Level 5 Enterprise level Flow of data 4 Plant level

Description / Examples Corporate information

Production system

Cell or system level

Manufacturing systemgroups of machines

Machine level

Individual machines

Device level

Sensors, actuators, other hardware elements

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Figure 3.6 Five levels of automation and control in manufacturing.

Business and engineering systems

Engineering workstation Finance Production planning Purchasing Quality control

Local operator station

Central control room

Enterprise communications network Local operator station Communications network

Process station

Process station

Process station

Process station Signals to and From process

Raw materials process

Product

Figure 4.13 Enterprise-wide PC-based DCS.

3.4 Material Handling Technology

Enterprise level

Manufacturing support systems Quality control systems Manufacturing systems

Manufacturing support systems

Production system

Factory level

Facilities Automation and control technologies Material Handling technologies

Figure 9.1 Material handling in the production system.

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3.4.1. Overview of Material Handling Equipment

Types of Handling Equipment Transport Equipment Storage System Unitizing Equipment Identification and tracking system Considerations in Material Handling system Design

3.4.2. Material transport systems : Their characteristics

Automated guided vehicle (AGV), Conveyor system

3.4.3. Analysis of transport systems : Flow rates and delivery cycle time
Charting technique in Material Handling Analysis of vehicle Based system Conveyor analysis

Basic Types of Material Transport Equipment

Electrified rail Deck Vehicle electrical pickup Forks Drive wheel Bumper

Monorail (I-beam)

(a)
Rolls

(b)

Motorized vehicle

(c)

Crane rail

Hoist

Frame

(d)

(e)

Figure 9.2 Examples of the five basic types of material handling equipment: (a) fork lift truck, industrial truck, (b) unit load automated guided vehicle, (c) monorail, (d) roller conveyor, and (e) jib crane with hoist.

Unit Load Container, Storage System, ID/Tracking

container
Figure 9.3 Examples of unit load containers for material handling: (a) wooden pallet, (b) pallet box, and (c) tote box.

(a) Storage carousel

Carousel structure Drive motor system

(b)

(c)

ID/Tracking System

Bar code

Carton

Carousel track Conveyor Bins for inventory Conveyor Moving beam

Scanner

Load/unload station

Figure 12.6 Stationary moving beam bar code scanner located along a moving conveyor.
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Figure 11.6 A horizontal storage carousel.

Determining Factors for Handling System Design

Material Characteristics Flow rate, Routing, and Scheduling Plant layout Flow rate of the materials to be moved Routing factors Scheduling of the moves The quantity or amount of material to be moved : timing of each individual delivery. Responsive to the need of timely pickup/ delivery Pick up and drop-off locations Move distance Routing variations
Quantities of material moved High Conveyors Conveyors AGV trains Powered trucks Unit load AGV Long Move distance
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Low

Manual handling Hand trucks Short

Figure 9.4 General types of Material transport equipment as a function of material quantity and distance moved.

Various Types of Conveyors

Rolls

(a)

Skate wheels

(b)

Figure 10.6 (a) Roller conveyor and (b) skate wheel conveyor.
Forward loop Vc Idler roll Support slider Return loop Drive roll Pin Slot in floor Towline (cable or chain) Tow force Cart

Figure 10.7 Belt (flat) conveyor (support frame not shown).

Figure 10.8 In-floor towline 8 conveyor.

continued

Track (I-beam)

Pull force Conveyor cart Trolley Drive wheel Spinning tube

Conveyor rails

Chain Load suspended From trolley

Figure 10.9 Overhead trolley conveyor.

Figure 10.10 Cart-on-track conveyor. (Diagram courtesy of SI Handling Systems.)

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conveyor
Ld Vc Conveyor path LOAD UNLD

(a)
Delivery loop LOAD Return loop Vc UNLD

Vc

(b)
Recirculating conveyor (c)

Figure 10.11 (a) Single direction conveyor and (b) continuous loop

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Conveyor Analysis : Single Direction conveyors

Ld Vc Conveyor path LOAD UNLD

(a) Td : Delivery time : Ld : length of conveyor between load and unload stations , Vc : conveyor velocity
TL : time required to load the carrier VC

Carrier Flow rate :

Rf : material flow rate (parts/min) RL : loading rate (parts/min) SC : carrier spacing

Unload time constraint :

Material flow rate,

VC

<Example>

SC

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Continuous Loop Conveyors

Ld : length of the delivery loop Le : length of the return loop nC : number of carriers L : total length of the conveyor SC : carriers at distance apart

Delivery time :
VC

Total travel time :

TC =

L VC

Total number of carriers :

Total parts in system :

VC

Material flow rate :

Vc Delivery loop LOAD Vc UNLD

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(b)

Recirculating Conveyors
To smooth out the effects of changes in the rate of loading and unloading
no loaded carriers available at the unloading station no empty carriers available at loading station

To meet this requirement ; conveyer speed : time required :

VC VC

flow rate capacity :

VC

For example :

VC

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Automated Guided Vehicles

Types of AGVS

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Vehicle Guidance and Routing Technology

The function operating the AGVs :
Vehicle guidance and routing traffic control and safety Paint stripes System management

