This document provides an introduction to automated material handling systems, specifically automated guided vehicle systems (AGVs) and industrial robots. It discusses the components, types, and guidance systems of AGVs. The routing and control of AGVs is explained. Industrial robots are introduced, including their anatomy, classifications, and applications in industry. Design considerations for AGVS like stopping accuracy, safety features, and flow path design are outlined. Methods for determining the required number of AGVs are also presented with examples.
This presentation discusses about Basics of automated guided vehicles and different types of automated guided vehicles and different types of guidance systems
these vechiles are used in almost every industry .the main thing in this ppt is that u will come to know about many new thing , u will feel it interesting.. u will know how these agv come to know about their path and many more ...
In the material handling industry safety has been a major consideration from the beginning and has only become more and more measured as liability and worker moral are taken into account. Ergonomics have also rewritten how employees are effected by the work they do. In current practice, the operators that works in a production line (especially in automotive plant) will have to give out their energy to manually push the trolley with an estimated weight that is nearly to 500kg. The trolley with the body frame needed to be deliver from one defined location to the next. It is believe that the current method applied is one of the effective way to bring the trolley to the next station. However, the push and pull forces that is applied to the skid or trolley with a heavy load may cause an ergonomics effects to the operators such as the Low – back Disorder (LBD). Manual material handling work has been reported contributing to a large percentage of MSDs annually. LBD is generally caused by cumulative effects of faulty body mechanics, poor posture, awkward movements and improper lifting techniques. The main objectives of this project is to fabricate an AGV by using appropriate material and process that is able to tow a trolley or skid with a load with an estimated weight of 500kg and accomplish a safe handling operations by replacing the operators with AGV. In this project, the AGV is fabricated accordingly through appropriate process such as welding, assembly and etc. This AGV responses and navigation is controlled by the microcontroller which is a device that act as the main brain. It has the ability to follow the black line as it guide path by using the IR line sensor and avoid the obstacles by using the ultrasonic sensor. The project implicates of fabrication of the hardware. AGV is, therefore, suitable for automating material handling in batch production and mixed model production,
This document provides an overview of automated guided vehicles (AGVs) in three paragraphs or less:
AGVs are self-propelled vehicles that are guided along defined pathways and used for material handling in industries. The document discusses the different types of AGVs, components of an AGV system including vehicles, guide paths, and controls, as well as methods of guidance and communication. Applications of AGVs are also covered, such as use in driverless train operations and storage/distribution systems to efficiently move material and products.
Abstract of Project:
In the material handling industry safety has been a major consideration from the beginning and has only become more and more measured as liability and worker moral are taken into account. Ergonomics have also rewritten how employees are effected by the work they do. In current practice, the operators that works in a production line (especially in automotive plant) will have to give out their energy to manually push the trolley with an estimated weight that is nearly to 500kg. The trolley with the body frame needed to be deliver from one defined location to the next. It is believe that the current method applied is one of the effective way to bring the trolley to the next station. However, the push and pull forces that is applied to the skid or trolley with a heavy load may cause an ergonomics effects to the operators such as the Low – back Disorder (LBD). Manual material handling work has been reported contributing to a large percentage of MSDs annually. LBD is generally caused by cumulative effects of faulty body mechanics, poor posture, awkward movements and improper lifting techniques. The main objectives of this project is to fabricate an AGV by using appropriate material and process that is able to tow a trolley or skid with a load with an estimated weight of 500kg and accomplish a safe handling operations by replacing the operators with AGV. In this project, the AGV is fabricated accordingly through appropriate process such as welding, assembly and etc. This AGV responses and navigation is controlled by the microcontroller which is a device that act as the main brain. It has the ability to follow the black line as it guide path by using the IR line sensor and avoid the obstacles by using the ultrasonic sensor. The project implicates of fabrication of the hardware. AGV is, therefore, suitable for automating material handling in batch production and mixed model production.
The document discusses automated storage/retrieval systems (AS/RS). It defines AS/RS as systems that transport, store, retrieve, and track inventory items with accuracy. The document outlines the key components of AS/RS including storage racks, aisles, storage/retrieval machines, and pickup/deposit stations. It describes different types of AS/RS like unit load and mini load systems. The document also covers various AS/RS layouts such as vertical lift modules, fixed aisles, and carousels. It provides details on designing an AS/RS system including determining load sizes and calculating storage space dimensions.
The document summarizes a technical seminar presentation on automated guided vehicles (AGVs). It discusses the history of AGVs, defines them as self-propelled vehicles that operate along defined pathways, and outlines the main types. The presentation covers the benefits of AGVs including flexible labor costs and delivery speed. It also describes different navigation techniques used by AGVs and gives examples of their applications and advantages/disadvantages. The conclusion is that AGVs can increase productivity in large factories while decreasing costs and transportation time.
This presentation discusses about Basics of automated guided vehicles and different types of automated guided vehicles and different types of guidance systems
these vechiles are used in almost every industry .the main thing in this ppt is that u will come to know about many new thing , u will feel it interesting.. u will know how these agv come to know about their path and many more ...
In the material handling industry safety has been a major consideration from the beginning and has only become more and more measured as liability and worker moral are taken into account. Ergonomics have also rewritten how employees are effected by the work they do. In current practice, the operators that works in a production line (especially in automotive plant) will have to give out their energy to manually push the trolley with an estimated weight that is nearly to 500kg. The trolley with the body frame needed to be deliver from one defined location to the next. It is believe that the current method applied is one of the effective way to bring the trolley to the next station. However, the push and pull forces that is applied to the skid or trolley with a heavy load may cause an ergonomics effects to the operators such as the Low – back Disorder (LBD). Manual material handling work has been reported contributing to a large percentage of MSDs annually. LBD is generally caused by cumulative effects of faulty body mechanics, poor posture, awkward movements and improper lifting techniques. The main objectives of this project is to fabricate an AGV by using appropriate material and process that is able to tow a trolley or skid with a load with an estimated weight of 500kg and accomplish a safe handling operations by replacing the operators with AGV. In this project, the AGV is fabricated accordingly through appropriate process such as welding, assembly and etc. This AGV responses and navigation is controlled by the microcontroller which is a device that act as the main brain. It has the ability to follow the black line as it guide path by using the IR line sensor and avoid the obstacles by using the ultrasonic sensor. The project implicates of fabrication of the hardware. AGV is, therefore, suitable for automating material handling in batch production and mixed model production,
This document provides an overview of automated guided vehicles (AGVs) in three paragraphs or less:
AGVs are self-propelled vehicles that are guided along defined pathways and used for material handling in industries. The document discusses the different types of AGVs, components of an AGV system including vehicles, guide paths, and controls, as well as methods of guidance and communication. Applications of AGVs are also covered, such as use in driverless train operations and storage/distribution systems to efficiently move material and products.
Abstract of Project:
In the material handling industry safety has been a major consideration from the beginning and has only become more and more measured as liability and worker moral are taken into account. Ergonomics have also rewritten how employees are effected by the work they do. In current practice, the operators that works in a production line (especially in automotive plant) will have to give out their energy to manually push the trolley with an estimated weight that is nearly to 500kg. The trolley with the body frame needed to be deliver from one defined location to the next. It is believe that the current method applied is one of the effective way to bring the trolley to the next station. However, the push and pull forces that is applied to the skid or trolley with a heavy load may cause an ergonomics effects to the operators such as the Low – back Disorder (LBD). Manual material handling work has been reported contributing to a large percentage of MSDs annually. LBD is generally caused by cumulative effects of faulty body mechanics, poor posture, awkward movements and improper lifting techniques. The main objectives of this project is to fabricate an AGV by using appropriate material and process that is able to tow a trolley or skid with a load with an estimated weight of 500kg and accomplish a safe handling operations by replacing the operators with AGV. In this project, the AGV is fabricated accordingly through appropriate process such as welding, assembly and etc. This AGV responses and navigation is controlled by the microcontroller which is a device that act as the main brain. It has the ability to follow the black line as it guide path by using the IR line sensor and avoid the obstacles by using the ultrasonic sensor. The project implicates of fabrication of the hardware. AGV is, therefore, suitable for automating material handling in batch production and mixed model production.
