KABALE UNIVERSITY

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Email: [email protected]
[email protected]

FACULTY OF ENGINEERING, TECHNOLOGY, APPLIED DESIGN & FINE ART

DEPARTMENT OF MECHANICAL ENGINEERING

BME 4101 MATERIALS HANDLING ASSIGNMENT TWO

BY
S/N NAME REGISTRATION NUMBER

1 KHAUKHA EMMANUEL 2018/KME/0064/G/F

2 MUTAMBI ARNOLD 2018/KME/0062/G/F

BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

ROBOTIC MATERIAL HANDLING

Robotic material handling and tending systems are commonplace in the industrial sector.
Material handling refers to robotic arms moving production parts, typically on or off a
conveyor belt or to hold a part in place for production.
Machine tending is similar, but more specific, referring to a robotic arm to load and unload a
stationary production machine.
Both robotic material handling and machine tending systems are in high demand as they reliably
deliver productivity gains in a wide range of applications.
THE BENEFITS OF ROBOTIC MATERIAL HANDLING AND MACHINE TENDING
SYSTEMS
 Much of the benefits of these systems comes from drastically increased uptime. Manual
material handling and tending is slow, inconsistent and less productive. Robots can work
around the clock, besides small periods of downtime for maintenance, with high levels of
consistency.
 In addition to increased uptime, robots are typically much faster than manual processes.
Decreasing the cycle time of a production part impacts productivity in a positive way.
The benefit of shorter cycle times compounds over time and are extremely valuable to
manufacturers.
 Robotic material handling and tending produce real results
 In theory and in practice, robotic material handling and tending solutions deliver major
productivity gains. Recently, an agricultural manufacturer was experiencing production
bottlenecks for pinion gear drive train components. They needed an automation solution
to replace manual loading/unloading for lathe and part washing processes.
After a robotic material handling and tending system was designed and installed, the
manufacturer was able to cut cycle time to under 60 seconds per part for 16 different
parts while maintaining high levels of uptime. The robotic material handling and tending
system had a transformative impact on their operations.
 Robotic material handling and tending systems offer many benefits for manufacturers.
When designed and implemented properly, they can overcome costly pain points in
production, just as in the example above.
There’s more to the story, however, in the example of the agricultural manufacturer achieving
exceptional cycle times and uptime. To understand how robotic automation improved their entire
production process, read the whole robotic material handling and tending case study.
MATERIALS HANDLING AT THE WORKPLACE
Materials handling at the workplace may be defined as the handling of materials after it has been
delivered for use at the workplace and before it is again picked up by some conventional
handling process and equipment, to be removed to the next operation.

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Materials handling at the workplace has long been neglected, possibly because they appeared to
be a minor part of the overall system and does not always involve large or expensive materials
handling equipment. However, studies have proved beyond any doubt that in most of the
manufacturing operations, the handling of individual jobs take more time than that for processing
the jobs.
Various activities at the workplace
The various activities at the workplace may be grouped under following different phases:
1. Preparatory: Handling of materials adjacent to the workplace consists of
o Bringing materials closer to or onto the workplace or machine.
o Unwrapping, unpacking, untangling, cleaning materials.
o Sorting or separating materials, re-arranging, restacking etc.

2. Feeding: Placing or directing materials closer to work place or point of-use.

3. Positioning: Orienting materials in exact location, placing into fixture, jig or machine.
4. Manipulating: Handling of materials during actual manufacturing operation.
5. Removing: Taking material out of workplace consisting of
 Taking out of jig, fixture etc.
 Keeping it at a position for moving to next workplace.
6. Transporting: Moving materials out of the workplace to the next workplace. This is generally
traditional/conventional materials handling.
The materials handling at workplace is not only monotonous, fatiguing but involves personal
safety of the operators. Moreover, time that can be saved from this handling time, directly
increases productivity of the manufacturing process. It is in this context industrial robots have
been increasingly used in materials handling at the workplace.

ROBOTS AND THEIR CLASSIFICATION

Robotic Institute of America (RIA) has defined a robot as: ‘‘A robot is a reprogrammable,
multifunctional manipulator designed to move material, parts, tools, or specialized devices
through variable programmed motions for the performance of a variety of task’s’’
 Spot welding: robots perform spot welding very accurately, with recurring operations
and are widely used in the automotive industry. They can extend to places and positions
which normally would be difficult for humans.

 Loading and unloading: robots are extensively being utilized for the loading and
unloading of machine parts in industries thus substituting human labor and other
mechanical methods. Robots possess the benefit of duplicating the designed tasks,
performing accurately and being compatible with the nearby environment.

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BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

 Arc welding: The surroundings of arc welding are unsafe for the fitness of human
beings, and achievement of quality welds is difficult by manual operations. Therefore,
since smooth movements provide superior welds, the use of robots for such operations is
growing very rapidly. Utilization of industrial robots for arc welding is economical, and
the welds are of an excellent quality.

