Implementation of Robotics

1. IMPLEMENTATION
OF
ROBOTICS

2. Material Handling
• It is defined as the function and systems
associated with the transportation , storage
and physical control to work in process
material in manufacturing.

3. • What is Material handling?
It can be defined as using the right
method to provide safely the right amount of the
right material at the right place at the right time
in the right sequence in the right position in the
right condition and the right cost.
It include the movement , storage and
control of material and considerable emphasis
placed on control.

4. Types of Material Handling Equipments
• Industrial Trucks
• Cranes
• Hoists
• Conveyer
• Monorails
• Automated guided vehicles
• Robots

5. Types of Transportation
• Overhead (Power and free conveyer , individually powered
monorail)
• Below Floor (AGV)
• Above Floor – Powered roller, powered slot , platen type
conveyer.
• Storage interface : AS/R machines

6. 1. Automated Guided Vehicle systems (AGV’s)
• Modern material handling conveyer systems that are more appropriate for
FMS aplications and automation.
• Also known as Laser Guided vehicle or Self Guided vehicle.
• AGV was brought into market in 1950’s, at that time it was simply a tow truck
that had a wire in the floor instead of rail.
• Over the years technology became more sophisticated and today automated
vehicles are mainly laser guided vehicles.
• It helps to reduce the cost of manufacturing and increases efficiency in the
manufacturing system.
• AGV’s tow objects behind them in small trailers.
• AGV’s also store objects on the bed.
• Some AGV’s uses fork lift to lift the objects for storage.
• LGV’s are programmed to communicate with robots to ensure the product is
moved smoothly to the ware house , whether it is stored for future use or
directly sent to shipping areas.

7. Uses of AGV
1. Navigation
Transport an object from A to B
 For navigation there are two sensors
 Wired and wireless sensor
2. Wired
 It is placed at the bottom of the robot
 wire is placed one inch below the ground
3. Guide Tape
Light duty AGV’s
Two styles are there 1. magnetic 2. colored
AGV is fitted with appropriate guide sensor to follow the path of the tape.
4. Laser Target Navigation
• The wireless navigation is done by mounting retro reflective tape on walls,
poles or machines.

8. 5. Gyroscopic Navigation
 Another form of AGV guidance is inertial navigation (using
accelerometers and gyrometers)
 A computer control system directs and assigns the task to
vehicles
 Transponders (wireless communication device ) are mounted
on the floor
 A gyroscope is able to detect the slightest change in the
direction of vehicle
 Inertial can operate in extreme temperature and has a longer
lifespan
Uses of AGV

9. Uses of AGV
6. Natural Features Navigation
 Navigation without retrofitting of the work
piece is called Natural Features navigation
 One method uses one or more range finding
sensors, such as laser range finder, gyroscope,
and/or inertial measurement
Highly flexible and can handle failure without
bringing down the entire manufacturing
operation.

10. Contd...
2. Steering control
• Differential speed control is most common
• Tight spaces
• Not used for towing
• Similar to car steering
3. Path Decision – Frequency select mode(wired navigation)
Path select mode(wireless navigation) – uses magnetic tape on floor to give
speed commands and steering commands.
Magnetic tape mode (used in TOYOTA USA and TOYOTA JAPAN)
4. Traffic control : FMS that have more than one AGV may require traffic control
- Forward sensing control (uses collision avoidance sensor)
Sensors include Sonic – which work like radar
Optical – which uses infrared sensor
Bumper – Physical contact sensor

11. Contd...
Combination control
 uses collision avoidance sensor as well as zone control sensors
 Collision voidance is used for fail safe .
 Eg : If the zone control system is down the collision avoidance
system would prevent the AGV from collision.
5. System Management - Local panel
- CRT colour Graphics display
- Central logging and report

12. Types of AGV
1. Towing
• 5000 to 50000 pounds at speed of 3 miles/hr
• The number and variety of ten trailers is the
limit
2. Unit load (high volume of materials)
3. Pallet (movement of palletized load at floor level)
4. Fork truck (pickup and deliver loads)
5. Light Load (Several hundred ponds) – small parts
6. Assembly line vehicles (carries sub assemblies)

13. Battery charging Techniques
• Battery swap
• Automatic / Opportunity Charging
• Automatic battery swap

14. Components of AGV
• Mechanical structure
• Driving and steering mechanism actuator
• Servo controllers
• On board computing facility
• Servo amplifiers
• Feed back components
• Onboard power system

15. Applications of AGV
• Driverless train operations ( large qty at large
distance)
• Storage / Distribution system (Unit load
carriers and pallet trucks)
• Assembly line operations
• Flexible Manufacturing systems
• Miscellaneous applications (mail delivery in
office buidings)

16. Advantages of AGV
• Flexible approach to material handling
• Decrease labour costs
• Operate in hazardous environment
• Compatible with production and storage
equipment.
• Can handle and transport hazardous materials
safely.
• Reduction in downtime of machines.
• Improvement in productivity and profit
• Continuous work without interruptions.

17. Monorail
• Rail guided equipments which consist motorized
vehices that are guided by a fixed rail system.
• Since there is one rail it is called as monorail
system
• Overhead monorails are used for interbay
transport from stocker to stocker.
• A monorail can be configured to any shape and
length to conform to tool layout.
• Monorails mounted overhead can use payload
hoists to load and unload tools, can use a transfer
device at tool level.

18. Feature for monorail
• Extremely clean operation
• Passing/ rerouting capability
• Intelligent positioning
• Overhead hoist monorails
• Hoist monorails

20. Performance measures
• Transport work
• Delivery distribution
• Machine interference
• Relative performance capabilities

21. Parameters for each technology
• Travel speed
• Number of loads
• Vehicles per bay
• Load/Unload time
• Base cost
• Incremental cost
• Footprint factor

22. Steps to be followed by the company in order to
implement robot programs and its operation
• Initial familiarization with the technology
• Plant survey to identify potential applications
• Selection of the best application
• Selection of the robot
• Detailed economic analysis and capital
authorization
• Planning and engineering the installation
• Robot installing

23. Plant survey to identify potential applications
• Hazardous or uncomfortable working
conditions
• Repetitive operations
• Difficult handling jobs
• Multi shift operation