Académique Documents
Professionnel Documents
Culture Documents
4/9/2013
5.1 INTRODUCTION
Fig. 5.1: The slightly asymmetrical threaded stud would not present significant problems in manual handling and insertion For automatic handling an expensive vision system would be needed to recognize its orientation. If the part were made symmetrical, automatic handling would be simple.
Dr. Mohammad Abuhaiba
4/9/2013
5.1 INTRODUCTION
if
a part can be handled automatically, then it can usually be assembled automatically. When we consider design for automation, we will be paying close attention to the design of the parts for ease of automatic feeding and orienting.
4/9/2013
5.1 INTRODUCTION
In automatic assembly:
Time taken to complete an assembly does not control the assembly cost. It is the rate at which the assembly machine or system cycles. If the total rate (cost per unit time) for the machine or system and all the operators is known, the assembly cost can be calculated.
Apportion the cost of product assembly between the individual parts and, for each part; we shall need to know the cost of feeding and orienting and the cost of automatic insertion.
Dr. Mohammad Abuhaiba
Cost of all the equipment Number of operators and technicians Assembly rate at which the system is designed to operate
4/9/2013
Cost of the equipment required Time interval between delivery of successive parts.
Let Fr = required delivery or feed rate (parts/min), then the cost of feeding each part Cf is given by
Dr. Mohammad Abuhaiba
4/9/2013
CF = feeder cost ($) Eo = equipment factory overhead ratio Pb = payback period in months Sn = number of shifts worked per day The constant 5760 = number of available seconds in one shift working for one month divided by 100 to convert dollars to cents.
Dr. Mohammad Abuhaiba
4/9/2013
4/9/2013
Feeding cost per part is inversely proportional to required feed rate and proportional to feeder cost. For otherwise identical conditions, it would cost twice as much to feed each part to a machine with a 6 s cycle compared with the cost for a machine with a 3 s cycle. This illustrates why it is difficult to justify feeding equipment for assembly systems with long cycle times. It would cost twice as much to feed a part using a feeder costing $10,000 compared with a feeder costing $5000.
Dr. Mohammad Abuhaiba
4/9/2013
5.2: The faster the parts are required, the lower the feeding cost. This is true only as long as there is no limit on the speed at which a feeder can operate. There is an upper limit to the feed rate obtainable from a particular feeder. Fm = maximum feed rate
Dr. Mohammad Abuhaiba
10
4/9/2013
11
4/9/2013
If required feed rate is greater than max feed rate obtainable from one feeder, feeding cost becomes constant and equal to cost of feeding when the feeder is operating at its max rate. This is shown in Fig. 5.2 by the horizontal line. If multiple feeders are used for increased feed rates, then the line will be saw-toothed as shown.
Two feeders could be used, each at a rate of 10 parts/min. Feeding cost per part using two feeders to give twice max feed rate will be the same as one feeder delivering parts at its max feed rate.
12
4/9/2013
Eq. (5.3) holds true only when required feed rate Fr<max feed rate Fm when this is not the case feeding cost is given by
Cf = 0.03(60/Fm)Cr
(5.4)
E = orienting efficiency for the part l (mm) = its overall dimension in the direction of feeding and where it is assumed that the feed speed is 25 mm/s.
Dr. Mohammad Abuhaiba
13
4/9/2013
The factor 1/6 is defined as the orienting efficiency E and it can be seen that the max feed rate is proportional to the orienting efficiency (Eq. (5.5)).
Dr. Mohammad Abuhaiba
a vision system could be employed to detect all other orientations and a solenoid operated pusher could be used to reject them. In this case the delivery rate would fall to an average of 1 die every 6 seconds or a feed rate of 1/6 per second.
14
4/9/2013
dies were doubled in size and that feed speed on the feeder track were unaffected. It would then take twice as long to deliver each die. Max feed rate is inversely proportional to length of part in the feeding direction [Eq. (5.5)].
15
4/9/2013
Eq. 5.4 shows that when Fr > Fm, the feeding cost per part is inversely proportional to Fm. Under these circumstances, cost of feeding is inversely proportional to orienting efficiency and proportional to length of part in the feeding direction. Automatic feeding and orienting methods are only applicable to "small" parts. Parts larger than about 8 in their major dimension cannot usually be fed economically.
Dr. Mohammad Abuhaiba
16
4/9/2013
When considering the design of a part and its feeding cost, the designer will know:
1. 2.
The remaining two parameters that affect feeding cost, namely, the orienting efficiency E and the relative feeder cost Cr, will depend on:
1.
2.
17
4/9/2013
5.3: 1st digit of a 3-digit shape code. Fig. 5.4: 2nd and 3rd digits are determined for a selection of rotational parts (1st digit 0, 1, or 2) and corresponding values of orienting efficiency E and relative feeder cost Cr. Fig. 5.5: 2nd and 3rd digits are determined for a selection of non-rotational parts (1st digit 6, 7, or 8).
