conveyors - Uses loops of chain
that are typically moved by sprockets as
driven by motors.
Overhead trolley conveyors - Items are
moved in discrete loads by hooks or
baskets suspended from overhead rails.
ME
ME 486
486 - Automation
Automation
Conveyors
Towline
ME
ME 486
486 - Automation
Automation
ME
ME 486
486 - Automation
Automation
Td = Ld /vc
(min)
Rf = RL = vc /sc 1/ TL
(num carriers/min)
unloading constraint
TU TL
(min)
unloading time must be less than loading time or else pile up carriers
ME
ME 486
486 - Automation
Automation
Tc = L /vc
(min)
time in delivery
Td = Ld/vc
(min)
number of carriers
nc = L /sc
num of carriers = loop distance divided by carrier spacing
Np = np nc Ld/ L
parts in system = num of parts per carrier times num carriers with parts
ME
ME 486
486 - Automation
Automation
Rf = np vc /sc
material flow rate = num parts per carrier times carrier flow rate
Equations recirculating:
Speed rule operating conveyor speed must fall within a certain range
from load/unload rates
flow rate of parts on conveyor must exceed the max load or unload part rate to maintain part spacing
vc /sc Min{1/TL,1/TU}
flow rate of carriers on conveyor must exceed the max load or unload carrier rate to maintain part spacing
np vc /sc Rf
ME
ME 486
486 - Automation
Automation
Conveyor questions
1.
2.
3.
4.
5.
6.
7.
8.
ME
ME 486
486 - Automation
Automation
Material handling
ME
ME 486
486 - Automation
Automation