Automated Material Handling System

Material handling is the art and science of moving, storing, protecting, and controlling material

1. AUTOMATED MATERIAL HANDLING PRESENTATION BY M RAKESH 1MS13MCM04 MSRIT

2. Content of presentation Material handling Material handling equipment Automation in Material handling Automated guided vehicles (AGV) Conveyors AGV example Simulation Limitations

3. MATERIAL HANDLING

4. What is material handling Material handling is the art and science of moving, storing, protecting, and controlling material Moving: Required to create time and place utility. The value of having the material at the right time and the right place. Storing : Provides a buffer between operations, facilitates the efficient use of people and machines. Protecting : Includes the packaging, packing against damage and theft. Controlling : Physical Orientation, sequence and space between material.

5. Categories of Material Handling Equipment Material transport equipment - to move materials inside a factory, warehouse, or other facility Storage - to store materials and provide access to those materials when required Unitizing equipment - refers to (1) containers to hold materials , and (2) equipment used to load and package the containers Identification and tracking systems - to identify and keep track of the materials being moved and stored

6. Material Transport Equipment Industrial trucks AGVs Robots Monorails and other rail guided vehicles Conveyors Cranes and hoists

7. Automation in material handling

8. Why use automation in material handling To increase labor productivity To reduce labor cost To mitigate the effects of labor shortages To reduce or remove routine manual and clerical tasks To improve worker safety To improve product quality To reduce manufacturing lead time To accomplish what cannot be done manually

9. Automated guided vehicles

10. Automated guided vehicle What is AGV ? Material handling system that uses independently operated, Self-propelled vehicles, Guided along defined pathways. Increase efficiency and reduce costs by helping to automate a manufacturing facility or warehouse. AGVs are employed in nearly every industry, including, paper, metals, newspaper and general manufacturing. They follow guidance circuits connecting various workstations in the warehouse

11. Components of agv Vehicle Guided path Control unit Computer interface

12. AGV types Driver less trains Pallet trucks Unit load carriers

13. Driver less trains Consists of towing vehicle, which is the AGV that pulls. One or more trailers forming a train. Heavy payloads. Large distances like in a warehouse. With or without intermediate pick-up and drop-off points along its path.

14. Driver less train

15. Pallet trucks

16. Pallet trucks

17. Unit load carrier These are used to move unit loads from one station to another. Light load AGVs, up to 250 kg or less.

18. Unit load carrier

19. Vehicle guidance technology Imbedded guide wires Paint strips (Optical navigation system) Self guided vehicles (Laser triangulation navigation system)

20. Imbedded guide wires Faster and safer More accurate Less costly Simpler and less programming required

21. Paint strips (optical navigation system) Chemical or tape strip is fixed or painted to the floor which contain fluorescent particles that reflect UV light source from vehicle Vehicle has an onboard sensor which allows it to detect the path. Not typically used in plants or warehouses because floor line needs to be cleaned or reapplied as it deteriorates with time. Useful in environment where guide wires in the floor surface is not practical.

22. 3. Self guided (Laser triangulation navigation system) Most popular method of AGV navigation. Operate without continuously defined pathways. Use combination of dead reckoning (capability of a vehicle to follow a given route in the absence of a defined pathway) and beacons located throughout the plant, which can be identified by on board sensors. Continuously verify position by comparing the calculated position with one or more known position

23. Conveyors

24. Conveyor Systems Large family of material transport equipment designed to move materials over fixed paths, usually in large quantities or volumes Non ‑ powered Materials moved by human workers or by gravity Powered Power mechanism for transporting materials is contained in the fixed path, using chains, belts, rollers or other mechanical devices

25. Conveyor Types Roller Skate ‑ wheel Belt In‑ floor towline

26. Roller Conveyor Pathway consists of a series of rollers that are perpendicular to direction of travel Loads must possess a flat bottom to span several rollers Powered rollers rotate to drive the loads forward

27. Skate-Wheel Conveyor Similar in operation to roller conveyor but use skate wheels instead of rollers Lighter weight and unpowered Sometimes built as portable units that can be used for loading and unloading truck trailers in shipping and receiving

28. Belt Conveyor Continuous loop with forward path to move loads Belt is made of reinforced elastomer Support slider or rollers used to support forward loop Two common forms: Flat belt (shown) V-shaped for bulk materials

29. In-Floor Tow-Line Conveyor Four-wheel carts powered by moving chains or cables in trenches in the floor Carts use steel pins (or grippers) to project below floor level and engage the chain (or pulley) for towing This allows the carts to be disengaged from towline for loading and unloading

30. AGV material handling analysis Equations: del cycle time T c = T L + T U + L d / v c + L e / v e (min) available time AT = 60 A T f E (min/ hr / veh ) rate of del per vehicle R dv = AT / T c ( num del/ hr / veh ) work by handling system per hr WL = R f T c (min/ hr ) num of vehicles for workload n c = WL/AT = R f / R dv ( num of veh for work load)

31. Agv example Given the AGV layout in the figure and the info listed, determine the number of vehicles required for a delivery (flow) rate of 40 del/hr. Info: Loading time = 0.75 min Unloading time = 0.5 min Vehicle speed = 50 m/min Availability = 0.95 Traffic factor = 0.9 (from fig) => L d = 110 m ; L e = 80 m E = 1 Solution: Ideal cycle time/del/ veh = T c = 0.75 + 0.5 + 110/50 + 80/50 = 5.05 min Compute workload = WL = (40) (5.05) = 202 min/ hr Available time = AT = (60) (0.95) (0.90) (1.0) = 51.3 min/ hr / veh Num of vehicles = n c = 202/51.3 = 3.94 veh => 4 vehicles!

32. Simulation Simulation is the only method that can accurately predict the system’s performance when using a specific number of specific vehicles in the system Video

33. LIMITATIONS OF AUTOMATED MATERIAL HANDLING SYSTEMS Additional investment Lack of flexibility Vulnerability to downtime whenever there is breakdown Additional maintenance staff and cost Cost of auxiliary equipment. Space and other requirements

34. DISQUS