The document discusses automated storage/retrieval systems (AS/RS). It defines AS/RS as systems that transport, store, retrieve, and track inventory items with accuracy. The document outlines the key components of AS/RS including storage racks, aisles, storage/retrieval machines, and pickup/deposit stations. It describes different types of AS/RS like unit load and mini load systems. The document also covers various AS/RS layouts such as vertical lift modules, fixed aisles, and carousels. It provides details on designing an AS/RS system including determining load sizes and calculating storage space dimensions.
The document summarizes a technical seminar presentation on automated guided vehicles (AGVs). It discusses the history of AGVs, defines them as self-propelled vehicles that operate along defined pathways, and outlines the main types. The presentation covers the benefits of AGVs including flexible labor costs and delivery speed. It also describes different navigation techniques used by AGVs and gives examples of their applications and advantages/disadvantages. The conclusion is that AGVs can increase productivity in large factories while decreasing costs and transportation time.
Automated guided vehicles (AGVs) are computer-controlled, non-manned vehicles used to transport materials around manufacturing facilities and warehouses. AGVs use guidance systems like wire embedding, lasers, or inertial navigation to follow predetermined routes. AGVs are useful for repetitive, long-distance material handling and can improve efficiency by reducing costs compared to other transport methods. Proper traffic management and load transfer systems ensure safe coordination of multiple AGVs within facility operations.
Basics of AGVs (Automated guided vehicles)smit1994
it's a basic explanation & types of AGVs , some basics of how does it works? , In which industries its being used?, & some expected future of AGVs. Thank you.
The document discusses various topics related to automated material handling systems. It begins by defining material handling and explaining that it involves the movement, storage, protection and control of materials throughout manufacturing and distribution processes. It then notes that material handling accounts for a significant portion of manufacturing costs. The document proceeds to discuss principles of material handling system design, objectives of material handling, considerations in system design such as material characteristics, and categories of material handling equipment including transport equipment, storage, unitizing equipment, and identification systems. It also covers specific equipment types like automated guided vehicles, rail-guided vehicles, robots, and conveyors.
Automated storage and retrieval systemsRAJA GAUTAM
This document provides an overview of automated storage and retrieval systems (AS/RS). It defines AS/RS as computer-controlled systems that automatically store and retrieve loads without human intervention. The document then discusses where AS/RS are used, their main components, types of AS/RS, considerations for designing an AS/RS, their applications, benefits, and limitations. It provides details on unit load, mini load, man-on-board, automated item retrieval, and vertical lift storage module systems. The document also outlines factors to consider when determining system throughput and layout.
The document provides an introduction to robotics, including definitions of key terms:
- A robot is an automatically controlled, reprogrammable device designed to perform tasks normally done by humans.
- Robots are classified based on their drive technology, work envelope/coordinate geometry, and motion control methods.
- Robotic systems have components like manipulators, end effectors, actuators, sensors, controllers, and software to allow various applications in manufacturing and other industries.
Stair climbing trolley is an extension of general trolleys. These are used to transport loads on stairs and uneven surfaces like holes, speed breakers etc. It is operated by a single operator and with less effort.
Material handling (MH) makes use of the robot's simple capability to transport objects. By fitting the robot with an appropriate end of arm tool (e.g. gripper), the robot can efficiently and accurately move product from one location to another.
Robot is a Machine designed to execute one or more tasks automatically by means of variable programmed motions with high speed and precision.
Fabrication of Automatic Guided Vehicle Ajith Aravind
Automatic Guided vehicle (AGV) is a part of flexible manufacturing system. Now a days large manufacturing industries use the transportation systems foe various transportation purposes. various types of AGVs are available. Manufacturing and installation of this system is a tough task. The vehicle is designed according to the need and type of transportation, material to be transformed etc.
The document discusses automated guided vehicles (AGVs) and automated storage and retrieval systems (AS/RS). It defines an AGV as a material handling system that uses self-propelled vehicles guided along defined pathways. It describes different types of AGVs including driverless trains, pallet trucks, and unit load carriers. It also explains various AGV navigation systems and functions. The document then defines an AS/RS as an automated storage system that stores and retrieves loads under computer control. It outlines the objectives and components of an AS/RS system and describes applications in warehousing, distribution and manufacturing.
Now a days manufacturing industries transportation taking major role it takes more time to transfer materials to one place to another plass when we use agvs we can increase production rate in large industries with decrease in pressure in decreasing in time.
An automated storage and retrieval system (ASRS) operates by automatically placing and retrieving loads from defined storage locations using computer-controlled systems. There are several types of ASRS including unit load, mini load, deep-lane, and man-on-board systems. ASRS provides benefits like reducing costs, improving organization and efficiency, and integrating with order processing. However, their confined reach also presents limitations. In conclusion, properly designed ASRS can produce benefits in manufacturing and distribution centers.
Automated Guided Vehicle with Robotic Logistics System,
Automated guided vehicle (AGV) is one type of versatile-mobile vehicle designed primarily to move the material from one place to another place.
The document provides an overview of automated guided vehicle systems (AGVS). It discusses the key components of an AGVS including the vehicle, guide path, control unit and computer interface. It describes different types of AGVS vehicles including driverless trains, pallet trucks and unit load carriers. The document also covers the history of AGVS, vehicle functions, guidance systems, safety features, control systems, communications and important considerations for AGVS design.
AGVs are battery-powered vehicles that transport materials automatically along predetermined pathways within facilities. They can rationalize manufacturing processes by conveying items between processes and supplying production lines. AGVs reduce labor costs, are flexible, intelligent, and less time consuming. They can significantly reduce production and warehouse costs while transforming materials handling. AGVs come in different types for various applications like transporting raw materials, work-in-process movement, pallet handling, and finished good transportation.
Introduction
Types of Material Handling Equipment
Material Transport Equipment
Storage Systems
Unitizing Equipment
Identification and Tracking Systems
Principles of Material Handling
Automated Guided Vehicles (AGVs)
Components of AGVS
Types of AGVs
Driverless Trains
Automated Guided Pallet Trucks
AGV Unit Load Carriers
Vehicle Guidance
Imbedded Guide Wires
Paint Strips
Self-guided Vehicles
Vehicle Routing
Frequency Select Method
Path Switch Select Method
Traffic Control
On-board Vehicle Sensing
Zone Control
Benefits of AGV
Applications of AGV
The document summarizes automated guided vehicles (AGVs) and their uses in industries. It discusses the history of AGVs from the 1950s to modern laser-guided vehicles. It describes common types of AGVs like driverless trains, pallet trucks, and unit load carriers. The document also outlines types of AGV navigation including wired, guide tape, and laser target methods. Finally, it lists some common AGV applications such as raw material handling, work-in-process movement, pallet handling, and finished good transportation.
“ASRS - Automated Storage/Retrieval System is defined as a storage system that performs storage and retrieval operations with speed and accuracy under a defined degree of automation.”
AGVs are mobile robots that use markers, wires, vision, magnets or lasers to navigate around facilities like manufacturing plants and warehouses. They can tow objects or store them to move materials autonomously. AGVs are used across many industries to transport items between areas. Some key advantages of AGVs include reduced labor costs, flexibility, reliability and lower long-term investment compared to other transport methods. They are well-suited for repetitive pallet handling and gentle finished goods movement applications.
The document is a presentation on automated material handling. It discusses material handling and different types of material handling equipment such as conveyors and automated guided vehicles (AGVs). It describes AGVs in detail, including their components, guidance technologies, and types. It provides an example of calculating the number of AGVs needed based on delivery rate, cycle time, and vehicle availability. The presentation also discusses using simulation to model AGV systems and limitations of automated material handling systems.
