Dr SS Chauhan 2019

UNIT- II Manufacturing Automation

Automated flow line

Introduction:-

 It consists of several machines or workstations which are linked together by work

handling devices that transfer parts between the stations is called automated flow line.

The objectives of use of flow line automation are:-

1) To reduce Labor cost
2) To increase the production rate
3) To reduce work in progress
4) To minimize distance moved between operations
5) To achieve specialization of operations.
6) To achieve integration of operations.

Types of automated flow line :-

 It is basically divided into two types depending upon the forms in which the work flow
can take place as.

1) In – Line type :-

 It consists sequence workstationsing more –or- less straight line arrangement.

 The flow of work can take a few 900 turns either for work piece orientation.
 Factory layout limitation or other reason is also responsible for straight line configuration.

Diagram :

2) Rotary types :-

 In this type work parts are indexed around a circular table or dial.
 The workstations are stationary and usually located around the periphery of the dial.
 The parts on the table are positioned at processing station for the operation.
Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

Diagram:

Various methods of work part transports :-

Method of work part transport :

1) Continuous transfer
2) Intermission or synchronous transfer
3) Asynchronous transfer

1) Continuous transfer :-

 In this method the work part are moved continuously at constant speed
 This requires the work heads to move during processing in order to maintain continuous
registration with the work part.

2) Intermittent transfer :-

 In this method the work pieces are transported with an intermittent or discontinuous
motion..
 The work stations are fixed in position and parts are moved between stations then
registration.
 All work parts are transported at the same time and for this reason it called synchronous
transfer system.

3) Asynchronous transfer :-

 In this system each work parts to move to next stations when processing at the current
station has been completed.
 In it each parts moves in dependently of other parts.
Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019
 Asynchronous transfer systems move flexible than the other two system.
 It is used where there are one or more manually operated stations and cycle time variation
station.
Different type of transfer mechanisms:

1. Linear transfer mechanism

2. Rotary transfer mechanism

1. Linear transfer mechanism:

a) Walking beam systems

b) Powered roller conveyor system

c) Chain-drive conveyor system

) Walking beam systems:

 In it the work-parts are lifted up from their workstation locations by a transfer bar and
moved one position ahead, to the next station.

 The transfer bar then lowers the pans into nests which position them more accurately for
processing

b) Powered roller conveyor system:

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

 This type of system is used in general stock handling systems as well as in automated
flow lines.

 The conveyor can be used to move pans or pallets possessing flat riding surfaces.

 The rollers can be powered by either of two mechanisms. The first is a belt drive, in
which a flat moving belt beneath the rollers provides the rotation of the rollers by
friction.

c) Chain-drive conveyor system:

 In it either a chain or a flexible steel belt is used to transport the work carriers.

 The chain is driven by pulleys in either an "over-and under“ configuration, in which the
pulleys turn about a horizontal axis, or an" around-the-corner" configuration, in which the
pulleys rotate about a vertical axis.

 It can be used for continuous, intermittent, or asynchronous movement of work parts. In

the asynchronous motion,

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

2. Rotary transfer mechanisms

a) Rack and pinion

b) Ratchet and pawl

c) Geneva mechanism

d) CAM Mechanisms

a) Rack and pinion:

 This mechanism is simple but is not considered especially suited to the high-speed
operation often associated with indexing machines.
 A piston to drive the rack, which causes the pinion gear and attached indexing table to
rotate, A clutch or other device is used to provide rotation in the desired direction.

b) Ratchet and pawl:

 A ratchet is a device that allows linear or rotary motion in only one direction, while
preventing motion in the opposite direction.

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019
 Ratchets consist of a gearwheel and a pivoting spring loaded finger called a pawl that
engages the teeth. the spring for forcing it back with a 'click' into the depression before
the next tooth.

