MEM 10303

ADVANCED AUTOMATION
SYSTEM

ASSIGNMENT 1

STUDENTS NAME

FIRDAUS BIN ALI

STUDENTS MATRIC

GE130066

LECTURERS NAME

DR. DIRMAN HANAFI

DATE OF

10 JUNE 2014

SUBMISSION

No. Question / Answer

Explain error detection and recovery in an automated system.
Error detection and recovery consists of two steps :
i.

Error detection
- The error detection step uses the automated systems available
sensor systems to determine when a deviation or malfunction
has occurred, correctly interpret the sensor signals and classify
the error. Design of the error detection subsystem must begin
with a classification of the possible errors that can occur during
system operation.

ii. Error recovery

- Error recovery is concerned with applying the necessary
corrective action to overcome the error and bring the system
back to normal operation. The problem of designing an error
recovery system focuses on devising appropriate strategies and
procedures that will either correct or compensate for the
variety of errors that can occur in the process.
2

Describe the two reasons why decision-making is required in a

programmed work cycle.
Many automated manufacturing operations require decisions to be made
during the programmed work cycle to cope with variations in the cycle. In many
cases, the variations are routine elements of the cycle, and the corresponding
instructions for dealing with them are incorporated into the regular part
program. These cases include :
i.

Operator interaction
- Although the program of instructions is intended to be carried out
without human interaction, the controller unit may require input data
from a human operator in order to function. For example, in an
automated engraving operation, the operator may have to enter the
alphanumeric characters that are to be engraved on the work unit.
Having entered the characters, the engraving operation is
accomplished automatically by the system.

ii. Different part or product styles processed by the system

- In this instance, the automated system is programmed to perform
different work cycles on different part or product styles. An example
is an industrial robot that performs a series of spot welding
operations on car bodies in a final assembly plant. These plants are
often designed to build different body styles on the same automated
assembly line, such as two-door and four-door sedans. As each car
body enters a given welding station on the line, sensors identify
which style it is, and the robot performs the correct series of welds for
that style.

Explain the three functions of adaptive control.

The three functions of adaptive control are :

i. Identification function, in which the current value of the index of
performance of the system is determined, based on
measurements collected from the process.
ii. Decision function, which consists of deciding what changes
should be made to improve system performance. Possible
decisions include changing one or more input parameters to the
process, altering some of the internal parameters of the
controller, or making other changes.
iii. Modification function, which means implementing the decision.
Whereas decision is a logic function, modification is concerned
with physical changes in the system, such as changing the
system parameters or process inputs to drive the system toward
a more optimal state.
Explain what is the direct digital control (DDC), and why is it no
longer used in industrial process control applications.

DDC is a computer process control system in which certain components

in a conventional analog control system are replaced by the digital
computer, and the regulation of the process is accomplished by the
digital computer on a time-shared, sampled-data basis rather than by
the many individual analog components working in a dedicated
continuous manner. The reason why DDC is no longer used in industrial
process control applications is that todays control computers are
capable of much more than simply imitating the proportion-integralderivative (PID) control mode of analog devices.
Differentiate between an active sensor and a passive sensor.
An active sensor is one that responds to a stimulus without the need for
any external power. A passive sensor is one that requires an external
source of power in order to operate.

Describe the three phases of the analog-to-digital conversion

process.

The three phases of the analog-to-digital conversion process are :

i. Sampling, this consists of converting the continuous signal into a
series of discrete analog signals at periodic intervals.
ii. Quantization, in which each discrete analog signal is assigned to
one of a finite number of previously defined amplitude levels,
which are discrete values of voltage ranging over the full scale of
the ADC.
iii. Encoding, in which the discrete amplitude levels obtained during
quantization are converted into digital code, representing the
amplitude level as a sequence of binary digits.
A tool-chip thermocouple is used to measure the cutting
temperature in a turning operation. The two dissimilar metals
in a tool-chip thermocouple are the tool material and the work
piece metal. During the turning operation, the chip from the
work metal forms a junction with the rake face of the tool to
create the thermocouple at exactly the location where it is
desired to measure temperature: at the interface between the
tool and the chip. A separate calibration procedure must be
performed for each combination of tool material and work
metal. In the combination of interest here, the calibration
curve (inverse transfer function) for a particular grade of
cemented carbide tool when used to turn C1040 steel is the
following: T = 88.1Etc 127, where T = temperature in F, and
Etc = the emf output of the thermocouple in mV.
i.
Revise the temperature equation so that it is in the
form of a transfer function similar to that given in Eq.
(6.3). What is the sensitivity of this tool-chip
thermocouple?
ii.
During a straight turning operation, the emf output
of the thermocouple was measured as 9.25 mV. What
was the corresponding cutting temperature?
i.

