AUTOMATIC MATERIAL HANDLING PPT

1. AUTOMATED MATERIAL
HANDLING
SUMITTTED BY
MANMEET SINGH
13209015
M.E (MECHANICAL)
FIRST YEAR
SUBMITTED TO
Dr. SANJEEV KUMAR

3. 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)


4. MATERIAL HANDLING 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

5. PRINCIPLES OF MATERIAL HANDLING
1)
Planning Principle
(needs, desirable option ,consultation, performance)
2)
3)
Standardization Principle
Work Principle
without sacrificing productivity)
4)
Ergonomic Principle
(safety, eliminate repetitive jobs )
5)
6)
7)
8)
9)
Unit Load Principle
Space Utilization Principle
System Integration Principle
Automation Principle
Environment Principle
(energy, impact, hazard)
10)
Life Cycle Cost Principle
(minimized

6. 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.

7. CONSIDERATIONS IN MATERIAL HANDLING
SYSTEM DESIGN
Material characteristics
 Flow rate
 Routing
 Scheduling
 Plant layout


8. MATERIAL CHARACTERISTICS
Category
1.
2.
3.
4.
5.
6.
Physical state
Size
Weight
Shape
Condition
Safety risk and risk
of damage
Measures
Solid, liquid, or gas
Volume; length, width, height
Weight /piece, weight/unit volume
Long and flat, round, square, etc.
Hot, cold, wet, etc.
Explosive, flammable, toxic; fragile,
etc.

9. FLOW RATE
Quantity of
material
moved
High
Low
Conveyors
Manual handling
Hand trucks
Short
Conveyors
AGV train
Powered trucks
Unit load AGV
Long
Move Distance

10. PLANT LAYOUT
Layout Type
Characteristics
Typical MH Equipment
Fixed – position
Large product size, low
production rate
Cranes, hoists, industrial
trucks
Process
Variation in product and
processing, low and
medium production rates
Hand trucks, forklift
trucks, AGVs
Limited product variety,
high production rate
Conveyors for product
flow, trucks to deliver
components to stations.
Product

11. 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


13. CATEGORIES OF
MATERIAL HANDLING EQUIPMENT
1.
2.
3.
4.
Material transport equipment - to move
materials inside a factory, warehouse, or other
facility
Storage - to store materials and provide access
to those materials when required
Unitizing equipment - refers to
(1) containers to hold materials, and
(2) equipment used to load and package the
containers
Identification and tracking systems - to identify
and keep track of the materials being moved and
stored

14. UNIT LOAD PRINCIPLE (UNITIZING)
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


15. UNIT LOAD CONTAINERS
(a) Wooden pallet,
(b) pallet box,
(c) tote box

16. MATERIAL TRANSPORT EQUIPMENT
Industrial trucks
 AGVs
 Robots
 Monorails and other rail guided vehicles
 Conveyors
 Cranes and hoists


17. AUTOMATION IN
MATERIAL HANDLING

18. WHY USE AUTOMATION IN MATERIAL
HANDLING
1.
2.
3.
4.
5.
6.
7.
8.
9.
To increase labor productivity
To reduce labor cost
To mitigate the effects of labor shortages
To reduce or remove routine manual and clerical
tasks
To improve worker safety
To improve product quality
To reduce manufacturing lead time
To accomplish what cannot be done manually
To avoid the high cost of not automating

19. AUTOMATED GUIDED
VEHICLES

20. 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.


21. 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.


22. COMPONENTS OF AGV




Vehicle
Guided path
Control unit
Computer interface

23. AGV TYPES
Driver less trains
 Pallet trucks
 Unit load carriers


24. 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.

25. DRIVER LESS TRAIN

26. 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.


28. PALLET TRUCKS

29. UNIT LOAD CARRIER
These are used to move unit loads from one
station to another.
 Light load AGVs, up to 250 kg or less.


30. UNIT LOAD CARRIER

31. VEHICLE GUIDANCE TECHNOLOGY
Imbedded guide wires
 Paint strips (Optical navigation system)
 Magnetic tape navigation systems
 Self guided vehicles (Laser triangulation navigation
system)


32. 1. IMBEDDED GUIDE
•Faster and safer
•More accurate
•Less costly
WIRES •Simpler and less programming
required

33. CHOOSING APPROPRIATE PATH IN WIRE
GUIDED SYSTEM
Frequency select method



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.
Path select method
Same frequency
throughout
 At switch power is
turned off in all other
branches except the
one that the vehicle is
to travel on.


34. Advantages
Drawbacks
Less costly
 More accurate and
safer
 Less programming


Energy consumption
 Embedded system
 Less flexible than other
types

35. 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.