Dr. Mohammad Abuhaiba
18
4/9/2013
19
4/9/2013
20
4/9/2013
21
4/9/2013
5.3 EXAMPLE
Part shown in Fig. 5.6 is to be delivered to an automatic assembly station working at a 5 s cycle. Use classification system and database to determine feeding cost assuming that cost of delivering simple parts at 1 per second using standard feeder of 0.03 cents per part.
Dr. Mohammad Abuhaiba
22
4/9/2013
5.3 EXAMPLE
A
= 30 mm, B = 20 mm, and C = 15 mm A/B = 1.5 and A/C = 2 Fig. 5.3: A/B < 3 and A/C < 4, part is cubic non-rotational and is assigned a 1st digit of 8. Fig. 5.5: part has no rotational symmetry about any of its axes.
23
4/9/2013
5.3 EXAMPLE
However, either groove apparent in the view in Y direction and step seen in the view in Z direction could also be used to determine the part's orientation. Select feature giving smallest 3rd classification digit; in this case it is the step seen in X direction. Thus appropriate column number in Fig. 5.5 is 0. Three-digit code: 840
A step or projection in the basic rectangular shape This feature alone can always be used to determine part's orientation. This means that if the outline in the X direction is oriented as shown in Fig. 5.6, part can be in only one orientation Therefore, 2nd digit of the classification is 4.
24
4/9/2013
5.3 EXAMPLE
Longest part dimension l = 30 mm Orienting efficiency E = 0.15 Eq. (5.5) gives max feed rate obtainable from one feeder
From the cycle time of 5 s the required feed rate Fr is 12 parts/min, which is higher than Fm. Since Fr > Fm we use Eq. (5.4)
25
4/9/2013
5.7: If edges of parts are thin, shingling or overlapping can occur during feeding, leading to problems with the use of orienting devices on feeder track
26
4/9/2013
Fig. 5.8: for each combination of features, an approximate additional relative feeder cost is given that should be taken into account in estimating the cost of automatic feeding.
27
4/9/2013
If a part can be sorted from bulk and delivered to a convenient location correctly oriented, a specialpurpose mechanism or work head can usually be designed that will place it in the assembly. Such work heads can generally be built to operate on a cycle as short as 1 second. For assembly machines operating on cycles greater than 1 sec, automatic insertion cost Ci is given by
Fr = required assembly rate (or feed rate of parts) Ri = cost (cents/s) of using the automatic work head
Dr. Mohammad Abuhaiba
28
4/9/2013
Assuming a standard work head costs $10,000, payback period is 30 months with two shifts working, and factory equipment overheads are 100% (Eo = 2), we get Ri = 10,000 x 2/(5760 x 30 x 2) = 0.06 cents/s
Dr. Mohammad Abuhaiba
29
4/9/2013
would cost 0.06 cents to use the equipment for 1 second. Taking this figure as the rate for a "standard" work head and assign a relative cost factor Wr to any work head under consideration, then Eq. (5.6) becomes
Insertion
cost is inversely proportional to required assembly rate and proportional to work head cost.
Dr. Mohammad Abuhaiba
30
4/9/2013
31
4/9/2013
5.6 EXAMPLE
Fig. 5.6:
For a cycle time of 5 s, assembly rate Fr is 12parts/min and Eq. (5.8) gives an insertion cost of:
part is inserted horizontally into the assembly in the direction of arrow Y It is not easy to align and position Not secured on insertion Appropriate classification is row 1, column 2 in Fig. 5.9 Automatic insertion code is thus 12, giving a relative work head cost of 1.6. Ci= 0.06(60/Fr) Wr = 0.06(60/12)1.6 = 0.48 cents
32
4/9/2013
33
4/9/2013
FIG. 5.11: Completed worksheets for high-speed automatic assembly analysis of the assemblies in Fig. 5.10 - Original Design
High speed automatic assembly
Handli ng difficul ty
Inserti on code
Relati Insertio Inserti Total Figur ve n/ on cost e for work operati difficul (cent min head on cost ty s) parts cost (cents)
ID 1 2
RP 1 1
HC 83100 02000
OE 0.20 0.40
CR 1 1 * 1
FM 4.8 21.4
DH 12.4 6.3
CF 0.40 0.20
IC 00 02
WC 1.0 1.5
DI 6.3 0.56
CI 0.38 0.56
CA 0.69 0.63
NM 1 1 Housing Plunger
3
4 5
1
1 2
00840
00800 21000
.*
.* 0.90
***.*
***.* 122.7
**.*
**.* 6.3
*.**
*.** 0.20
7.13
6.67 1.44
0
1 0
Gasket
cover screw
34
4/9/2013
FIG. 5.11: Completed worksheets for high-speed automatic assembly analysis of the assemblies in Fig. 5.10 Re-Design
High speed automatic assembly
Handli ng difficul ty
Inserti on code
Relati Insertio Inserti Total Figur ve n/ on cost e for work operati difficul (cent min head on cost ty s) parts cost (cents)
ID
1 2 3 4
RP
1 1 1 1
HC
83100 02000 00040 02000
OE
0.20 0.40 0.70 0.40
CR
1 1 3 1
FM
4.8 21.4 26.3 15.0
DH
12.6 6.3 18.8 6.3
CF
0.40 0.20 0.61 0.20
IC
00 02 00 38
WC
1.0 1.5 1.0 0.8
DI
6.3 9.4 6.3 5.0
CI
0.29 0.43 0.29 0.23
CA
0.69 0.63 0.90 0.43
NM
1 1 0 1 Housing Plunger Gasket cover
35
4/9/2013
2.