Project Report for Automated Guided VehicleSOORAJ V R
The document describes the design and fabrication of an automated guided vehicle (AGV). Key points:
1) The AGV uses a microcontroller and wireless transmitter-receiver to receive commands from a central computer and navigate autonomously through a factory or warehouse along predetermined paths.
2) The mechanical design includes an aluminum chassis that can carry a 10kg payload. A differential steering system allows the AGV to turn within its width.
3) Electrical components include motors, a motor driver, microcontroller, and wireless electronics to control the motion and receive commands. Sensors provide feedback to navigate paths safely.
4) Programming algorithms allow the AGV to navigate paths as instructed through combinations of forward, backward
AGVs were first introduced in the 1950s as tow trucks that followed wires in the floor instead of rails, and have since evolved to play an important role in modern factory and warehouse design. AGVs are self-propelled material handling vehicles that are guided along defined pathways, using independently operated systems. They feature high dynamic operation, innovative steering methods, robust designs, and individual speed and position control for wheels and axles. Common types include driverless trains, pallet trucks, and unit load carriers, which can navigate using wired, tape-guided, or laser-based systems and are used for applications like pallet and finished goods handling.
Automated Guided Vehicles Flexible, Yet Automated Material HandlingARC Advisory Group
Automated Guided Vehicles Flexible, Yet Automated Material Handling
Automated Guided Vehicles (AGVs) have long been the most flexible of
automated material handling systems. Now Siemens
Dematic has introduced a user friendly system
design program that eliminates the need for any
service support when the AGV system’s operation
needs to be changed. An already flexible solution
has become even more so.
Automated material handling systems
reduce labor costs, but most lack
flexibility. Now the most flexible of
automated material handling systems,
the AGV, has just become even easier to
redeploy to meet changing needs.
Automated guided vehicles (AGVs) are computer-controlled, non-manned vehicles used to transport materials around manufacturing facilities and warehouses. AGVs use guidance systems like wire embedding, lasers, or inertial navigation to follow predetermined routes. AGVs are useful for repetitive, long-distance material handling and can improve efficiency by reducing costs compared to other transport methods. Proper traffic management and load transfer systems ensure safe coordination of multiple AGVs within facility operations.
Basics of AGVs (Automated guided vehicles)smit1994
it's a basic explanation & types of AGVs , some basics of how does it works? , In which industries its being used?, & some expected future of AGVs. Thank you.
The document discusses various topics related to automated material handling systems. It begins by defining material handling and explaining that it involves the movement, storage, protection and control of materials throughout manufacturing and distribution processes. It then notes that material handling accounts for a significant portion of manufacturing costs. The document proceeds to discuss principles of material handling system design, objectives of material handling, considerations in system design such as material characteristics, and categories of material handling equipment including transport equipment, storage, unitizing equipment, and identification systems. It also covers specific equipment types like automated guided vehicles, rail-guided vehicles, robots, and conveyors.
Automated storage and retrieval systemsRAJA GAUTAM
This document provides an overview of automated storage and retrieval systems (AS/RS). It defines AS/RS as computer-controlled systems that automatically store and retrieve loads without human intervention. The document then discusses where AS/RS are used, their main components, types of AS/RS, considerations for designing an AS/RS, their applications, benefits, and limitations. It provides details on unit load, mini load, man-on-board, automated item retrieval, and vertical lift storage module systems. The document also outlines factors to consider when determining system throughput and layout.
The document provides an introduction to robotics, including definitions of key terms:
- A robot is an automatically controlled, reprogrammable device designed to perform tasks normally done by humans.
- Robots are classified based on their drive technology, work envelope/coordinate geometry, and motion control methods.
- Robotic systems have components like manipulators, end effectors, actuators, sensors, controllers, and software to allow various applications in manufacturing and other industries.
Stair climbing trolley is an extension of general trolleys. These are used to transport loads on stairs and uneven surfaces like holes, speed breakers etc. It is operated by a single operator and with less effort.
Material handling (MH) makes use of the robot's simple capability to transport objects. By fitting the robot with an appropriate end of arm tool (e.g. gripper), the robot can efficiently and accurately move product from one location to another.
Robot is a Machine designed to execute one or more tasks automatically by means of variable programmed motions with high speed and precision.
Fabrication of Automatic Guided Vehicle Ajith Aravind
Automatic Guided vehicle (AGV) is a part of flexible manufacturing system. Now a days large manufacturing industries use the transportation systems foe various transportation purposes. various types of AGVs are available. Manufacturing and installation of this system is a tough task. The vehicle is designed according to the need and type of transportation, material to be transformed etc.
The document discusses automated guided vehicles (AGVs) and automated storage and retrieval systems (AS/RS). It defines an AGV as a material handling system that uses self-propelled vehicles guided along defined pathways. It describes different types of AGVs including driverless trains, pallet trucks, and unit load carriers. It also explains various AGV navigation systems and functions. The document then defines an AS/RS as an automated storage system that stores and retrieves loads under computer control. It outlines the objectives and components of an AS/RS system and describes applications in warehousing, distribution and manufacturing.
Now a days manufacturing industries transportation taking major role it takes more time to transfer materials to one place to another plass when we use agvs we can increase production rate in large industries with decrease in pressure in decreasing in time.
An automated storage and retrieval system (ASRS) operates by automatically placing and retrieving loads from defined storage locations using computer-controlled systems. There are several types of ASRS including unit load, mini load, deep-lane, and man-on-board systems. ASRS provides benefits like reducing costs, improving organization and efficiency, and integrating with order processing. However, their confined reach also presents limitations. In conclusion, properly designed ASRS can produce benefits in manufacturing and distribution centers.
Automated Guided Vehicle with Robotic Logistics System,
Automated guided vehicle (AGV) is one type of versatile-mobile vehicle designed primarily to move the material from one place to another place.
The document provides an overview of automated guided vehicle systems (AGVS). It discusses the key components of an AGVS including the vehicle, guide path, control unit and computer interface. It describes different types of AGVS vehicles including driverless trains, pallet trucks and unit load carriers. The document also covers the history of AGVS, vehicle functions, guidance systems, safety features, control systems, communications and important considerations for AGVS design.
AGVs are battery-powered vehicles that transport materials automatically along predetermined pathways within facilities. They can rationalize manufacturing processes by conveying items between processes and supplying production lines. AGVs reduce labor costs, are flexible, intelligent, and less time consuming. They can significantly reduce production and warehouse costs while transforming materials handling. AGVs come in different types for various applications like transporting raw materials, work-in-process movement, pallet handling, and finished good transportation.
Introduction
Types of Material Handling Equipment
Material Transport Equipment
Storage Systems
Unitizing Equipment
Identification and Tracking Systems
Principles of Material Handling
Automated Guided Vehicles (AGVs)
Components of AGVS
Types of AGVs
Driverless Trains
Automated Guided Pallet Trucks
AGV Unit Load Carriers
Vehicle Guidance
Imbedded Guide Wires
Paint Strips
Self-guided Vehicles
Vehicle Routing
Frequency Select Method
Path Switch Select Method
Traffic Control
On-board Vehicle Sensing
Zone Control
Benefits of AGV
Applications of AGV
The document summarizes automated guided vehicles (AGVs) and their uses in industries. It discusses the history of AGVs from the 1950s to modern laser-guided vehicles. It describes common types of AGVs like driverless trains, pallet trucks, and unit load carriers. The document also outlines types of AGV navigation including wired, guide tape, and laser target methods. Finally, it lists some common AGV applications such as raw material handling, work-in-process movement, pallet handling, and finished good transportation.
“ASRS - Automated Storage/Retrieval System is defined as a storage system that performs storage and retrieval operations with speed and accuracy under a defined degree of automation.”