T = 88.1 Etc - 127

S = Etc
s=Ts=C+ms
Manipulating the temperature equation into the form of Eq.
(6.3),
T + 127 = 88.1 Etc

Etc = (T + 127) / 88.1 = 0.01135 T + 1.4415

In Eq. (6.3), C = 1.4415 and m = 0.01135, where m =
sensitivity
ii. T = 88.1(9.25) 127 = 815 127 = 688 F
A voltage of 24 V is applied to a DC servomotor whose torque
constant = 0.115 N-m/A and voltage constant = 0.097 V/
(rad/sec). Armature resistance = 1.9 ohms. The motor is
directly coupled to a blower shaft for an industrial process.
i.
What is the stall torque of the motor?
ii.
Determine the operating point of the motor if the
torque-speed characteristic of the blower is given by
the following equation: TL = KL1 + KL2 2, where TL =
load torque, N-m; = angular velocity, rad/sec; KL1 =
0.005 N-m/(rad/sec), and KL2 = 0.00033 N-m/(rad/sec)2.
iii.
What horsepower is being generated by the motor
at the operating point?

i.

Ia = 24/1.9 = 12.63 A

T = 0.115(12.63) = 1.45 N-m

ii.

Load torque (given): TL = 0.005 + 0.00033 2

24 0.097

1.9

Motor torque: T = 0.115

T = 1.452 0.00587

= 0.115(12.63 0.051)
Set T = TL

1.452 0.00587 = 0.005 + 0.00033 2

1.452 0.01087 - 0.000332 = 0
Rearranging, 0.000332 + 0.01087 - 1.452 = 0
Solving the quadratic equation, = -16.47 68.35 = 51.88
rad/sec (negative
value not feasible)
iii.
9

HP = 1.148(51.88) / 745.7 = 0.08 hp

Explain five of the ten features and capabilities of a modern CNC

machine control unit listed in the text.
The five of the ten features and capabilities of a modern CNC machine

control unit are :

i. Storage of more than one part program.
ii. Various forms of program input, such as punched tape, magnetic
tape, floppy diskette, RS-232 communications with external
computers, and manual data input.
iii. Program editing at the machine tool.
iv. Fixed cycles and programming subroutines (macros).
v. Linear and circular interpolation.
An end milling operation is performed on an NC machining
center. The total length of travel is 625 mm along a straight line
path to cut a particular workpiece. Cutting speed = 2.0 m/s and
chip load (feed/tooth) = 0.075 mm. The end milling cutter has
two teeth and its diameter = 15.0 mm. Determine the feed rate
and time to complete the cut.
N=

10

2.0(60)m / min .
= 2546.5 rev/min
15 (10 3 )m / rev

fr = 2546.5 rev/min(2 teeth/rev)(0.075 mm/tooth) = 382.0 mm/min

Tm =

625 15 *
= 1.675 min
382.0

* overtravel allowance = 1.0 tool diameter = 15 mm.

11

A dc servomotor drives the x-axis of a NC milling machine table.

The motor is coupled directly to the table lead screw, whose
pitch = 6.25 mm. An optical encoder is connected to the lead
screw. The optical encoder emits 125 pulses per revolution. To
execute a certain programmed instruction, the table must move
from point (x = 87.5 mm, y = 35.0) to point (x = 25.0 mm, y =
180.0 mm) in a straight-line trajectory at a feed rate = 200
mm/min. Determine (a) the control resolution of the system for
the x-axis, (b) rotational speed of the motor, and (c) frequency
of the pulse train emitted by the optical encoder at the desired
feed rate.
(a)

CR = p/ns = (6.25 mm/rev)/(125 pulse/rev) = 0.05 mm

(b)