36. Advantage




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
Drawback


Repaint
Cannot be used in dirty
conditions

37. 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


38. 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

39. HOW ARE THE VEHICLES POWERED?
TYPES OF BATTERIES, INDUCTIVE POWER AND FUEL
CELLS
1.




2.
3.

Most common batteries
Flooded lead acid
Sealed batteries
NiCad
Lithium ion
Inductive power – vehicle receives power from plate(s)
embedded in the floor. Used in some applications that
require less flexibility
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.

40. VEHICLE MANAGEMENT
Two aspects of vehicle management:
 Traffic control - to minimize interference between
vehicles and prevent collisions
1.
2.

Forward (on-board vehicle) sensing
Zone control
Vehicle dispatching
1.
2.
3.
On-board control panel
Remote call stations
Central computer control

41. 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.


42. 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.

43. 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





44. 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

45. bumper

46. 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


47. ROBOTS

48. 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


49. INDUSTRIAL ROBOT APPLICATIONS
1.
Material handling applications


2.
Processing operations



3.
Material transfer – pick-and-place, palletizing
Machine loading and/or unloading
Welding
Spray coating
Cutting and grinding
Assembly and inspection

50. 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.


51. 1. PART PLACEMENT
o
o
o
o
The basic operation in this category is the relatively simple
pick-and-place operation.
This application needs a low-technology robot of the
cylindrical coordinate type.
Only two, three, or four joints are required for most of the
applications.
Pneumatically powered robots are often utilized

52. 2. PALLETIZING AND/OR DEPALLETIZING
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.
o

53. 3. MACHINE LOADING AND/OR UNLOADING:
Robot transfers parts into and/or from a production machine.
 There are three possible cases:
1.
2.
3.
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.
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
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

54. 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.

56. RAIL GUIDED VEHICLES

57. 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

58. OVERHEAD MONORAIL

59. CONVEYORS

60. 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

2.
Materials moved by human workers or by gravity
Powered

Power mechanism for transporting materials is
contained in the fixed path, using chains, belts, rollers
or other mechanical devices

61. CONVEYOR TYPES
1.
2.
3.
4.
Roller
Skate - wheel
Belt
In- floor towline

62. 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

63. 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


64. 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


65. 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


66. POWERED CONVEYOR
OPERATIONS AND FEATURES

Types of motions
1.
2.
Continuous - conveyor moves at constant velocity
Asynchronous - conveyor moves with stop-and-go
motion


They stop at stations, move between stations
Another classification of conveyors:
1.
2.
3.
Single direction
Continuous loop
Recirculating

67. (a) Single direction
conveyor
(b) Continuous loop
conveyor

68. CRANES AND HOISTS

69. 5. CRANES AND HOISTS
Handling devices for lifting, lowering and transporting
materials, often as heavy loads
 Cranes


Hoists


Used for horizontal movement of materials
Used for vertical lifting of materials
Cranes usually include hoists so that the craneand-hoist combination provides
Horizontal transport
 Vertical lifting and lowering


70. BRIDGE CRANE

71. GANTRY CRANE------TYPES----
Double gantry
 Half gantry
 Cantilever gantry

Half gantry

72. JIB CRANE

73. ANALYSIS OF
MATERIAL TRANSPORT SYSTEMS
1.
2.
3.
Charting techniques in material handling
Vehicle based system
Conveyor analysis

74. 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


75. CHARTING TECHNIQUES IN MATERIAL HANDLING
(FROM –TO CHART)
TO
FRO
M
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

76. 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)
Guide path
UN
LOAD
AGV
20
Tc = TL +[Ld/v ]+ [Le/v] + Tu
55
40
Tc= 0.75 + [110/50]+[80/50]+ 0.5
Tc= 5.05 min
Tc ideal value because it ignores
 Traffic congestion
 Reliability problems etc
20
LOAD
Direction of
AGV

77. 1. RATE OF DELIVERIES PER VEHICLE

1)
2)
3)

Possible time loss include
Availability ( A) -proportion of total shift time that te vehicle is
operational and not broken down or being repaired)
Traffic congestion ( Tf)- blocking, waiting in queue etc
Many vehicles Tf decreases ,value ranges from 0.85 to 1
Efficiency (E)-of manual drivers if any(worker efficiency)
if not apply is taken as unity (1)
AT = available time (min/hr per vehicle)
AT = 60× A × Tf × E

Rdv = rate of deliveries per vehicle (del/hr per vehicle)
Rdv = AT
Tc
1

78. 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

79. 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


80. END
THANK YOU