AGVs are mobile robots that use markers, wires, vision, magnets or lasers to navigate around facilities like manufacturing plants and warehouses. They can tow objects or store them to move materials autonomously. AGVs are used across many industries to transport items between areas. Some key advantages of AGVs include reduced labor costs, flexibility, reliability and lower long-term investment compared to other transport methods. They are well-suited for repetitive pallet handling and gentle finished goods movement applications.
The document is a presentation on automated material handling. It discusses material handling and different types of material handling equipment such as conveyors and automated guided vehicles (AGVs). It describes AGVs in detail, including their components, guidance technologies, and types. It provides an example of calculating the number of AGVs needed based on delivery rate, cycle time, and vehicle availability. The presentation also discusses using simulation to model AGV systems and limitations of automated material handling systems.
Project Report for Automated Guided VehicleSOORAJ V R
The document describes the design and fabrication of an automated guided vehicle (AGV). Key points:
1) The AGV uses a microcontroller and wireless transmitter-receiver to receive commands from a central computer and navigate autonomously through a factory or warehouse along predetermined paths.
2) The mechanical design includes an aluminum chassis that can carry a 10kg payload. A differential steering system allows the AGV to turn within its width.
3) Electrical components include motors, a motor driver, microcontroller, and wireless electronics to control the motion and receive commands. Sensors provide feedback to navigate paths safely.
4) Programming algorithms allow the AGV to navigate paths as instructed through combinations of forward, backward
AGVs were first introduced in the 1950s as tow trucks that followed wires in the floor instead of rails, and have since evolved to play an important role in modern factory and warehouse design. AGVs are self-propelled material handling vehicles that are guided along defined pathways, using independently operated systems. They feature high dynamic operation, innovative steering methods, robust designs, and individual speed and position control for wheels and axles. Common types include driverless trains, pallet trucks, and unit load carriers, which can navigate using wired, tape-guided, or laser-based systems and are used for applications like pallet and finished goods handling.
Automated Guided Vehicles Flexible, Yet Automated Material HandlingARC Advisory Group
Automated Guided Vehicles Flexible, Yet Automated Material Handling
Automated Guided Vehicles (AGVs) have long been the most flexible of
automated material handling systems. Now Siemens
Dematic has introduced a user friendly system
design program that eliminates the need for any
service support when the AGV system’s operation
needs to be changed. An already flexible solution
has become even more so.
Automated material handling systems
reduce labor costs, but most lack
flexibility. Now the most flexible of
automated material handling systems,
the AGV, has just become even easier to
redeploy to meet changing needs.
This document describes a mini project to construct a simple line following robot. The robot uses infrared sensors to detect a black line on a white surface and follows the line path. It is designed to be simple to build using a breadboard and components like a microcontroller, motors, batteries, and infrared sensors. The objectives are for the robot to strictly follow the line, including when it turns. Potential applications mentioned include use in automated guided vehicles for industrial transport.
This document discusses the current state of forklift automation technology and considerations for organizations looking to implement it. While automation has been successful in manufacturing environments with predictable tasks, the less structured warehouse environment presents challenges. Current forklift automation solutions involve retrofitting manual forklifts with sensors, which can reduce reliability. The document outlines evaluation criteria for automation systems, including reliability, flexibility, scalability, and safety. It recommends carefully evaluating the application and ensuring organizational support for any automation project. The technology is still maturing, so a long-term strategy is important to guide deployment and protect investments.
The presentation from the FlexQube webinar about forkfree production from September 15, 2016. The presentation includes details about different types of tugger train system such as tongue and hitch or mother-daughter cart systems. What are the benefits by going forklift free in production areas and how to achieve it.
DHL Supply Chain has deployed an automated guided vehicle (AGV) in one of its warehouses in Japan, becoming the first time the company has used an AGV in the country. The AGV, made by Toyota Industries Corporation, is expected to improve efficiency and save an estimated 785 working hours during peak seasons by transporting goods between picking, packing and shipping areas at speeds up to 50 meters per minute. DHL Supply Chain plans to introduce more AGVs and explore other technologies like wearable devices to further boost operational efficiency and address labor shortages.
This document provides information on automated guided vehicles (AGVs), automated storage and retrieval systems (AS/RS), and tool management. It discusses the main parts of AGVs and lists six types of AGVs, describing unmanned AGV trains, AGV pallet trucks, AGV fork lift trucks, AGV unit load vehicles, AGV light load vehicles, and AGV assembly line vehicles. It also discusses the components, types, and analysis of AS/RS, including unit load, mini load, deep-lane, man-on-board, and automated item retrieval systems. The document is intended to provide information on these material handling topics for a class on computer aided manufacturing.
Integrate with AGVs - Webinar Presentation by FlexQubeAnders Fogelberg
- What is an AGV?
- History of the AGV
- AGV tasks in material handling
- Why use AGVs?
- Different types of AGVs
- AGV guidance methods
- Designing carts for AGV
Agile manufacturing is an operational strategy focused on inducing velocity and flexibility in make-to-order or configure-to-order production with minimal changeover time and interruptions. It differs from lean manufacturing in that lean is for high-volume/low-mix production while agile is for low-volume/high-mix. Agile manufacturing applies to environments where customized orders provide a competitive advantage. The main characteristics of agile manufacturing are short time-to-market, modular design/assembly, and configurable components. A major challenge is the high capital required for production/assembly flexibility, but payback periods are often less than two years.
Introduction
Elements of Flexible Manufacturing System
Objective of Flexible Manufacturing System
Classification of Flexible Manufacturing System
Flexible Manufacturing System layout
Advantages & Limitation of Flexible Manufacturing System
Application of Flexible Manufacturing System
Manufacturing Flexibility
This project uses soil moisture sensor and if the soil is dry, a mechanism to water the soil is set into motion. The whole circuit is controlled by the micro-controller based Arduino Uno Development Board.
The document discusses material handling, which involves moving materials efficiently through the production process. It defines material handling and lists its goals as reducing costs, maintaining quality, and promoting safety, productivity and facility usage. The document outlines principles for effective material handling system design, such as considering material characteristics, plant layout, simplification, use of gravity, standardization, and maintenance. It also discusses various material handling equipment options.
This document summarizes a student project to design and build an automated guided vehicle (AGV) for transporting materials in a factory. The AGV uses a microcontroller and wireless communication to receive transport instructions from a central computer and follow marked paths. Sensors allow it to detect and avoid obstacles. The design incorporates mechanical, electrical, and electronic systems, including a motor, motor driver, receiver, and proximity sensor. The students developed the design, wrote control software in Python, and tested the AGV's ability to navigate paths and transport loads automatically.
Elson Paul V's thesis discusses direct numerical control (DNC) systems. A DNC system connects multiple machine tools to a central computer in real-time. The computer stores NC part programs and transmits them to machines on demand over telecommunication lines. This allows programs to be edited centrally and eliminates tape readers. DNC systems provide advantages like convenient program storage, reporting, and editing compared to conventional NC systems.
The document discusses agile manufacturing, which aims to rapidly respond to changing customer demand through organizational flexibility. It defines agile manufacturing and why it is needed given globalization and customization trends. The key is determining customer needs quickly and responding rapidly through design, production, and volume/mix changes. Transitioning requires new conceptual frameworks and overcoming dependencies on economies of scale. Real-world examples show how companies like automakers implemented agile practices like distributed mini-plants and customizable production.
The document describes the design of a belt conveyor system. It discusses key considerations for the design such as ensuring continuous material flow, standardization, and minimizing the ratio of non-payload weight to payload weight. It also outlines important design parameters that must be determined like belt dimensions and speed, roller diameter, belt power and tension, idler spacing, pulley diameter, motor selection, shaft design, and control systems. The design aims to provide efficient transportation of materials while allowing for flexibility and automation with low costs.