Guidance system
Embedded guide wires Self guided vehicles

Frequency generators : < 40V , < 400m A frequency 1~15 KHz

Routing : Selecting among alternative pathways

Guided vehicle layout multiple loops branches, side tracks Selecting path frequency select method path switch select method spurs
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Traffic Control and Safety

The traffic control : collision avoidance blocking system
On board vehicle sensing Zone blocking On board sensing (forward sensing) : detect the presence of vehicles (optical/ultrasonic Sensors) 4 1 5 9 6 2 3 7 10 8

Zone control : Divide the AGV zone into separate zones and the operating rule is the at no vehicle is permitted to enter a zone if that zone is already occupied by another vehicle. Vehicle Management and Safety

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From To Chart Showing Flow Rates

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Determining Number of Vehicles in an AGV

Rate of delivery / vehicle Number of vehicle (Delivery cycle time) Possible time losses include Availability (A) Traffic congestion (Tf) Efficiency of manual (E) drivers for manually operated trucks

WL = Work load (min/hr), Tf : traffic factor ne = number of vehicles, E : work efficiency A : availability

Delivery cycle time,

Availability
AT = 60 A Tf E

TL : time to load at load station (min) TU : time to unload at unload station VC : carrier velocity Ld : distance between load and unload station

Le : distance the vehicle travels empty

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AGV

Unld Man

AGV guide path

20 55

40

20
Direction of vehicle movement

Load Man

Tc = 0.75 +

80 110 + 0.50 + = 5.05 min 50 50

WL = 40(5.05) = 202 min/hr AT = 60ATfE60(0.95)(0.90)(1.0) = 51.3 min/ hr per vehicle nc =

202 WL = = 3.94 vehicle 51.3 AT
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Figure 10.15 AGVS loop layout for Example 10.1. Key: Unld = unload, Man = manual operation, dimensions in meters (m).

Determining Ld for a More complex AGVa Layout

AGV 3 Proc Aut AGV guide path 30

50 35 4 Proc Aut 15

50 2 Proc Aut 10 Direction of vehicle movement 10 Unld Man 30 10 Load 1 Man 30

Ld =

9(50) + 5(120) + 6(205) +9(80) + 2(85) +3(170) +8(85) = 4360 42 9 + 5+ 6 + 9 + 2+ 3+8

= 103.8m
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Figure 10.16 AGVS layout for production system of Example 10.2. Key: Proc = processing operation, Aut = automated, Unld = unload, Man = manual operation, dimensions in meters (m).

Automatic Data Capture (ADC)

Automatic Identification Methods Encoded Data 1. Optical 2. Magnetic 3. Electromagnetic 4. Smart card 5. Touch techniques 6. Biometric

Machine Reader

Decoder

Bar code

Carton

Conveyor

Moving beam Scanner

Figure 12.6 Stationary moving beam bar code scanner located along a moving conveyor.

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Bar Code ( Encoded Data)

* T 1 2 3 0 2 4 *

Quiet zone (10X) Start Data 3

Quiet zone garments (10X) Stop Typical data character in a variety of configurations

multiple rows of conventional lines bar codes

Figure 12.8 A 2-D stacked bar code. Shown is an example of a PDF417 symbol.

Matrix symbologies

00000

9 Bits Figure 12.5 A typical grouping of characters to form a bar code in Code 39. (Reprinted from [4] by permission of Automatic Identification Manufacturers, Inc.)

Figure 12.9 A 2-D matrix bar code. Shown is an example of the Data Matrix symbol.

One Dimensional

Two Dimensional

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Storage System
Storage system performance (1) storage capacity, (2) density, (3) accessibility, (4) through-put. In addition, standard measures used for mechanized and automated systems include (5) utilization (6) reliability.
Storage Location Strategy
120 Inventory level 100 80 60 40 20 0
50 day cycle Safety stock level Order quantity = 100 cartons Average inventory level Depletion rate = 2 cartons/day

Time
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Figure 11.1 Inventory level as a function of time for each SKU in Example 11.1.

Automated Storage Systems

Automated Storage / Retrieval Systems
Carosel Storage System

Storage structure (rack framework)

Carousel structure

H
Storage module (pallet loads)

Drive motor system Carousel track

S/R machine

L
Pick-anddeposit station

Conveyor Bins for inventory

Load/unload station

Figure 11.5 A unit load automated storage/retrieval system.

Figure 11.6 A horizontal storage carousel.

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Storage capacity
C = 2( L W ) + W
C + Tpd 4VC

Carousel Storage System

Total number of bins = ncnb Rt = RC = 60 TC s cnc = C

TC =

ncnb = 75 x 6 = 450 bins

C = 2( 12 1) + 1 = 25.14 m

TC = 25.14 + 20/60 = 0.647 min

4(20)

Rt = 60/0.647 = 92.7 retrieval transactions / hr

Load Unld W Top view

Carrier nc = 81 Bins nb = 4

Side view

Figure 11.9 Top and side views of horizontal storage carousel with 18 carriers (nc = 18) and 4 bins/carrier (nb = 4).

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Rate of delivery / vehicle Number of vehicle Delivery cycle time Possible time losses include Availability (A) Traffic congestion (Tf) Efficiency of manual (E) drivers for manually operated trucks

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