Module-Iv Module-Iv: PE-402 PE-402

11/9/2021
MODULE-IV
PE-402
AUTOMATION IN
MANUFACTURING
Dr. Binay Kumar, Department of Production and Industrial Engineering, BIT Mesra, Ranchi
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Module 4: Assembly Automation [8]

Assembly Automation: Automatic Assembly Transfer
Systems, Transfer mechanism, buffer storage and
control functions for transfer devices, feeding
mechanism definition and concept, AGV, AS/RS
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Dr. Binay Kumar, Department of Production
and Industrial Engineering, BIT Mesra,
Ranchi 1
11/9/2021
Automated Production Lines

• High production of parts requiring multiple processing operations
• Fixed automation
• Applications:
– Transfer lines used for machining
– Robotic spot welding lines in automotive final assembly
– Sheet metal stamping
– Electroplating of metals
Where to Use Automated Production Lines

• High product demand
– Requires large production quantities
• Stable product design
– Difficult to change the sequence and content of processing operations
once the line is built
• Long product life
– At least several years
• Multiple operations required on product
– The different operations are assigned to different workstations in the line
©2008 Pearson Education, Inc. Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition,
by Mikell P. Groover.
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Benefits of Automated Production Lines

• Low direct labor content
• Low product cost
• High production rates
• Production lead time and work-in-process are minimized
• Factory floor space is minimized
Automated Production Line – Defined

Fixed-routing manufacturing system that consists of multiple workstations
linked together by a material handling system to transfer parts from one station
to the next
• Slowest workstation sets the pace of the line
• Workpart transfer:
– Palletized transfer line
• Uses pallet fixtures to hold and move workparts between stations
– Free transfer line
• Part geometry allows transfer without pallet fixtures
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General configuration of an automated production line consisting of n automated workstations that perform
processing operations
System Configurations
• In-line - straight line arrangement of workstations
• Segmented in-line – two or more straight line segments, usually perpendicular to each
other
• Rotary indexing machine (e.g., dial indexing machine)
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Segmented In-Line Configurations
L-shaped layout
U-shaped layout
Rectangular configuration
©2008 Pearson Education, Inc. Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition,
9 by
Mikell P. Groover.
Two Machining Transfer Lines
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Rotary Indexing Machine
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Transfer Mechanisms
In the rotary configuration, the work parts are attached to fixtures around the periphery of a circular work table
and the table is indexed (rotated in fixed angular amounts) to present the parts to workstations for processing.
The worktable is often referred to as a dial, and the equipment is called a dial indexing machine, or simply,
indexing machine. Compared with the in-line and segmented in-line configurations, rotary indexing systems
are commonly limited to smaller work parts and fewer workstations; and they cannot readily accommodate
buffer storage capacity. On the positive side, the rotary system usually involves a less expensive piece of
equipment and typically requires less floor space.
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Figure : Two types of transfer mechanisms: (a) In-line and (b) Rotary.
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Work part Transfer Mechanisms

• Linear transfer systems:
– Continuous motion – not common for automated systems
– Synchronous motion – intermittent motion, all parts move simultaneously
– Asynchronous motion – intermittent motion, parts move independently
• Rotary indexing mechanisms:
– Geneva mechanism
– Others
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Side view of chain or steel belt-driven conveyor (over and under type) for linear transfer using work carriers
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Walking Beam Transfer System
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Geneva Mechanism with Six Slots
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Geneva Mechanism with Six Slots
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Cam Mechanism to Drive Dial Indexing Table
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Drum type transfer machine

• It is similar in concept but different in configuration to the rotary table type machine
• In these machines, the work fixtures are fastened to the outer periphery of a drum
• The arrangement enables the workpieces to transfer around a circular path to work
stations placed radially at equal distances
• The main limitation of this method is, the machining is horizontally from sides only and
the lower station always remains idle as it is practically not possible to arrange a
machining head to operate in the limited space under the drum
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Storage Buffers in Production Lines

A location in the sequence of workstations where parts can be collected and
temporarily stored before proceeding to subsequent downstream stations
• Reasons for using storage buffers:
– To reduce effect of station breakdowns
– To provide a bank of parts to supply the line
– To provide a place to put the output of the line
– To allow curing time or other required delay
– To smooth cycle time variations
– To store parts between stages with different production rates
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Storage Buffer
Storage buffer between two stages of a production line
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Control Functions in an Automated Production Line