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The line follower uses infrared sensors to detect a black line on a white surface and follow the path by adjusting its movement left, right or forward based on the sensor readings. It is programmed with an AVR microcontroller and uses an L298 motor driver to control the DC motors. Potential applications include automated cars using embedded magnets for guidance and industrial robots navigating factory floors.
This document provides an overview of automated material handling systems, including automated guided vehicle systems (AGVS) and industrial robots. It describes the key components of AGVS, including different types of vehicles, guidance systems, and routing. Industrial robots are also introduced, covering their anatomy, classifications, control systems, and applications in industry. The objectives are to understand the importance of AGVS in manufacturing and the role of robots, as well as alternatives for automated material handling.
Automatic guided vehicles (AGVs) play an
important role in the small-scale industry as well as the largescale industry in handling materials inside factories from one
place to another. In the last days, the materials to be handled are
more numerous and as production and demand increase, it
strongly influences the transport of materials in desperate need
of a vehicle to distribute, position the materials within the
industry. AGVs are generally installed with wires at ground
level and signals are transmitted through them to be controlled.
Due to the emergence of the AGV, the workload of the human
being gradually decreased and the production efficiency
increased. Thus, the need for an AGV has become more
technologically important in the advanced robotic world.
Normally, these systems are integrated into a global production
system, where is a need to make direct changes in the design and
planning of the floor store to get most of them. But in the rapidly
changing production system and the adaptable floor store, the
implementation of AGV has become very important and
difficult, because it depends on many systems, such as wires,
frequency, total production, etc. Therefore, it is necessary to
develop an independent AGV, which can operate on its own and
make decisions based on changes in the environment.
Microsoft word chapter10 f-automated material handling and storage systemsPadmalathaTSRV1
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The document discusses automated guided vehicles (AGVs) which are used for material handling in manufacturing facilities. AGVs can move materials autonomously along predetermined routes with minimal human intervention. They have on-board batteries and controls to navigate pathways using embedded wires, painted lines, or lasers and sensors. AGVs improve productivity and safety by automating material transportation between different locations in a facility without requiring manual labor.
Today’s pressures on warehouse managers are endless and unrelenting – to increase productivity,
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- Fleet management software coordinates the vehicles and optimizes transport routes. The vehicles can have their routes adapted easily if production changes.
- The system allows for flexibility compared to rigid conveyor systems and easy retroactive integration into existing facilities without needing structural changes.
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Agv
1. 39
Automated Material
HandlingUNIT 3 AUTOMATED MATERIAL HANDLING
Structure
3.1 Introduction
Objectives
3.2 Introduction to AGVS
3.2.1 Automated Guided Vehicles
3.2.2 The Components of AGVS
3.2.3 Different Types of AGVS
3.2.4 Guidance Systems for AGVS
3.2.5 Routing of the AGVS
3.2.6 AGVS Control Systems
3.2.7 Interface with other Sub-systems
3.2.8 AGVS Design Features
3.2.9 System Design for AGVS
3.2.10 Flow Path Design
3.3 Introduction to Industrial Robots
3.3.1 Robot Anatomy
3.3.2 Robot Classification
3.3.3 Classification based on Control Systems
3.3.4 Robotic Applications in the Industry
3.3.5 Double-Gripper Robot in a Single-Machine Cell
3.4 Summary
3.5 Key Words
3.1 INTRODUCTION
Automated material handling (AMH) systems improve efficiency of transportation,
storage and retrieval of materials. Examples are computerized conveyors, and automated
storage and retrieval systems (AS/RS) in which computers direct automatic loaders to
pick and place items. Automated guided vehicle (AGV) systems use embedded floor
wires to direct driverless vehicles to various locations in the plant. Benefits of AMH
systems include quicker material movement, lower inventories and storage space,
reduced product damage and higher labour productivity.
Objectives
After studying this unit, you should be able to understand the
importance of AGV in a computer-integrated manufacturing system,
role of industrial robots in a computer-integrated manufacturing systems, and
alternative for automated material handling system.
3.2 INTRODUCTION TO AGVS
A material-handling system can be simply defined as an integrated system involving such
activities as handling, and controlling of materials. Materials include all kinds of raw
material, work-in-progress, sub-assemblies, and finished assemblies. The main motto of
an effective material-handling system is to ensure that the material in the right amount is
safely delivered to the desired destination at the right time and at minimum cost. It is an
2. 40
Fundamentals of CIM integral part of any manufacturing activity. Role of AGVs and Robots have become
strategic with respect to the modern material handling practices followed in the present
day industry. The next section deals with the automated guided vehicles (AGVs). In
Section 3.2, we have introduced the modern industrial robots and the attributes related
with them, which are essential for their understanding.
3.2.1 Automated Guided Vehicles
Automated guided vehicle systems (AGVs), commonly known as driverless vehicles, are
turning out to be an important part of the automated manufacturing system. With the shift
from mass production to mid-volume and mid-variety, flexible manufacturing systems,
are increasingly in use. They require not only machine flexibility but also material-
handling, storage, and retrieval flexibility. Hence, the importance of AGVs has grown in
manifold. It is a battery-powered driverless vehicle with programming capabilities for
destination, path selection, and positioning. The AGVs belongs to a class of highly
flexible, intelligent, and versatile material-handling systems used to transport materials
from various loading locations to various unloading locations throughout the facility. The
capability related to collision avoidance is nicely inbuilt in AGVS. Therefore, the vehicle
comes to a dead stop before any damage is done to the personnel, materials, or structures.
They are becoming an integral part of flexible manufacturing system installations.
Now-a-days, AGVS are versatile in nature and possess flexible material-handling system.
They use modern microprocessor technology to guide a vehicle along a prescribed path
and makes correction if the vehicle strays from the path. A system controller receives
instructions directly from the host computer, communicates with other vehicles, and
issues appropriate commands to each vehicle. To avoid collision, communication is
necessary among the AGVs. To facilitate the communication, they are connected through
a wire in the floor or by radio.
3.2.2 Components of AGVS
There are four main components of an automated guided vehicle system. They are as
follows :
The Vehicle : It is used to move the material within the system without a
human operator.
The Guide Path : It guides the vehicle to move along the path.
The Control Unit: It monitors and directs system operations including
feedback on moves, inventory, and vehicles.
The Computer Interface : It is connected with other computers and systems
such as mainframe host computer, the Automated Storage and Retrieval
System (AS/RS), and the Flexible Manufacturing System.
3.2.3 Different Types of AGVS
There are different types of automated guided vehicles that are able to cater different
service requirements. The vehicle types include :
AGVS towing vehicles
AGVS unit load transporters
AGVS pallet trucks
AGVS forklift trucks
AGVS light-load transporters
AGVS assembly line vehicles
The level of sophistication of the AGVS has increased to allow automatic positioning and
pickup and drop-off (P/D) of cargo, and they also perform P/D services between
machining work centers, storage racks, and the AS/RS. They are also capable of two-way
3. 41
Automated Material
Handling
travel on the same path and real-time dispatching under the control of the computer. The
different types of AGVS are discussed in the section to follow.
AGVS Towing Vehicle
AGVS towing vehicles were the earliest variety to be introduced. A towing
vehicle is an automated guided tractor. A wide variety of tractors can be used,
such as flatbed trailers, pallet trucks, custom trailers, and bin trailers. Different
types of loading equipment used for loading and unloading the trailer include an
AGV-pulled train, hand pallet truck, cranes, forklift truck, automatic transfer
equipment, manual labor, shuttle transfer, and programmed automatic loading and
unloading device.
AGVS Pallet Trucks
AGVS pallet trucks are designed to lift, maneuver, and transport palletized loads.
It is used for picking up or dropping off loads from and on to floor level, than
removing the need for fixed load stands. No special accessories are needed for
loading and unloading the AGVS pallet except that the loads should be on a pallet.
