Automated Material Handling and Storage Systems

Transcription

1 Automated Material Handling and Storage Systems How do we define automated material handling and storage systems? How do they work? What is automated guided vehicle systems?

2 Automated Material Handling and Storage Systems Automated guided vehicle systems == driverless vehicles Flexible manufacturing systems requires Machine/machining flexibility Storage and retrieval flexibility

3 Automated Material Handling and Storage Systems Material handling systems: Handling, storing and controlling of materials Materials are: Raw materials Work in progress Sub-assemblies Finished assemblies The goal in material handling is: Right amount of material Delivered safely To required location At the right time At a minimum possible cost Depends on the business, material handling cost might take up to 10 to 80% of total cost

4 Automated Material Handling and Storage Systems Principles of material handling Orientation principle: study and understand the system for further enhancements Planning principle: Establish a plan to include basic requirements, options etc. System Principles: Integrate the handling and storage activities Unit load principle: Handle products as large units as possible Space utilization: Use the cubical space efficiently Standardization: Standardize handling and methods and equipments if possible Ergonomic principles: Do not ignore human factor Energy principle: Energy consumptions should be justified economically Ecology principle: Minimize the effects to environment Flexibility: Use methods and equipment can easily be modified Simplification: Eliminate, reduce or combine unnecessary movements/equipments Gravity principles: Take advantage of gravity when you can Safety: Use safe equipment and methods

5 Automated Material Handling and Storage Systems Principles of material handling Computerization principles: Consider computerization systems as much as you can System flow principle: Integrate data flow with the physical material flow in handling and storage Layout: Prepare an operational sequence and equipment layout for all viable system solutions then select the alternative system that best integrates efficiency and effectiveness Cost: Justify the system economically Maintenance: Schedule regular maintenance that has minimal effect to work delays Obsolescence principles: Develop systematic approaches for replacement of the equipments

6 Automated Material Handling and Storage Systems Material handling equipments Industrial Trucks Hand trucks Two-wheeled, Fourwheeled, Hand lift, Forklift Powered Trucks Forklifts, Tractors, Trailer trains, Crane trucks, Side loaders Conveyers Monorails Hoists Cranes Automated guided vehicle systems Automated storage and retrieval systems Belt, Chute, Roller, Wheel, slat, chain, bucket, trolley, tow screw, vibrating, and pneumatic Bridge, Gantry, Tower, Stacker Unit load carriers, towing, pallet trucks, fork trucks and assembly lines Unit load, mini-load, person-on-board, deep lane, storage carousel systems

7 Automated Material Handling and Storage Systems Automated Guided Vehicle Systems Battery-powered, driverless vehicle system Destination, path selection, positioning capabilities can be programmed They are used to transport material from various loading locations to unloading locations These systems includes intelligent collision avoidance capabilities Communication with the vehicle sustained by Wires installed on the floor Radio signals

8 Automated Material Handling and Storage Systems Components of automated guided vehicle systems (AGVS) The vehicle: transports the material The guide path: guide The control unit: monitors, evaluate the feedback etc The computer interface: interacts with other computers/systems Mainframe Host computer Automated storage and retrieval system Flexible manufacturing systems etc

9 Automated Material Handling and Storage Systems The type of AGVSs Towing vehicle Unit load transporter Pallet trucks Forklift trucks Light-load transporters Assembly-line vehicles

10 Automated Material Handling and Storage Systems Unit Load Transporters Towline Conveyor Systems Power and Free Overhead conveyor systems

11 Automated Material Handling and Storage Systems Forklift and Pallet Trucks Outrigger Type Pallet AGV Reach Type Forklift AGV Forklift

12 Automated Material Handling and Storage Systems Conveyor Deck type AGV Lift Deck type AGV Custom made AGVS

13 Automated Material Handling and Towing vehicles Storage Systems First kind and it is still popular It is a automated guided towing tractor Efficient to use for long distances with high volumes Distance is > 1000 ft Capacity range might be 8000 to 50,000 lb Speed is 264 ft/min Turning radius is 7 ft

14 Automated Material Handling and Unit load transporters Storage Systems Carries only one individual material (container etc) on the board Deck might have powered or non-powered roller, belt etc Can lift Might have multiple compartments Used in warehousing and distribution systems Guide length path is short Volumes is high Travels about 176 ft/min, carries 500 to 1000 lb. Turning radius is 2 ft

15 Automated Material Handling and Storage Systems Pallet trucks Lift, maneuver and transport palletized loads Pick up and deliver in floor level 1000 to 2000 lb capacity 264 ft/min speed 7 ft turning radius They can be loaded/unloaded Automatically Manually