Move from (87.5, 35.0) to (25.0, 180.0) at fr = 200 mm/min

x = 25.0 - 87.5 = -62.5, y = 180.0 - 35.0 = 145.0,
Angle A = tan-1(145/-62.5) = 113.32

fr = 200 cos 113.32 = 200(-0.3958) = -79.19 mm/min

N = frx/p = (-79.17 mm/min)/(6.25 mm/rev) = -12.67 rev/min
(c)
12

fp = nsN/60 =

12.67 125
60

= 26.4 Hz

The part in Figure P7.27 is to be drilled on a turret-type drill

press. The part is 15.0 mm thick. There are three drill sizes to
be used: 8 mm, 10 mm, and 12 mm. These drills are to be
specified in the part program by tool turret positions T01, T02,
and T03. All tooling is high speed steel. Cutting speed = 75
mm/min and feed = 0.08 mm/rev. Use the lower left corner of
the part as the origin in the x-y axis system. Write the part
program in the word address format using absolute positioning.
The program style should be similar to Example A7.1. (Note:
Appendix A7 will be required to solve this problem)
At the beginning of the job, the drill point will be positioned at a target
point located at
x = 0, y = 0, and z = + 10. The program begins with the tool positioned
at this target point. Feed is given as 0.08 mm/rev. Rotational speeds for
the three drill diameters are calculated as follows:
For the 8 mm drill, N = 75/(8 x 10-3) = 2984 rev/min
For the 10 mm drill, N = 75/(10 x 10-3) = 2387 rev/min
For the 12 mm drill, N = 75/(12 x 10-3) = 1989 rev/min

NC part program code

Comments

N001 G21 G90 G92 X0 Y0

Z010.0;
N002 G00 X025.0 Y025.0
T01;

Define origin of axes.

Rapid move to first hole location,
select 8 mm drill.
Drill first hole.

N003 G01 G95 Z-20.0 F0.08

S2984
M03;
N004 G01 Z010.0;
N005 G00 X150.0;
N006 G01 G95 Z-20.0 F0.08;
N007 G01 Z010.0;
N008 G00 X175.0;

Retract drill from hole.

Rapid move to second hole
location.
Drill second hole.
Retract drill from hole.
Rapid move to third hole location.
Drill third hole.
Retract drill from hole.

N009 G01 G95 Z-20.0 F0.08;

N010 G01 Z010.0;
N011 G00 X100.0 Y075.0
T02;
N012
N013
N014
N015
N016
N017
T03;

G01
G01
G00
G01
G01
G00

G95 Z-20.0 F0.08;

Z010.0;
X050.0;
G95 Z-20.0 F0.08;
Z010.0;
X050.0 Y075.0

N018 G01 G95 Z-22.0 F0.08;

N019 G01 Z010.0;
N020 G00 X0 Y0 M05;

Rapid move to fourth hole

location, select 10 mm drill.
Drill fourth hole.
Retract drill from hole.
Rapid move to fifth hole location.
Drill fifth hole.
Retract drill from hole.
Rapid move to sixth hole location,
select 12 mm drill.
Drill sixth hole.
Retract drill from hole.
Rapid move to target point, stop
spindle rotation.
End of program, stop machine.

N021 M30;
Explain the five joint types used in robotic arms and wrists.

13

14

The five joint types used in robotic arms and wrists are :
i.
Linear joint (type L joint), in which the relative movement
between the input link and the output link is a translational
sliding motion, with the axes of the two links being parallel.
ii. Orthogonal joint (type O joint), which is also a translational
sliding motion, but the input and output links are perpendicular
to each other during the move.
iii. Rotational joint (type R joint), which provides rotational relative
motion, with the axis of rotation perpendicular to the axes of the
input and output links.
iv. Twisting joint (type T joint), which also involves rotary motion,
but the axis of rotation is parallel to the axes of the two links.
v. Revolving joint (type V joint), in which the axis of the input link is
parallel to the axis of rotation of the joint, and the axis of the
output link is perpendicular to the axis of rotation.
The arc-on time is a measure of efficiency in an arc welding
operation. As indicated in our discussion of arc welding in
Section 8.5.2, typical arc-on times in manual welding range
between 20% and 30%. Suppose that a certain welding
operation is currently performed using a welder and a fitter.
Production requirements are steady at 500 units per week. The
fitter's job is to load the component parts into the fixture and
clamp them in position for the welder. The welder then welds
the components in two passes, stopping to reload the welding
rod between the two passes. Some time is also lost each cycle
for repositioning the welding rod on the work. The fitter's and

welder's activities are done sequentially, with times for the

various elements as follows:
repositioning the welding rod on the work. The fitter's and
welder's activities are done sequentially, with times for the
various elements as follows:
Se
q.
1
2
3
4
5
6