It is basically used in floor-level loading and unloading operation. Loading and
unloading can be done in two ways viz. automatically or manually. For the
transportation of load, the normal course followed by the vehicle is determined by
the storage area destination. Normal operations carried out in pallet trucks are :
(i) loads are pulled off onto a spur,
(ii) lowering of the pallet forks to the floor,
(iii) pulling out from the pallet, and
(iv) finally automatically returns empty to the loading area.
AGVS Forklift Trucks
An AGVS forklift truck has the capability to pick up and drop off palletized loads
both at floor level and on stands, and the pickup height can be different from the
drop-off height. They are capable of picking up and dropping off a palletized load
automatically. It has the ability to position its forks at any height so that conveyors
or load stands with different heights in the material-handling system can be
serviced. AGVS forklift trucks are one of the most expensive AGVS types.
Therefore, they are used in the case of full automation. The truck is accoutered
with sensors at the fork end, so that it can handle high-level stacking on its own.
These systems have the advantage of greater flexibility in integrating with other
subsystems with various loading and unloading heights throughout the material
handling system.
AGVS Light Load Transporters
They are applied in handling small, light parts over a moderate distance and
distribute the parts between storage and number of work stations.
AGVS Assembly-Line Vehicles
AGVS assembly line vehicles are an acclimatization of the light-load transporters
for applications involving serial assembly processes. The guided vehicle carries
major sub-assemblies such as motors, transmissions, or even automobiles. As the
vehicle moves from one station to the next, succeeding assembly operations are
performed. After the loading of part onto the vehicle, the vehicle moves to an
assembly area and stops for assembly. As the assembly process is completed, the
operator releases the vehicle that proceeds to the next part’s staging area for new
parts. After that the vehicle moves forward to the next assembly station. The
process is repeated until the final unloading station is reached.
The main advantage of the AGVS assembly line is its lower expense and ease of
installation compared with “hard” assembly lines. The line can be easily
reconfigured by altering the guide path and by reprogramming. Variable speeds
and dwell intervals can be easily programmed into the system. However, an
4. 42
Fundamentals of CIM extensive planning and complex computer control is needed in the case of overall
integration. Some of the guiding factors determining the functioning of the AGVS
are :
(i) Guidance Systems
(ii) Routing
(iii) AGVS Control Systems
(iv) Load Transfers
(v) Interfacing with other subsystems
Next section deals with the guidance systems designed for keeping the vehicle on
predetermined path.
3.2.4 Guidance Systems for AGVS
The main purpose of a guidance system is to keep the vehicle in the predestinated path.
The main advantage of AGVS guidance system is that the guide path can be changed
easily at low cost compared to the high cost of modifying fixed-path equipment such as
conveyors, chains, and tow lines. Many guidance systems are available and their
selection will depend on need, application, and environmental constraints. Some of the
familiar guidance systems are wire-guided guidance system, optical guidance system,
inertial guidance system, infrared guidance system, laser guidance system, and teaching-
type guidance system.
3.2.5 Routing of the AGVS
AGVS routing means determining how the vehicle conforms the path and takes a
shortest path between the two points. The commonly used methods are : “frequency
selection method ” and the “path switch selection method ”.
3.2.6 AGVS Control Systems
Three types of AGVS control systems are available.
(i) Computer-controlled system
(ii) Remote dispatch control system
(iii) Manual control system
Computer Controlled System
Here, all the exchanges and AGVS vehicle movements are controlled and
monitored by the system controller. A detailed sketch of the computer-controlled
system is shown in Figure 3.1. The guide path controller controls the guide path of
the AGVS and transfers the information to the AGVS process controller.
Movements of AGVS vehicle are directly controlled by the AGVS process
controller.
Figure 3.1 : Computer-controlled Architecture for AGVS Control
5. 43
Automated Material
Handling
Remote Dispatch Control System
Here, a human operator controls the movement of AGVS through a remote control
station. The control system sends destination instructions directly to the vehicle.
Manual Control System
In this type of system, the operator loads the vehicle and enters a destination into
the onboard control panel of the vehicle. The efficiency of the system depends on
the skill of the operator.
3.2.7 Interface with Other Subsystems
The computer-controlled system can link the AGVS materials-handling system with
other subsystems in the organisation. These subsystems include:
(i) Automated storage and retrieval systems.
(ii) Computer numerical control (CNC) machines.
(iii) Shop floor control system.
(iv) Process control equipment.
(v) Flexible manufacturing systems.
They may be linked by a distributed data processing network and the host computer. In
the distributed data processing network, the system control computers communicate with
each other directly without the intermediate or host computer.
In the next section, we will elucidate the main features considered for designing the
AGVS system.
3.2.8 AGVS Design Features
Many design features pertaining to AGVS are common to other material handling
systems. However, there are several special features unique to the AGVS, such as
stopping accuracy, facilities, safety, and maintenance.
A very important attribute of the AGVS system is “Stopping Accuracy” and it varies
considerably with the nature and requirements of the system. A system with automatic
load transfer requires high stopping accuracy. In case of manual load transfer, lower
stopping accuracy is required. In addition to that, unit load transporters are used for
systems that require higher accuracy. In an AGVS, the stopping accuracy is provided by
the feedback of Computer Control Systems. Stopping accuracy depends on the
applications, for example, erfacesinttoolr machineinch fo001.0 , 1 inch or more
for towing and light-load vehicles, and 3 inch for a manual system.
Many considerations are undertaken while designing the AGVS, like incorporation of
automatic door-opening devices, elevators etc. Safety features such as emergency contact
bumpers and stop buttons, object detectors, automatic warning signals, and stopping
devices must be built in the AGVS. These features must be of paramount importance in
the minds of the designers so as to avoid the human injuries and damage to other
equipment, materials, and vehicle itself.
3.2.9 System Design of AGVS
The decision process related to the system design is very complex in nature. A number of
issues are to be addressed which includes:
(i) Guide path layout
(ii) Number of vehicles required
(iii) Flow path design
(iv) Selection of guide path type and vehicle type
(v) Type of flow path within the layout
6. 44
Fundamentals of CIM (vi) Location and number of load transfer points and load transfer station storage
space.
Operational issues such as the routes used by the vehicles during operation are also taken
into consideration. There must be a synergy between the operational and design features
for the successful implementation of AGVS.
3.2.10 Flow Path Design
The flow path design is one of the most important processes in the AGVS design. Some
of the important decisions involved in flow path design are:
(i) Type of guide path layout.
(ii) Flow path within the layout.
(iii) The number and locations of load transfer points.
(iv) Load transfer function station storage space.
Areas of application of the AGVS determine the critical issues like guide path layout,
P/D (Place and Delivery) location points, and load transfer station storage space.
However, the complexity of controls and economic considerations influence the direction
of flows.
Vehicle blocking, congestion, and unloaded vehicle travel are the issues to be taken into
consideration and depend on the number of the vehicles and the requests for vehicles
from various pickup and delivery stations. Simulation is used to develop the realistic
design under aforementioned circumstances. The type of information required for
developing a simulation model would include layout of departments, aisles, location of
load transfer stations, and charts containing the material flow intensities between
departments.
Required Number of AGVS
Estimation of the number of AGVs required in the system is an important element
of the system design. Here, we provide a simple mathematical analysis for the
determination of the number of vehicles. The following notations are used :
Dd = Total average loaded travel distance.
Dc = Total average empty travel distance.
Ndr = Number of deliveries required per hour.
Tf = Traffic factor that accounts for blocking of vehicles and waiting of
vehicles in line and at intersection. If there is no congestion, the traffic
factor is 1. However, when more vehicles are involved, the traffic factor
value will certainly be less than 1. Normally, Tf lies between 0.85 and 1.
v = Vehicle speed.
Th = Loading and unloading time.