• Sequence control
– To coordinate the sequence of actions of the transfer system and
workstations
• Safety monitoring
– To avoid hazardous operation for workers and equipment
• Quality control
– To detect and possibly reject defective work units produced on the line
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Applications of Automated Production Lines

• Transfer lines for machining
– Synchronous or asynchronous workpart transport
– Transport with or without pallet fixtures, depending on part geometry
– Various monitoring and control features available
• Rotary transfer machines for machining
– Variations include center column machine and trunnion machine
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System Design Considerations

• Building block approach: machine tool companies specialize in transfer lines
and indexing machines
– User contracts for custom-engineered line
– Standard modules such as workheads, feed units, transfer mechanisms, and
bases
– Called a unitized production line
• Link line: uses standard machine tools connected by specialized handling
system
• Specialized processes often engineered by the user company
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Standard Feed Units used with In-Line or Rotary Transfer Machines
(a) Horizontal feed drive unit, (b) angular feed drive unit, and (c) vertical column feed drive unit
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Automated Assembly
The use of mechanized and automated devices to perform the various assembly
tasks in an assembly line or cell.
• Fixed automation usually
– Most automated assembly systems are designed to perform a fixed
sequence of assembly steps on a specific product that is produced in very
large quantities.
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Application of Automated Assembly

Alarm clocks Light bulbs
Ball bearings Locks
Ball point pens Mechanical pencils
Cigarette lighters PCB assemblies
Door mechanisms Small electric motors
Gear boxes Wrist watches
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System Configurations
1. In-line assembly machine
2. Dial indexing machine
3. Carousel assembly system
4. Single-station assembly cell
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In-Line Assembly Machine

A series of automatic workstations located along and in-line transfer system
• Either synchronous or asynchronous work transfer used
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Dial Indexing Machine

Base parts are loaded onto fixtures or nests attached to a circular dial table, and
components are added at workstations located around the periphery of the dial
as it indexes from station to station.
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Dial Indexing Machine
Dial indexing assembly machine (Bodine Corp.)

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Carousel Assembly System

A hybrid between circular work flow of dial indexing machine and straight work flow of
in-line system
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Single-Station Assembly Cell

Assembly operations are performed on a base part at a single location
• A robot is sometimes used as the assembly machine
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Difference of assembly system

• Multi-station assembly machine or line
– Faster cycle rate
– High production quantities
– More operations possible
– More components per assembly
• Single-station assembly cell
– Suited to robotic assembly
– Intended for lower production quantities
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Parts Delivery at Workstations

• Typical parts delivery system at a workstation consists of the following
hardware components:
1. Hopper - container for parts
2. Parts feeder - removes parts from hopper
3. Selector and/or orientor - to assure part is in proper orientation for
assembly at workhead
4. Feed track - moves parts to assembly workhead
5. Escapement and placement device - removes parts from feed track and
places them at station
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THANK YOU
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11/9/2021

Module 4: Assembly Automation [8]

Automated Production Lines

Where to Use Automated Production Lines

Benefits of Automated Production Lines

Automated Production Line – Defined

Segmented In-Line Configurations

Two Machining Transfer Lines

Rotary Indexing Machine

Work part Transfer Mechanisms

Walking Beam Transfer System

Geneva Mechanism with Six Slots

Geneva Mechanism with Six Slots

Cam Mechanism to Drive Dial Indexing Table

Drum type transfer machine

Storage Buffers in Production Lines

Storage buffer between two stages of a production line

Control Functions in an Automated Production Line

Applications of Automated Production Lines

System Design Considerations

Standard Feed Units used with In-Line or Rotary Transfer Machines

Application of Automated Assembly

In-Line Assembly Machine

Dial Indexing Machine

Dial Indexing Machine

Dial indexing assembly machine (Bodine Corp.)

Carousel Assembly System

Single-Station Assembly Cell

Difference of assembly system

Parts Delivery at Workstations

Dr. Binay Kumar, Department of Production

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