 Repetitive work cycle: A second characteristic that tends to promote the use of robotics
is a repetitive work cycle. If the sequence of elements in the cycle is the same, and the
elements consist of relatively simple motions, a robot is usually capable of performing
the work cycle with greater consistency and repeatability than a human worker. Greater
consistency and repeatability are usually manifested a higher product quality than can he
achieved in a manual operation

 Painting: It is a difficult and unhealthy operation, where hazardous fumes are released
that are extremely dangerous for human beings, and in which a danger of explosion exists
in the areas of operation. Furthermore, manual painting results are not consistent due to
unpredictable speed of movement of the components involved in this process.

 Investment Casting: Investment casting requires duplication, accuracy, and uniformity

in production, all of which can be achieved with employment of industrial robots.

 Integration of Parts: The integration of parts in various sub systems of production is an

important application where robots can function more efficiently and with extra speed,
thus assisting in the increase of production rate. Presently, robots are being used for
tightening of bolts and nuts, placing of components in circuit boards, and a variety of
other similar tasks. Logic devices are used for identification and rectification of defects or
inconsistencies
 Hazardous work environment for humans: When the work environment is unsafe,
unhealthful, hazardous, uncomfortable, or otherwise unpleasant for humans, there is
reason to consider an industrial robot for the work.
MAJOR COMPONENTS OF A ROBOT
Four common components of a robot are:
1) The manipulator: The manipulator is the body of a robot, made of a collection of
mechanical linkages connected at joints to form an open-loop kinematic chain. The
manipulator is capable of movement in various directions and does the work of the robot.
It can conveniently be compared with the arm of a human. At the joint, the individual link
can either rotate (revolute joint) or make translatory motion (prismatic joint) by means of
electric motors (servo or stepper) and hydraulic or pneumatic cylinders. Through a
combination of motions of the joint, the manipulator can achieve different desired

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BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

positioning and orientation. A manipulator can have many joints up to 8, and a robot
manipulator with six joints (six degrees of freedom) is considered quite versatile for most
the robot tasks. A manipulator generally has three structural elements: the arm, the wrist
and the hand (end effector). The end effector is individually designed to grip individual
tools or jobs, and simulates palm of a human arm.

2) Sensory devices: These elements inform the robot controller about status of the
manipulator. These sensors may be;
(i) Non visual
(ii) Visual.
Nonvisual sensors provide information about position, velocity, force etc. Connected with
manipulator motion. The visual sensors are used for tracking an object, its recognition and
grasping. These are comparable to senses like kinesis, touch, vision etc.
3) The controller: Robot controllers generally perform three function which are:
 Initiation and termination of motion of different joints at desired sequence
and specific points.
 Storage of positional and sequence data in memory.
 Interfacing the robot with outside world through the sensors. Generally, a
microcomputer or minicomputer acts as the robot controller, and acts as the
brain of the robot.

4) The power conversion unit: This component provides necessary power for movement
of the manipulator for doing work. It can be electrical power source with amplifiers to
feed servo motors or compressor or hydraulic power pack. With proper programming of
the robot controller, the manipulator can be made to undergo a desired sequence of
motions of linkages of the manipulator, repeatedly and accurately and thus make the
robot to perform its desired task. Another advantage of a robot is that by changing the
programme, the manipulator can instantly change from one set of task to another, thus
making it a flexible and versatile equipment.

CLASSIFICATION OF ROBOTIC MANIPULATORS

Manipulators are generally classified in two ways, one based on mechanical configuration and
the other based on method of controlling individual joints.
Classification by configuration (coordinate system)
Cylindrical coordinate robots: When a horizontal arm (boom) is mounted on a vertical column
which is mounted on a rotating base. The projected length of arm is adjustable. The workspace of
the arm tip is a hollow cylindrical space as shown

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BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

Spherical coordinate robots: A manipulator resembling a tank turret, is called a spherical

coordinate device. The workspace is frustrum of a hollow sphere.

Fig 1 Shows Robots with their workspaces, (a) cylindrical, (b) spherical

Cartesian coordinate robots: This is a robot which can have independent translatory motion in
three Cartesian coordinates. The wrist and end effector may have additional rotational motions.
This robot may be a cantilevered type or a gantry style.

Fig 2 Show Cantilevered Cartesian coordinate robot

Jointed arm (also called articulated) robots: There are three distinct types of jointed arm robots:
 pure spherical,
 parallelogram jointed
 jointed cylindrical.

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BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

Pure spherical: This is the most common of the jointed configuration. All the links are pivoted
and hence can move in a rotary manner. It consists of a jointed arm consisting of upper portion
and lower portion (forearm). Forearm is connected to a base. The base can also rotate. The major
advantage of this design is that it is possible to reach close to the base of the robot over any
obstacle within its workspace. The workspace (or work envelope) is approximately spherical.
Puma (made by Unimation, Inc.), Cincinnati Milacron T3, Fanuc Japan are having this
configuration.

Fig 3 shows Pure spherical robot Fanuc six axis robot with controller at Mechanical Engineering
Department, NITTTR, Kolkata
Parallelogram jointed: Here the single rigid upper arm is replaced by a multiple closedlinkage
parallelogram arrangement, actuated by a hydraulic cylinder. This robot can carry larger load
than a pure spherical one, but has limited workspace. Robots of this type are made by ASEA,
Hitachi, Cincinnati Milacron, Toshiba etc.