The total time per delivery per vehicle (Tdv) is given by the sum of loaded travel
time, loading and unloading time, and empty travel time as follows :
Tdv =
v
D
T
v
D c
h
d
Number of deliveries per vehicle per hour
dv
f
d
T
T
N
60
Number of automated guided vehicles = Ndr/Nd
The treatise discussed here provides an approximate estimate of number of
vehicles.
7. 45
Automated Material
Handling
Example 3.1
Pradeep Engineering is contemplating to integrate the AGVS and AS/RS with
their flexible manufacturing system. It is also in the process of determination of
number of AGVSs for its manufacturing system. It has to deliver 67 pieces per
hour. The company has decided in favour of installing a wire guided path system
and the unit load AGVS. The following data has been collected as shown in
Table 3.1.
Table 3.1 : Data Pertaining to the AGVS in the Industry
Vehicle Speed 200 ft/min
Average loaded travel distance per delivery 600ft
Average empty travel distance per delivery 400 ft
Pickup time 0.25 min
Drop-off time 0.25 min
Traffic factor 0.75
The total time per delivery per vehicle (Tdv) is given by
Tdv =
v
D
T
v
D c
h
d
200
400
25.025.0
200
600
= 5.5
Number of deliveries per vehicle per hour,
dv
f
d
T
T
N
60
= 18.8
5.5
)75.0(60
Hence, the number of vehicles required = 67/8.18 = 8 vehicles.
Example 3.2
An automated manufacturing system for machining crankshafts in a forging
industry is planning to implement AGVs in the organisation. There are five CNC
workstations (A, B, C, D, E) and a load-unload station (F). Approximate time of
moving the crankshaft on AGVS between stations is shown in Table 3.2.
Table 3.2 : Approximate Time of Moving the Crankshaft on
AGVS between Stations
A B C D E F
A - 2 1
B 2.5 - 2.5
C 3 - 1.0
D 2 - 0.5
E 1.5 - 1.0
F 0.5 0.5
One hundred crankshafts are machined in every 8-h shift and the operations on the
crankshaft are performed in sequence from station A through E. Taking an
assumption that every pickup and drop-off operation takes approximately
0.75 min, determine the number of AGVSs to meet the demand of moving
100 crankshafts. The load factor is assumed to be 0.75 and the traffic factor 0.95.
Solution
In this problem, the empty travel times of the AGV is not known though load
factor is known to us. Here, load factor refers to the percentage of time the AGVS
carries the load.
Total travel time of a crankshaft from a pickup operation to a drop-off operation
= 1 + 2.5 + 3 + 2.0 + 1.5 + 0.5 = 10.50.
8. 46
Fundamentals of CIM Total pickup and drop-off time = 4.50 min because there are only six stations
including the pickup and drop-off station and each takes 0.75 min.
Total transit time = 10.50 + 4.50 = 15.00 min.
Considering that there are delays due to congestion and there is empty travel of
AGVs:
Total AGVS travel time for one crankshaft = 10.00/ (traffic factor × load factor)
= 10.00/ (0.75 × 0.95) = 14.03 min.
Total available time per shift = 8 hr/ shift × total time per crankshaft)/ available
time = 100 × 14.03 / 480 = 2.92 vehicles.
This means that approximately 3 vehicles are required.
SAQ 1
(a) Discuss the following types of AGVSs and their applications:
(i) AGVS towing vehicle
(ii) AGVS unit load transporters
(iii) AGVS pallet trucks
(iv) AGVS forklift trucks
(v) AGVS light-load transporters
(vi) AGVS assembly-line vehicles
(b) Discuss various types of guidance system.
(c) Describe the following types of AGVS control methods:
(i) Computer-controlled system
(ii) Remote dispatch control system
(iii) Manual control system.
3.3 INTRODUCTION TO INDUSTRIAL ROBOTS
An industrial robot is a general-purpose, programmable machine possessing certain
anthropomorphic characteristics. Mechanical arm is the most common characteristic of
an industrial arm and is used to perform various industrial tasks. Making decisions,
capability to communicate with other machines, and capability to respond to sensory
inputs are the important attributes of an industrial robot. These capabilities allow the
robots to be more versatile in nature. It involves the coordinated control of multiple axes
(joints) and use dedicated digital computers as controllers.
The various reasons for the commercial and technological importance of industrial robots
include the following :
(i) Robots can be substituted for humans in hazardous or uncomfortable work
environments. A robot performs its work cycle with a consistency and
repeatability that cannot be attained by humans.
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Automated Material
Handling
(ii) Robots can be reprogrammed. When the production run of the current task
is completed, a robot can be reprogrammed and equipped with necessary
tooling to perform an altogether different task.
(iii) Robots are controlled by computers and can therefore be connected to other
computer systems to achieve computer integrated manufacturing.
3.3.1 Robot Anatomy
A robot joint is a mechanism that permits relative movement between parts of a robot
arm. The joints of a robot are designed to enable the robot to move its end-effector along
a path from one position to another as desired. The basic movements required for the
desired motion of most industrial robots are :
Rotational Movement
This enables the robot to place its arm in any direction on a horizontal direction.
Radial Movement
This helps the robot to move its end-effector radially to reach distant points.
Vertical Movement
This enables the robot to take its end-effector to different heights.
These degrees of freedom, in combination with others or independently, define the
complete motion of the end-effector. Individual joints of the robot arm are responsible
for the accomplishment of different movements. The joint movements are in synergy
with the relative motion of adjoining links. Depending on the nature of this relative
motion, the joints are classified as prismatic or revolute.
3.3.2 Robot Classification
Robots are being classified on the basis of their physical configuration and control
systems adopted. These classifications are briefly described as follows :
Classification on the Basis of Physical Configurations
On the basis of physical configuration industrial robots are classified in four
different types. They are :
(i) cartesian configuration,
(ii) cylindrical configuration,
(iii) polar configuration, and
(iv) jointed-arm configuration.
Cartesian Configuration
Robots having cartesian configurations consist of links connected by linear joints
(L). As the configuration has three perpendicular slides, they are also called
rectilinear robots. Robot having a similar configuration is known as Gantry
Robots. Its structure resembles a gantry-type crane.
Cylindrical Configuration
In the cylindrical configuration, robots have one rotatory (R) joint at the base and
linear (L) joints succeed to connect the links. The space in which this robot
operates is cylindrical in shape, hence the name cylindrical configuration.
Polar Configuration
Polar robots have a work space of spherical shape. In general, the arm is linked to
the base with a twisting (T) joint and rotatory (R) and or linear (L) joints. The
designation of the arm for this arm can be TRL or TRR. Robots with the
description of TRL are also called spherical robots. Those having the designation
of TRR are called as articulated robots. It resembles a human arm in terms of
configuration.
10. 48
Fundamentals of CIM Jointed-Arm Configuration
The combination of cylindrical and articulated configurations is known as
jointed-arm configuration. The arm of the robot is connected to the base with a
twisting joint. Rotatory joints are used to connect the links in the arm. Generally,
the rotation takes place in the vertical plane. Popular robot falling under this
category is called SCARA (Selective Compliance Assembly Robot Arm). It is
basically used for the assembly purpose.
In the next section, we will elicit the classification based on the control systems.
3.3.3 Classification based on Control Systems
On the basis of the control systems adopted, robots are classified into the following
categories :
(i) Point-to-point (PTP) control robot
(ii) Continuous-path (CP) control robot
(iii) Controlled-path robot
Point-to-Point (PTP) Control Robot
The PTP robot is capable of moving from one point to the other point. The
locations are recorded in the control memory. The paths are not controlled by the
path guide. Instead the desired path is traced by programming a series of points.
Component insertion, spot welding, hole drilling, machine loading, unloading and
crude assembly are some of the common applications of this type of robot.
Continuous-Path (CP) Control Point
The movement along the controlled path is performed by the CP robot. Along the
controlled path, with CP control, the robot can stop any specified point. In the
robot’s control memory, all the points must be stored explicitly. Straight-line
motion is being carried out by these types of robots. Some continuous-path
controlled robots also have the capability to follow a smooth curve path that has
been defined by the programmer. Here, the programmer manually moves the robot
arm through the desired path and the controller unit stores a large number of
individual point locations along the path in memory.