Worker and activity

Time

Fitter: load and clamp

parts
Welder: weld first
pass
Welder: reload weld
rod
Welder: weld second
pass
Welder: repositioning
time
Delay time between
work cycles

4.2
min.
2.5
min.
1.8
min.
2.4
min.
2.0
min.
1.1
min.

Because of fatigue, the welder must take a 20 minute rest at

mid-morning and mid-afternoon, and a 40 minute lunch break
around noon. The fitter joins the welder in these rest breaks.
The nominal time of the work shift is eight hours, but the last 20
minutes of the shift is non- productive time for clean-up at each
workstation. A proposal has been made to install a robot
welding cell to perform the operation. The cell would be set up
with two fixtures, so that the robot could be welding one job
(the set of parts to be welded) while the fitter is unloading the
previous job and loading the next job. In this way, the welding
robot and the human fitter could be working simultaneously
rather than sequentially. Also, a continuous wire feed would be
used rather than individual welding rods. It has been estimated
that the continuous wire feed must be changed only once every
40 parts and the lost time will be 20 minutes to make the wire
change. The times for the various activities in the regular work
cycle are as follows:
Se
q.
1
2

Fitter and robot

activities
Fitter: Load and
clamp parts
Robot: Weld complete

Times
4.2
min.
4.0
min.

Repositioning time

Delay time between

work cycles

1.0
min
0.3
min.

A 10 minute break would be taken by the fitter in the morning

and another in the afternoon, and 40 minutes would be taken
for lunch. Clean-up time at the end of the shift is 20 minutes. In
your calculations, assume that the proportion uptime of the
robot will be 98%. Determine the following:
(a)
arc-on times (expressed as a percent, using the eight
hour shift as the base) for the manual welding operation
and the robot welding station, and
(b)
hourly production rate on average throughout the
eight-hour shift for the manual welding operation and the
robot welding station.
(a)

Manual cycle arc-on time:

Cycle time Tc = 4.2 + 2.5 + 1.8 + 2.4 + 2.0 + 1.1 = 14.0 min
Time arc is on = 2.5 + 2.4 = 4.9 min

Out of 8 hours, time available = 480 - 20 - 20 - 40 - 20 = 380

min/shift.
Number of cycles in 380 min = 380/14 = 27.143 cycles/shift
Time arc is on during shift = 27.143(4.9) = 133 min/shift
Arc-on time = 133/480 = 0.277 = 27.7%0
Robot cycle arc-on time:
Cycle time Tc = Max{(4.2 + .3), (5.0 + .3)} = 5.3 min/cycle
Time arc is on each cycle = 4.0 min
Out of 8 hours, time available = 480 - 10 - 10 - 40 - 20 = 400
min/shift.
Number of cycles in 400 min = 400/5.3 = 75.472 cycles/shift
Time arc is on during shift = 75.472(4.0) = 301.9 min/shift

Arc-on time = 301.9/480 = 0.629 = 62.9%

(b)
Manual cycle production rate Rp = (27.14 units/shift)/(8 hr) =
3.393 units/hr
Robot cycle production rate Rp = (75.47 units/shift)/(8 hr) = 9.434
units/hr

The revolving joint (type V) of an industrial robot has a range of

240 rotation. The mechanical errors in the joint and the
input/output links can be described by a normal distribution
with its mean at any given addressable point, and a standard
deviation of 0.25. Determine the number of storage bits
required in the controller memory so that the accuracy of the
joint is as close as possible to, but less than, its repeatability.
Use six standard deviations as the measure of repeatability.
Repeatability = 6 = 6(0.25) = 1.5 and Accuracy = 0.5 SR = 0.5
CR + 3
Find bit storage capacity n so that 0.5 CR + 3 = approx 6
15