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BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

Fig 4 Shows Parallelogram jointed robot and its workspace (dimensions in mm, not to scale)
Jointed cylindrical: In this configuration, the single arm of a cylindrical coordinate robot is
replaced by an articulated open kinematic chain. These robots are precise and fast working but
have a limited vertical reach. This configuration robot is made by Hirata, Reis, GCA and United
States Robots.
ROBOT APPLICATIONS.
Material handling by robots are of two categories;
1. Material transfer
2. Machine loading and unloading.
Both these two categories are applicable to different phases of work place handling like feeding,
positioning, manipulating and removing.
i. Material transfer: The task of moving a part from one location to another within the
workplace
is one of the common applications for robots (pick-and-place operations). A slightly more
complex operation of the same category is palletisation or depalletization. Robot deposits
to or takes from a new position and height of the pallet in each subsequent operation.
After the pallet/box is filled up or emptied, the same may be moved by the same or by a
larger robot.
ii. Machine loading and/or unloading: Robot centred machine cell is most common
example of this category of application. The work cell consists of one or more production
machines, the robot and some material handling system for delivering parts into or out of
the work cell. A mobile robot may also be employed for this operation, though less
common. Some of the processes in which robotic loading/unloading is often used are:
 Die-casting—unloading of parts and dipping them in water bath for cooling. The
robot also unloads parts from the die casting machines.
 Plastic moulding—unloading of injection moulded parts.
 Machining—loading raw blank and unloading finished product. The end effector
should be designed to handle sizes and shapes of both raw material and finished
product.
 Forging—loading raw stock to furnace, unload hot material from furnace and
transfer to forging press and hold and manipulate during forging.
 Press working—loading individual blanks into press. However, when coiled strip is
fed, no robot is needed in the continuous pressing operation.
 Heat treatment—loading and unloading of parts from a furnaces.
ROBOTS IN ASSEMBLY
Assembly robots are used for lean industrial processes and have expanded production
capabilities in the manufacturing world. An assembly line robot can dramatically increase
production speed and consistency. They also save workers from tedious and dull assembly line

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BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

jobs. End of arm tooling can be customized for each assembly robot to cater to the
manufacturing requirements. Additional options, like robotic vision, can also be incorporated to
improve efficiency and accuracy of part orientation or sorting identifiers
Applications
Applications for robotic assembly include automotive components, like pumps, motors and
gearboxes. Computers and consumer electronics are another excellent area, as are medical
devices and household appliances. Assembly robots are ideal for tasks demanding speed and
precision like applying sealants and adhesives. Not only can they put together parts that are too
small or intricate for a human, but they work quickly and accurately without tiring or making
mistakes. They are good in applications where cleanliness is paramount, like pharmaceuticals
and medical device assembly, and they aren’t prone to debilitating injuries, like carpal tunnel
syndrome, that come with repetitive work.
ADVANTAGES
Increased efficiency
Industrial robots can complete certain tasks faster and more efficiently than humans as they are
designed and built to perform them with higher accuracy. This combined with the fact they are
used to automate processes which previously might have taken significantly more time and
resource results in the use of industrial robots to increase the efficiency of production lines.
Improved quality
Given their higher levels of accuracy, industrial robots can be used to produce higher quality
products which result in the reduction of time required for quality control and ensures that
standards of quality are adhered to.

Improved working environment

Some tasks are deemed as too dangerous or laborious and repetitive for humans to carry out and
so instead robots can perform these tasks instead. Working conditions, therefore, can be vastly
improved as well as the safety within factories and production plants by introducing industrial
robots.

Increased profitability
The results of introducing industrial robots can only ensure higher profitability levels with lower
cost per product as by
increasing the efficiency of your process, reducing the resource and time required to complete it
whilst also achieving higher quality products, introducing industrial robots save money in the
long run.

Longer working hours

As human breaks in the working day are required, distractions happen and attention spans slow.
Whereas robots can work 24/7 and keep working at 100% efficiency. On average a 40% increase
in the output of a production line occurs when one key person is replaced by a robot who

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BME 4101 MATERIALS HANDLING ASSIGNMENT TWO (PRESENTATION)

operates the same working hours, simply because of stamina. Also, robots don’t take
holidays or have unexpected absences.
DISADVANTAGES
Capital cost
Implementing industrial robots can incur a high capital cost however, they do prove highly
effective and bring a positive ROI. This is why, prior to decisions being made, we always
recommend consideration is given to both the investment required and also the ROI you expect
to achieve in implementing robots. Often the advice we give is to take out asset finance and the
ROI of the robot more than pays for the interest on the asset finance.

Expertise
The initial set up of industrial robots requires a lot of training and expertise as with any other
type of technology, this is because they are excellent for performing many tasks. Good
automation companies provide a support package of their expertise which is an extremely
important factor. However, to minimize reliance on automation companies, training can be given
to engineers to allow them to program the robots – though the assistance of experienced
automation companies is still required for the original integration of the robot.

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