 When the teeth are moving in the other direction, the angle of the pawl causes it to catch
against a tooth and stop further motion in that direction

c) Geneva mechanism:

 The Geneva mechanism uses a continuously rotating driver to index the table

 If the driven member has six slots for a six-station dial indexing machine, each turn of the
driver will cause the table to advance one-sixth of a turn.

d) CAM Mechanisms:

 Cam mechanism provide probably the most accurate and reliable method of indexing the
dial.

 They are in widespread use in industry despite the fact that the cost is relatively high
compared to alternative mechanisms.

 The cam can be designed to give a variety of velocity and dwell characteristics.

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

Elements of the parts delivery system:

 The hardware system that delivers components to the work head in an automated
assembly system typically consists of the following elements:

Hopper:
 This is the container into which the components are loaded at the workstation.

 The components are usually loaded into the hopper in bulk. This means that the parts are
randomly oriented initially in the hopper.

Parts feeder:

 This is a mechanism that removes the components from the hopper one at a time for
delivery to the assembly work head.

 The hopper and parts feeder are often combined into one operating mechanism.

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

Selector and/or orienteer:

 These elements of the delivery system establish the proper orientation of the components
for the assembly work head.

 A selector is a device that acts as a filter, permitting only parts that are in the correct
orientation to pass through. Components that are not properly oriented are rejected back
into the hopper.

 An orientor is a device that allows properly oriented pans to pass through but provides a
reorientation of components that are not properly oriented initially

Feed track:
 A feed track is used to transfer the components from the hopper and parts feeder to the
location of the assembly work head, maintaining proper orientation of the parts during the
transfer.

Two general categories of feed tracks:

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019
1. Gravity: The force of gravity is used to deliver the components to the work head.

2. Powered: vibratory action, air pressure, or other means to force the parts to travel along
the feed track toward the assembly work head.

Different Type of Chutes:

1. Straight slide chutes

2. Roller chutes

3. Spiral chutes

4. Spiral roller chutes

5. A vertical open core chute

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019
6. A zig-zag or curvilinear chute

7. A ladder chute of retarding type

8. Powered chutes

9.Chain controlled chute

Control strategies to control the operation of automatic transfer system as follows:

1. Sequence control
Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

2. Safety monitoring

3. Quality monitoring

a) Instantaneous control

b) Memory control
1. Sequence control:

 The purpose of this function is to coordinate the sequence of actions of the transfer
system and its workstations.

 The various activities of the automated flow line must be carried out with split-second
timing and accuracy.

2. Safety monitoring:

 This function ensures that the transfer system does not operate in an unsafe or hazardous
condition.

 Sensing devices may be added to make certain that the cutting tool status is satisfactory to
continue to process the work part in the case of a machining-type transfer line.

 Other checks might include monitoring certain critical steps in the sequence control
function to make sure that these steps have all been performed and in the correct order.

3. Quality monitoring:

 The third control function is to monitor certain quality attributes of the work part

 Its purpose is to identify and possibly reject defective work parts and assemblies.

 The inspection devices required to perform quality monitoring are sometimes

incorporated into existing processing stations or separate stations are included

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

There are alternative control strategies

a) Instantaneous control

b) Memory control.

a) Instantaneous control:

 This mode of control stops the operation of the flow line immediately when a malfunction
is detected.

 It is relatively simple, inexpensive, and trouble-free.

 Diagnostic features are often added to the system to aid in identifying the location and
cause of the trouble to the operator so that repairs can be quickly made.

 stopping the machine results in loss of production from the entire line, and this is the
system's biggest drawback.

b) Memory control:

 In contrast to instantaneous control, the memory system is designed to keep the machine
operating.

 It works to control quality and/or protect the machine by preventing subsequent stations
from processing the particular work part and by segregating the part as defective at the
end of the line.

 The flow line will continue to operate, with the consequence that bad parts will continue
to be produced.
Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019
Assembly involves the joining together of two or more separate parts to form a new entity
is called assembly or subassembly.

the assembly of the components can be divided into three major categories.

1. Mechanical Fastening: Screws, bolts, nuts etc. Rivets, crimping and other methods Press
fits Snap fits –temporary interface of the two parts C-ring. Sewing and stitching –for soft, thin
material.