3.
a complete station on an assembly machine-including the parts feeder special work head associated portion of the transfer device
36
4/9/2013
can be facilitated by the introduction of guides and chamfers. Figs. 5.12 and 5.13 Sharp corners are removed so that the part can be guided into its correct position during assembly leading to:
1.
2.
less control by the placement device or can even eliminate the need for a placement device.
Dr. Mohammad Abuhaiba
37
4/9/2013
38
4/9/2013
39
4/9/2013
Screws that tend to centralize themselves in the hole give the best results in automatic assembly:
1.
2. 3. 4. 5. 6.
Rolled thread point: very poor location; will not centralize without positive control on the outside diameter of the screws. Header point: only slightly better than (1) if of correct shape. Chamfer point: reasonable to locate. Dog point: reasonable to locate Cone point: very good to locate. Oval point: very good to locate.
Dr. Mohammad Abuhaiba
40
4/9/2013
Assembly assist in the problem of keeping parts in their correct positions during the machine index period, when dynamic forces in the horizontal plane might tend to displace them.
With proper product design using self-locating parts, force due to gravity should be sufficient to hold the part until it is fastened or secured.
Dr. Mohammad Abuhaiba
41
4/9/2013
Assembly from above is not possible: divide assembly into subassemblies. Fig. 5.15: Difficult to position and drive the two cord grip screws from below. The two screws, cord grip, and plug base could be treated as a subassembly dealt with prior to main machine assembly.
Dr. Mohammad Abuhaiba
42
4/9/2013
Figure 5.16a:
Must have features to be suitable for quick and accurate location on the work carrier. If a force were applied at A, part would rotate unless adequate clamping was provided. To ensure that a base part is stable, Arrange that its center of gravity be contained within flat horizontal surfaces.
43
4/9/2013
5.17: Location of base part in the horizontal plane is often achieved by tapered dowel pins mounted in the work carrier to provide guidance
44
4/9/2013
versatile parts feeder is the vibratory bowl feeder. Three basic design principles:
1.
2. 3.
Avoid designing parts that will tangle, nest, or shingle. Make the parts symmetrical. If parts cannot be made symmetrical, avoid slight asymmetry or asymmetry resulting from small or non-geometrical features.
Dr. Mohammad Abuhaiba
45
4/9/2013
46
4/9/2013
add asymmetrical features for the purpose of orienting. The features that require alignment are difficult to utilize in an orienting device, so corresponding external features are deliberately added.
Dr. Mohammad Abuhaiba
47
4/9/2013
FIG 5.20a: a part that would be difficult to handle FIG 5.20b: redesigned part, which could be fed and oriented in a vibratory bowl feeder at a high rate.
48
4/9/2013
that are easy to handle automatically will also be easy to handle manually. Very small parts or complicated shapes formed from thin strips are difficult to handle in an automatic environment.
Manufacture the parts on the assembly machine or to separate them from the strip at the moment of assembly.
Dr. Mohammad Abuhaiba
49
4/9/2013
50
4/9/2013
Avoid projections, holes, or slots that cause tangling with identical parts when placed in bulk in the feeder. Attempt to make the parts symmetrical If symmetry cannot be achieved, exaggerate asymmetrical features to facilitate orienting or, alternatively, provide corresponding asymmetrical features that can be used to orient the parts.
51
4/9/2013
Single-station with one robot arm Single-station with two robot arms Multi station with:
52
4/9/2013
reasons of safety it would usually be necessary to transfer the assembly to a location or fixture outside the working environment of the robot.
Robot place the assembly on a transfer device that carries the assembly to the manual station. After manual operation has been completed, assembly can be returned in a similar manner to within reach of the robot.
Dr. Mohammad Abuhaiba
53
4/9/2013
insertion situations:
2.
Insertion or placement of part by the robot without it being secured immediately. followed by transfer of assembly to an external workstation to carry out the securing operation. A special-purpose work head is engineered to interact directly at the robot work fixture.