Set (0.5 CR + 3) - 6 = 0
0.5 CR = 3
CR = 6 = 1.5
2n = (240)/(1.5) = 160
n ln(2) = ln(160),
n = 8 bits

0.69315 n = 5.07517,

n = 7.3 -->

CR = (240)/(28-1) = 240/255 = 0.9412

Accuracy = 0.5(.9412) + 3(0.25) = 1.221 which is repeatability
= 1.5
16

Explain the advantages of using a PLC rather than conventional

relays, timers, counters, and other hard-wired control

components.
The advantages of using PLC rather than conventional relays, timers,
counters, and other hard-wired control components are :
i. Programming the PLC is easier than wiring the relay control
panel.
ii. PLC can be reprogrammed, whereas conventional controls must
be rewired and are often scrapped instead.
iii. PLCs take less floor space than relay control panels.
iv. Reliability is greater, and maintenance is easier.
v. PLC can be connected to computer systems more easily than
relays.
vi. PLCs can perform a greater variety of control functions than can
relay controls.

17

In the fluid filling operation of Example 9.6, suppose a sensor

(e.g., a submerged float switch) is used to determine whether
the contents of the tank have been evacuated, rather than rely
on timer T2 to empty the tank. (a) Construct the ladder logic
diagram for this revised system.
(a) Ladder logic diagram. Assume FS2 (new float switch) is open when
tank is empty. FS1 is the tank full float switch.

X1

FS1

C1

C1
S1

C1
FS1

FS2

C2

C2
T1

C2
T1

120 s

S2

What features distinguish self-guided vehicles from

conventional AGVs?

18

19

Conventional AGVs use either imbedded guide wires in the floor or paint
strips on the floor surface as the guidance technology, whereas selfguided vehicles use a combination of dead reckoning, which refers to the
capability of the vehicle to follow a given route by counting its own
wheel rotations along a specified trajectory, and beacons located
throughout the facility that serve to verify the vehicles location in the
facility.

A planned fleet of forklift trucks has an average travel distance

per delivery = 500 ft loaded and an average empty travel
distance = 350 ft. The fleet must make a total of 60 deliveries
per hour. Load and unload times are each 0.5 min and the speed
of the vehicles = 300 ft/min. The traffic factor for the system =

0.85. Availability = 0.95, and worker efficiency = 90%.

Determine (a) ideal cycle time per delivery, (b) the resulting
average number of deliveries per hour that a forklift truck can
make, and (c) how many trucks are required to accomplish the
60 deliveries per hour.
(a)
(b)

Tc = 0.5 + 500/300 + 0.5 + 350/300 = 3.83 min/delivery

Ideally, Rdv =

60
383
.

= 15.66 deliveries/hr per truck

Accounting for traffic factor, availability, and worker efficiency,

Rdv = 15.66(0.85)(0.95)(0.90) = 11.39 deliveries/hr per truck
(c)
20

nc = 60/11.39 = 5.27 6 forklift trucks

The from-to Chart in the table below indicates the number of

loads moved per 8-hour day (above the slash) and the distances
in ft (below the slash) between departments in a particular
factory. Fork lift trucks are used to transport materials between
departments. They move at an average speed = 275 ft/min
(loaded) and 350 ft/min (empty). Load handling time per
delivery is 1.5 min, and anticipated traffic factor = 0.9. Assume
reliability = 1.0 and worker efficiency = 110%. Use an
availability factor = 95% and worker efficiency = 110%.
Determine the number of trucks required under each of the
following assumptions: (a) the trucks never travel empty; and
(b) the trucks travel empty a distance equal to their loaded
distance.
To Dept.
A B
C
D
E
From Dept 62/50 51/45 45/35 0
A
0
0
0
B
0
0
22/40 0
0
C
0
0
0
76/20
0
D
0
0
0
65/15
0
E
0
0
0
0
(a)

62(500) 51( 450) 45( 350) 22( 400) 76( 200) 65(150)
= 322.27 ft
62 51 45 22 76 65
322.27
0

Using Le = 0, Tc = 1.5 +
= 2.67 min/delivery cycle
275
275

Ld =

Rdv =

60( 0.95)( 0.90)(110

. )
2.672

= 21.12 deliveries/hr per vehicle

Rf = 321/8 = 40.125 deliveries/hr

nc = 40.125/21.12 = 1.90 Use nc = 2 vehicles.
(b)

Ld = 322.27 ft, same as before.