Controlled-Path Robot
In controlled-path robots, the control equipment can develop paths of different
geometry such as straight lines, circles, and interpolated curves with a high degree
of accuracy. Good accuracy can be obtained at any point along the specified path.
Only the start and finish points and the path definition function must be stored in
the robot’s control memory. It is important to mention that all controlled-path
robots have a servo capability to correct their path.
In the next section, we will elicit the robotic applications in the industry.
3.3.4 Robotic Applications in the Industry
Work environment is one of the several characteristics that should be considered when
selecting a robot application. The hazardous characteristics of industrial work tend to
promote the substitution of robots for human labour. Hence, robots are being used in a
wide field of applications in industry. Currently, robots are mostly used in the field of
manufacturing. The applications can usually be classified into following characteristics :
(i) Material handling
(ii) Processing operations
(iii) Assembly and inspection
Application of the robots in the industry must be technically and economically viable for
the industry.
11. 49
Automated Material
Handling
Material Handling Applications
Material handling applications are those in which the robot moves the materials or
parts from one place to another. The robot is equipped with a gripper type of
end-effector to accomplish this type of transfer. The gripper must be designed to
handle the specific part or parts that are to be moved. Within this application
category are the following cases which are
(i) Material transfer, and
(ii) Machine loading/unloading.
In almost all the material handling applications, the part must be presented to the
robot in familiar position and orientation.
Material Transfer
These are the operations in which the robot picks up the parts at one location and
place them at a new location. The basic application in this category is pick and
place operation, where robot picks up a part and deposits at a new location.
Transferring parts from one conveyor to another is a classic example of this
application. However, palletizing is a more complex example of the material
transfer application. Here, the robots must retrieve parts, cartons, or other objects
from one location and deposit them onto a pallet or other container with multiple
locations.
Machine Loading/Unloading Operations
In machine loading and unloading operations, the parts are transferred into/from a
machine. The three possible scenarios can be machine loading, machine
unloading, machine loading and unloading. In the machine loading operations, the
robot loads parts into machine, but the parts are unloaded from the machine by
some other mechanism. In the unloading operations, the machines are unloaded
using the robots. When both the earlier situations are present, then this can be
placed into the third category.
Numerous applications of machine loading and unloading operations are as
follows :
(i) Die casting operations
(ii) Metal machining operations
(iii) Plastic molding
(iv) Forging
(v) Heat treating
(vi) Press working
Robots as mentioned earlier are also used in the process industry. Numerous
applications in this category are spot welding, continuous arc welding, spray
painting, various rotating processes, and machining processes.
Spot Welding
Spot welding is a metal joining process in which two sheet metal parts are fused
together at localized points of contact. It has got a widespread use in the
automobile industry. The end-effector used here is a spot welding gun used to
pinch the car panels together and perform the resistance welding process.
Continuous Arc Welding
Continuous arc welding is used to provide continuous welds rather than points in a
spot welding process. As the working condition is tough, therefore automation is
recommended in this case. The robotic cell consists of a robot, the welding
apparatus (power unit, controller, welding tool, and wire feed mechanism), and a
fixture that positions the components for the robot. The fixture might be
12. 50
Fundamentals of CIM mechanized with one or two degrees-of-freedom so that it can present different
portions of the work to the robot for welding.
Spray Coating
Spray coating makes use of a spray gun directed at the object to be coated. Fluid
flows through the nozzle of the spray gun and is dispersed and applied over the
surface of the object. Here, robot applications consist of spray coating appliances,
automobile car bodies, engines, and other parts, spray painting of wood products,
and spraying of porcelain coating on bathroom fixtures.
Other Processing Applications
The list of other industrial processes that are being performed by robots is as
follows :
(i) Drilling, routing and other machining process.
(ii) Laser cutting.
(iii) Riveting.
(iv) Grinding, wire brushing, and similar operations.
(v) Water jet cutting.
In the next section, we detail the assembly and inspection operations performed by
the robots.
Assembly and Inspection
Assembly and inspection are hybrids of the previous two application categories:
material handling and processing. Assembly and inspection applications can
involve either the handling of materials or the manipulation of a tool. Assembly
and inspection are traditionally labour-intensive, boring and highly repetitive
activities. Hence, they are the fitting cases for the robotic applications.
Production rate is one of the important performance measures for such robotic
applications. Therefore, industrially relevant problems have been presented and
solved in the next section.
Example 3.3
Calculate the cycle and production rate for a single-machine robotic cell for an
8-hr shift if the system availability is 85%. Also determine the percent utilization
of machine and robot. On average, the machine takes 35 sec. to process a part. The
other robot operation times are as follows :
Robot picks a shaft from the conveyor 4.0 sec
Robot moves the shaft to the lathe 1.5 sec
Robot loads the shaft onto the lathe 1.0 sec
Robot unloads the shaft from the lathe 0.5 sec
Robot moves the conveyor 1.5 sec
Robot puts the shaft on the outgoing conveyor 0.5 sec
Robot moves from the output conveyor to the input
conveyor
5.0 sec
Description of Solution Approach
The total cycle time of 49 seconds is obtained by adding all the activities of the
robot including the machining time and other related activities. The production
rate is the reciprocal of cycle time. The production rate considering system
availability is therefore
13. 51
Automated Material
HandlingProduction rate )uptime%85.0(
shift
8
)h/min60(min)/s60(
.sec49
unit1
h
= 500 units per shift
Machine Utilization =
e timeTotal cycl
cle timeMachine cy
= 35/49 = 0.7142 or 71.42%
Robot utilization =
e timeTotal cycl
e timeRobot cycl
= 14/49 = 0.2857 or 28.57
3.2.5 Double-Gripper Robot in a Single-Machine Cell
A double-gripper robot has two gripping devices attached to the wrist. They can be put
into action independently. The double gripper can be used to handle a finished and
unfinished items simultaneously. This helps in increase in the productivity. A numerical
example has been given to clarify this point.
Example 3.4
In this case study, we elucidate the improvement in productivity with the use of
double-handed grippers using the data in the previous example.
Solution
The operation sequence with double-handed gripper is
Machine cycle time = 35 sec.
Robot unloads the shaft from the lathe = 0.5 sec
Robot loads the part onto the machine = 1.0 sec
The total cycle time is 36.5 sec.
The production rate considering system availability is therefore
Production rate = uptime85.0
shift
h8
min
s60
min
s60
5.36
1
= 671 units per shift.
The productivity increase obtained by using a double-handed gripper is
(617 – 500) / 500 = 0.234 or 23.4%.
SAQ 2
(a) Describe the physical components of a typical industrial robot.
(b) Discuss the following robot configurations
(i) Cartesian robot configuration
(ii) Cylindrical robot configuration
(iii) Polar robot configuration
(iv) Jointed-arm configuration
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Fundamentals of CIM
3.4 SUMMARY
In this unit, we have dealt with the automated guided vehicles and Robots used in the
industry. Due to the industrial automation, many changes have taken place in the field of
microprocessor, programmable controllers, industrial logic controls, computer numeric
control (CNC) etc. Automated Guided Vehicle systems are material-handling systems
that are flexible, reliable, inexpensive to operate, and easy to interface with systems such
as FMSs, AS/RS, and other material handling systems. Robots have also played a vital
role in the automation of the industry. Industrial robots now perform a wide variety of
tasks and are used in all kinds of applications. For effective management of robot and
AGV, it is important to understand the basics of robotics and AGVS. In this unit, we
have attempted to cover such basic aspects related to Robots and AGVS.
3.5 KEY WORDS
AGVS Guide Path : Automated Guided Vehicle Systems. It guides the
vehicle to move along the path.