54
4/9/2013
2.
3. 4.
Average assembly cycle time Cost per assembly of manual labor involved in:
special-purpose work heads special fixtures special robot tools or grippers special-purpose feeders special magazines, pallets, or part trays
machine supervision loading feeders, magazines, pallets, or part trays performing any manual assembly tasks
Dr. Mohammad Abuhaiba
55
4/9/2013
classification & one data chart for each of the three basic robot assembly systems.
Insertion or other required operations are classified according to difficulty For each classification, and depending on difficulty of operation, relative cost &time factors are given that can be used to estimate equipment costs & assembly times
Dr. Mohammad Abuhaiba
56
4/9/2013
whether part needs a special gripper, clamping temporarily after insertion whether it tends to align itself during insertion
57
4/9/2013
58
4/9/2013
59
4/9/2013
For a typical present-generation robot, this process might take 3 s. Since relative time penalty for gripper or tool change is zero, no additional time penalty is incurred and total operation time is 3 s. A further time penalty must be added when the part to be inserted is not completely oriented by the part presentation device.
move approximately 0.5 m grasp the part Return insert the part when the motion is simple and no insertion problems exist
The robot arm must perform final orientation with the aid of a simple vision system and an additional 2 to 3 s must be added to the operation time.
60
4/9/2013
In addition to cost of robot and special tools or grippers, costs of part presentation must be estimated. In practice there are usually only two choices:
1. 2.
The special-purpose feeder The manually loaded magazine, pallet, or part tray.
Labor costs:
2.
Equipment costs:
material handling (loading parts feeders or magazines) system tending (freeing jams in feeders, handling parts trays, etc.) system changeover costs (changing of work fixture, feeders, and magazines and robot reprogramming)
feeder depreciation depreciation of special fixtures, special tooling, magazines, pallets, or part trays.
Dr. Mohammad Abuhaiba
61
4/9/2013
Bulk material handling costs are negligible compared with cost of manually loading individual parts one-by-one into magazines, pallets, or part trays. 3 significant factors needed to estimate cost of part presentation:
1.
Special-purpose feeders:
2.
cost of a special-purpose feeder, fully tooled and operating on the robot system, is assumed to be a min of $5000. Actual cost of a feeder, for a particular part, can be obtained from the data presented earlier in this chapter. cost of one set of special magazines, pallets, or part trays for one part type is assumed to be $1000. For large parts this figure may considerably underestimate the actual cost and extra allowance should be made.
3.
Loading of magazines:
time needed to hand-load one part into a magazine can be estimated to be part-handling time, obtained from data in Chapter 3, plus 1 s. a typical value of 4 s may be used.
Dr. Mohammad Abuhaiba
62
4/9/2013
3.
Reduce part count Include features such as leads, lips, chamfers, etc., to make parts self-aligning in assembly. Ensure that parts which are not secured immediately on insertion are self-locating in the assembly.
63
4/9/2013
Design parts so that they can all be gripped and inserted using the same robot gripper.
Each change to a special gripper and then back to standard gripper is approximately equal to two assembly operations.
5. 6.
Design products so that they can be assembled in layer fashion from directly above. Avoid the need for reorienting the partial assembly or for manipulating previously assembled parts.
These operations increase robot assembly cycle time without adding value to assembly. If the partial assembly has to be turned to a different resting aspect during assembly process, then this will usually result in increased work fixture cost and the need to use a more expensive 6 DOF robot arm.
Dr. Mohammad Abuhaiba
64
4/9/2013
Design parts that can be easily handled from bulk. Avoid parts that Nest or tangle in bulk Are flexible Have thin or tapered edges that can overlap or "shingle" as they move along a conveyor or feed track Are so delicate or fragile that recirculation in a feeder would cause damage Are sticky or magnetic so that a force comparable to the weight of the part is required for separation Are abrasive and will wear the surfaces of automatic handling systems Are light so that air resistance will create conveying problems
Dr. Mohammad Abuhaiba
65
4/9/2013
If parts are to be presented using automatic feeders, then ensure that they can be oriented using simple tooling. 9. If parts are to be presented using automatic feeders, then ensure that they can be delivered in an orientation from which they can be gripped and inserted without any manipulation.
Dr. Mohammad Abuhaiba
66
4/9/2013
If parts are to be presented in magazines or part trays, then ensure that they have a stable resting aspect from which they can be gripped and inserted without any manipulation by the robot.
If the production conditions are appropriate, the use of robots holds advantages over the use of special purpose work heads and some design rules can be relaxed. For example, a robot can be programmed to acquire parts presented in an arraysuch as in a pallet or part tray which has been loaded manually, thus avoiding many of the problems arising with automatic feeding from bulk.
Dr. Mohammad Abuhaiba