16 Automated Material Handling and Storage Systems Forklift trucks Relatively new AGVS Pick up/ drop off palletized materials Both at the floor level or Higher levels within the forklifts reach One of the most expansive AGVS types Mostly used in fully automated systems Can handle 1000 to 2000 ld load 264 ft/min speed with 7 ft turning radius

17 Automated Material Handling and Storage Systems Assembly-line vehicles Main part is carried on the trucks among the different work stations Most of the machining and assembly operations being done while the material is still on the board When the assembly is completed in one station, operator releases the vehicle, so it can go to the next assembly station Such systems is efficient in measuring the efficiency of assembly job Speed range is 100 to 2000 ft/min Load capacity is between 500 to 2000 lb 2 to 7 ft turning radius

18 Automated Material Handling and Storage Systems AGVS guidance systems The goal is to keep the vehicle in pre-designed path The main advantage comparison to fixed systems is the path can be changed easily Guidance systems are: Wire-guided systems: energized wire is located in the floor. The antennas of receives the information from embedded wires. Optical guidance systems: colorless florescent particles are painted on the path. Vehicle finds its path sensing these signs on the floor Inertial guidance systems: vehicle follows a preprogrammed path. A sonar system is used to detect obstacles around the vehicle Infrared guidance system: infrared light reflectors located on the roof of the building is traced by the vehicle and used to calculate position and directions. Laser guidance systems: laser beams are used to compute location and direction Teaching type guidance systems: neural networks concepts is used.

19 Automated Material Handling and Storage Systems AGVS control systems Computer control systems Most efficient but most expensive and complex controller Remote dispatch control system Human interactions takes place using remote controls Human factor is not directly involved in performing the task Only destination and material information are sent Manual control systems Operator loads the vehicles Inputs the location and path information on the board Vehicle is routed by itself Unloading is being done by humans as well

20 Automated Material Handling and Storage Systems Advantages of AGVS over other material handling systems Flexibility Higher reliability Higher operating savings and lower investment Unobstructed movements Easy interfacing with other systems

21 Automated Material Handling and Storage Systems The Intelligent Assembly System (IAS) vehicles are either passive-inductive or optically guided. The AGV typically moves from one workstation to another and production / assembly operations are undertaken upon its build platform. The kit of parts required during assembly can also be carried by the IAS. Intelligent Assembly System with fixed height build platform. Intelligent Assembly System with adjustable lift table

22 Automated Storage and Retrieval Systems Imagine your plant without cluttered aisles, excess inventory, lost or damaged products, inaccurate records, endless searching, climbing, bending and frustration. Imagine a highly profitable operation that adds value and decreases expense.

23 Automated Storage and Retrieval Systems AS/RS Functions of storage systems For: Raw materials, purchased parts, work in progress, Finished products,pallets, fixtures, tools, spare parts, Rework and scraps, office supplies AS/RS performs following functionalities Receiving, identifying and sorting Dispatching to storage, placing in storage and storage Retrieving from storage Order accumulation, packing, shipping and record keeping

24 Automated Storage and Retrieval Systems AS/RS AS/RS is a combination of equipment and controls Handles, stores and retrieves materials With precision, accuracy and speed Under a defined degree of automation

25 Automated Storage and Retrieval Systems AS/RS components AS/RS A series of storage aisles having storage racks Storage and retrieval machines-normally one machine per aisle One or more pick up and delivery stations An optimal AS/RS uses all 3 dimensions available

26 Automated Storage and Retrieval Systems AS/RS Examples AS/RS General AS/RS systems HIGH-SPEED, HIGH- DENSITY STORAGE FOR BOXES AND TOTES

27 Automated Storage and Retrieval Systems AS/RS Why companies need AS/RS Space efficient (Cubical space usage) Increase storage capacity, can reach far corners Improve inventory control system Fast response time to locate, store and retrieve Better inventory management therefore less shortages and excess inventory Reduce labor cost Improve security Flexible and can be used with other computerized systems (AGVS and FMS) An important factor in JIT concept

28 Automated Storage and Retrieval Systems AS/RS Types of AS/RS: Unit load systems: Controls parts in pallets or containers over 500 lb Mini-load systems: Designed to handle small loads Person-on-board: A person rides with the Storage/Retrieval machine Deep-lane: Items are stored in multi-deep storage with up to 10 items per row Automated item retrieval system: Items stored individual and can be automatically released