Using Le = Ld = 322.26 ft, Tc = 1.5 +

322.27 322.27

275
275

= 3.59

min/delivery cycle
Rdv =

60( 0.95)( 0.90)(110

. )
359
.

= 15.71 deliveries/hr per vehicle

nc = 40.125/15.71 = 2.55 Use nc = 3 vehicles.

21

A roller conveyor moves tote pans in one direction at 150 ft/min

between a load station and an unload station, a distance of 200
ft. With one worker, the time to load parts into a tote pan at the
load station is 3 sec per part. Each tote pan holds 8 parts. In
addition, it takes 9 sec to load a tote pan onto the conveyor.
Determine (a) spacing between tote pan centers flowing in the
conveyor system and (b) flow rate of parts on the conveyor
system. (c) Consider the effect of the unit load principle.
Suppose the tote pans were smaller and could hold only one
part rather than 8. Determine the flow rate in this case if it
takes 7 sec to load a tote pan onto the conveyor (instead of 9
sec for the larger tote pan), and it takes the same 3 sec to load
the part into the tote pan.
(a)

TL = 9 + 3(8) = 33 sec = 0.55 min/tote pan

sp = (150 ft/min)(0.55 min/tote pan) = 82.5 ft/tote pan

(b)
(c)

Rf =

n p vc
sc

(8pc / totepan)(150ft / min.)

82.5ft / totepan

= 14.55 pc/min = 872.7 pc/hr.

TL = 7 + 3(1) = 10 sec = 0.167 min/tote pan

sp = (150 ft/min)(0.167 min/tote pan) = 25 ft/tote pan
Rf =

(1pc / totepan)(150ft / min.)

25ft / totepan

= 6.0 pc/min = 360 pc/hr.

A recirculating conveyor has a total length of 200 m and a speed

of 50 m/min. Spacing of part carriers = 5 m. Each carrier holds
two parts. Time needed to load a part carrier = 0.15 min.
Unloading time is the same. The required loading and unloading
rates are 6 parts per min. Evaluate the conveyor system design
with respect to the three Kwo principles.
Speed rule: Lower limit:
22

( 2parts / carrier )(50m / min.)

5m / carrier

n p vc
sc

Max{RL, Ru}

= 20 parts/min Max{6, 6} (OK)

vc

Upper limit: s Min{ T , T }

c
L
u
50m / min.
5m / carrier

= 10 carrier/min Min{

1
1
,
}
015
. 015
.

= Min{6.67, 6.67} (not

OK)
23

Name and briefly describe four of the six measures used to

assess the performance of a storage system?
The four of the six performance measures used to assess the
performance of a storage system are :
i. Storage capacity, which is defined and measured either as the
total volumetric space available or as the total number of storage
compartments in the system available for items or loads.
ii. Storage density, defined as the volumetric space available for
actual storage relative to the total volumetric space in the
storage facility.
iii. Accessibility, which refers to the capability to access any desired
item or load stored in the system.
iv. System throughput, defined as the hourly rate at which the
storage system receives and puts loads into storage and/or
retrieves and delivers loads to the output station.

24

A unit load AS/RS is being designed to store 1000 pallet loads in

a distribution center located next to the factory. Pallet
dimensions are: x = 1000 mm, y = 1200 mm; and the maximum
height of a unit load = 1300 mm. The following is specified: (1)
the AS/RS will consist of two aisles with one S/R machine per
aisle, (2) length of the structure should be approximately five
times its height, and (3) the rack structure will be built 500 mm
above floor level. Using the allowances a = 150 mm, b = 200
mm, and c = 250 mm, determine the width, length, and height
of the AS/RS rack structure.
Assumption: the L/H ratio does not include the 500 mm
foundation.
1000 pallets/ 2 aisles = 500 pallets/aisle. 500 pallets/aisle 250
pallets per aisle side.
Thus ny nz = 250

Eq. (1)