2. Joining Methods: Welding, brazing and soldering

3. Adhesive Bonding: Thermoplastic, thermosetting (chemical reaction

There are various methods used in industry to accomplish the assembly processes. Major
methods can be classified:

1. Manual Single-Station Assembly

2. Manual Assembly Lines

3. Automated Assembly System

1. Manual Single-Station Assembly:

 It consist of a single workplace to accomplish the product or some major subassembly of

the product.

 It used on a product that is complex and produced in small quantities, one or more
workers depending on the size of the product and the production rate.

Such as machine tools, industrial equipment, aircraft, ships and complex consumer products
(appliances, car,...)
2. Manual Assembly Lines

 Consist of multiple workstations in which the assembly work is accomplished as the

product (subassembly) is passed from station to station along the line.

 At each workstation one or more human workers perform a portion of the total assembly
work on the product, by adding one or more components to the existing subassembly.

 Manual Assembly Lines Are used in high-production situations where the work to be

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019
performed can be divided into small tasks and tasks assigned to the workstations on the
line.

 Key advantage of using manual assembly line is specialization of labour –By giving each
worker a limited set of tasks to do repeatedly.

Automated assembly system refers to the use of mechanized and automated devices to
perform various functions like handling and fastening with following strategies

1. Reduce the amount of assembly required

2. Use modular design

3. Reduce no of fasteners required

4. Reduce the no of component to handle

5. Limiting the no. of unnecessary motion

1. Reduce the amount of assembly required:

It implies the combining the functions of same part that previously accomplished by
separate components in product.
2. Use modular design:
It reduces the no. of assembly stations for assembling the complicated assembly products.
3. Reduce no of fasteners required:
It reduces the no of fastener parts to simplify the design
4. Reduce the no of component to handle:
It reduces the no of component that requires for assembly to handle
5. Limiting the no. of unnecessary motions:
Its reduces the unnecessary motion of work part and assembly machines
Types of automated Assembly flow line:

1. Continuous Transfer System

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

2. Synchronous transfer system

3. Asynchronous transfer system

4. Stationary base part system

Classification on basis of Physical configuration:

1. Dial- type assembly machines

2. Inline assembly machines

3. Carousel system

1. Dial- type assembly machines:

 The base part are indexed around a circular table or dial. The workstations are stationary
and usually located around the outside periphery of the dial.

2. Inline assembly machines:

 The in-line configuration assembly system consists of a sequence of workstations in a

more-or-less straight-line

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

3. Carousel assembly system:

 It represents a hybrid between the circular flow of work provided by the dial assembly
machine and straight work flow of the in-line

Assembly line balancing:

 It means that arranging the individual processing and assembly task at the work stations
so that time required on each station on each station is same

 It is the concept in which we have to integrate the all work station and balance the time
required in such a way that the flow of work part should be smooth

Following are the benefit of line balancing:

1. Allocating Balance work load

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019

2. Increase production rate

3. Reduce idle time of machine

4. Reduce wastage

5. Reduces material handling

Different constraints for assembly line balancing:

1. Precedence Constraint

2. Zoning Constraint

3. Position Constraint

1. Precedence Constraint:

 It is refer to as „technological sequencing requirement‟

 It causes the delay in work progress and line become unbalance

For example: A threaded hole must be dilled before tapped A nut an be turned and tighten after washer

must placed

Zoning Constraint:

 It is concern with restriction of arrangement of the stations according to the sequence of

work

 It may be positive or negative

 Positive zoning constraint means that certain work element should be placed nearer to
each other

 Negative zoning constraint indicates that work elements might interfere with one another

 It is created due lesser space available

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Dr SS Chauhan 2019
Position Constraint:

 It is concern with physical arrangement of recourses according to the sequence of the

work process
 It creates waiting of work part and causes the delay in production
 It would be encountered in the assembly of large products such as automobiles or major
appliances

Reference: Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.