L = ny (y + b) = ny (1200 + 200) = 1400 ny (ny in mm) = 1.4 ny (ny

in m)
H = nz (z + c) = nz (1300 + 250) = 1550 nz (nz in mm) = 1.55 nz
(nz in m)
Given the specification L/H = 5
1.40n y
1.55nz

nz

= 0.9032ny / nz = 5

0.9032 ny = 5.0 nz

ny = 5.536

Eq. (2)

Combining Eqs. (1) and (2): ny nz = (5.536 nz) nz = 250

nz2 = 250/5.536 = 45.161

nz = 6.72 use nz = 7

ny = 250/nz = 250/7 = 35.71 use nz = 36

W = 3(1000 + 150) = 3450 mm = 3.45 m/aisle.
With 2 aisles, W = 2(3.45) = 6.9 m
L = 1.4 ny = 1.4(36) = 50.4 m
10.85 m

H = 1.55 nz = 1.55(7) =

Given that the rack structure is built 500 mm above floor level,
H = 10.85 + 0.5 = 11.35 m
Check on specifications: Capacity = 2 x 2 x 36 x 7 = 1008 pallets.
L/H = 50.4/10.85 = 4.645
An automated storage/retrieval system installed in a warehouse
has five aisles. The storage racks in each aisle are 30 ft high and
150 ft long. The S/R machine for each aisle travels at a
horizontal speed of 350 ft/min and a vertical speed of 60 ft/min.
The pick and deposit time = 0.25 min. Assume that the number
of single command cycles per hour is equal to the number of
dual command cycles per hour and that the system operates at
75% utilization. Determine the throughput rate (loads
moved/hour) of the AS/RS.
0.5(150) 0.5( 30)
,

350
60

Tcs = 2 Max

25

+ 2(0.25) = 1.00 min/cycle

0.75(150) 0.75( 30)

,

350
60

Tcd = 2 Max

+ 4(0.5) = 1.75 min/cycle

1.00 Rcs + 1.75 Rcd = 60(0.75) = 45 min

Given Rcs = Rcd, 1.00 Rcd + 1.75 Rcd = 2.75 Rcd = 45.0
Rcd = 16.36 cycles/hr
Rcs = Rcd = 16.36 cycles/hr.
Rt = Rcs + 2Rcd = 16.36 + 2(16.36) = 49.1 transactions/hr.
With 5 aisles, Rt = 5(49.1) = 245.5 transactions/hr
26

Your company is seeking proposals for an automated

storage/retrieval system that will have a throughput rate of 300
storage/retrieval transactions/hour during the one 8-hour shift

per day. The request for proposal indicates that the number of
single command cycles is expected to be four times the number
of dual command cycles. The first proposal received is from a
vendor who specifies the following: ten aisles, each aisle 150 ft
long and 50 ft high; horizontal and vertical speeds of the S/R
machine = 200 ft/min and 66.67 ft/min, respectively; and pick
and deposit time = 0.3 min. As the responsible engineer for the
project, you must analyze the proposal and make
recommendations accordingly. One of the difficulties you see in
the proposed AS/RS is the large number of S/R machines that
would be required - one for each of the 10 aisles. This makes the
proposed system very expensive. Your recommendation is to
reduce the number of aisles from 10 to 6 and to select a S/R
machine with horizontal and vertical speeds of 300 ft/min and
100 ft/min, respectively. Although each high speed S/R machine
is slightly more expensive than the slower model, reducing the
number of machines from 10 to 6 will significantly reduce total
cost. Also, fewer aisles will reduce the cost of the rack structure
even though each aisle will be somewhat larger since total
storage capacity must remain the same. The problem is that
throughput rate will be adversely affected by the larger rack
system. (a) Determine the throughput rate of the proposed 10aisle AS/RS and calculate its utilization relative to the specified
300 transactions/hour. (b) Determine the length and height of a
six-aisle AS/RS whose storage capacity would be the same as
the proposed 10-aisle system. (c) Determine the throughput
rate of the 6-aisle AS/RS and calculate its utilization relative to
the specified 300 transactions/hour. (d) Given the dilemma now
confronting you, what other alternatives would you analyze and
recommendations would you make to improve the design of the
system?
(a)

0.5(150)

200

Tcs = 2

0.75(150)

200

Tcd = 2

+ 2(0.3) = 1.35 min/cycle

+ 4(0.3) = 2.325 min/cycle

1.35 Rcs + 2.325 Rcd = 60

Given Rcs = 4 Rcd, 1.35(4 Rcd) + 2.325 Rcd = 7.725 Rcd = 60
Rcd = 7.767 cycles/hr.
cycles/hr

Rcs = 4(7.767) = 31.068

Rt = Rcs + 2 Rcd = 31.068 + 2(7.767) = 46.6 transactions/hr per

aisle
With 10 aisles, Rt = 10(46.6) = 466 transactions/hr
Given the specification Rt = 300 transactions/hr, U = 300/466 =
0.644 = 64.4%
This utilization is somewhat lower than desirable.
(b)
Assume capacity is a function of (# aisles) L H. Let subscript 1
represent the 10
aisle AS/RS.
Let subscript 2 represent the 6 aisle AS/RS. Then,
6 L2 H2 = 10 L1 H1 = 10(150)(50) = 75,000
To maintain square-in-time proportions for the 6-aisle system,
L2/H2 = L1/H1 = 150/50 = 3.0
Thus, L2 = 3 H2. Thus, 6(3 H2)H2 = 18(H2)2 = 75,000
(H2)2 = 75,000/18 = 4166.67
H2 = 64.55 ft and L2 = 3 H2 = 3(64.55) = 193.65 ft.
(c)

0.5(193.65)

300

Tcs = 2

+ 2(0.3) = 1.246 min/cycle

0.75(193.65)

+ 4(0.3) = 2.168 min/cycle

Tcd = 2

300
1.246 Rcs + 2.168 Rcd = 60

Given Rcs = 4 Rcd, 1.246(4 Rcd ) + 2.168 Rcd = 7.152 Rcd = 60

Rcd = 8.389 cycles/hr.
Rcs = 4(8.389) = 33.556 cycles/hr.
Rt = Rcs + 2 Rcd = 33.556 + 2(8.389) = 50.334 transactions/hr
per aisle.
With 6 aisles, Rt = 6(50.334) = 302.0 transactions/hr.
Given the specification of 300 transactions/hr for the AS/RS,

U = 300/302 = 0.993 = 99.3%

This utilization is much higher than desirable.
(d)

Other alternatives and recommendations:

i. Investigate the possibility of an AS/RS with 7 or 8 aisles. The
throughput performance should be between the two
alternatives analyzed above.
ii. Improve scheduling of the AS/RS to achieve Rcs = Rcd rather
than Rcs = 4 Rcd as given in problem statement.
iii. Operate a 9-hour shift rather than an 8-hour shift. Although
hourly throughput will not be improved, the extra hour of
AS/RS operation will improve daily throughput rates.

A single carousel storage system has an oval rail loop that is =

30 ft long and 3 ft wide. Sixty carriers are equally spaced
around the oval. Suspended from each carrier are 5 bins. Each
bin has a volumetric capacity = 0.75 ft3. Carousel speed = 100
ft/min. Average pick and deposit time for a retrieval = 20 sec.
Determine (a) volumetric capacity of the storage system and (b)
hourly retrieval rate of the storage system.
(a)

Total number of bins = nc nb = 60(5) = 300 bins

Total volume capacity = 300(0.75) = 225 ft3

27

(b)

C = 2(L - W) + W = 2(30 - 3) + 3 = 63.42 ft

C

63.42

Tc = 4v + Tpd = 4(100) + 20/60 = 0.4916 min

c
Rt = 60/0.4916 = 122.1 transaction/hr
28

What are the three principal components in automatic

identification technologies?
The three principal components in automatic identification technologies
are :
i. Data encoder.
The data are translated into a machine-readable code. A label
or tag containing the encoded data is attached to the item that is
to be later identified.
ii. Machine reader or scanner.

This device reads the encoded data, converting them to

alternative form, usually an electrical analog signal.
iii. Data decoder.
This component transforms the electrical signal into digital data
and finally back into the original alphanumeric characters.
What are the relative advantages of RFID over bar codes?

29

The relative advantages of RFID over bar codes are :

i. Read-write capability.
ii. Large storage capacity.
iii. Line-of sight reading is not required.
iv. Not susceptible to dirt or scratching that would destroy the label.
v. The tags can be reused.