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Automation and Robotics
Miltiadis A
...
Boboulos
Automation and Robotics
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Boboulos & bookboon
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3
Automation and Robotics
Contents
Contents
Abstract
7
1
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
8
1
...
2
8
Developing a dolly removal strategy
10
1
...
5
Involvement of the dolly in the coil assembly operation, motor unit
assembly and dust cap cone
14
1
...
4
Feeder design
25
1
...
1 Introduction
42
2
...
sylvania
...
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Automation and Robotics
Contents
2
...
4
Feeder design
59
2
...
1 Introduction
83
3
...
3
The performers
87
3
...
5
Market & production line
89
3
...
7 Machines
3
...
9
...
10 Conclusions
References
360°
thinking
...
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...
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© Deloitte & Touche LLP and affiliated entities
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deloitte
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© Deloitte & Touche LLP and affiliated entities
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1
Enviromental model
100
4
...
1 Introduction
118
5
...
3
Closed loop control system
120
5
...
5 Conlcusion
126
References
126
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Automation and Robotics
Abstract
Abstract
In this book for the optimisation of assembly conveyor lines we are dealing with series part production
featured by a medium complexity degree and a medium number of individual components and assembly
technique alternatives
...
They still use hand labour more or less automated
...
This
usually widely involves industrial robots and handlers
...
Recently, latest assembly techniques for simpler or more complicated products in engineering, device
manufacturing and electronics involve computer-aided automated assembly means in Flexible Automated
Production Lines or other types of automated conveyor lines, which provide full automation and human
labour replacement
...
Practically, this means no large investment in the
modernisation and expansion of the production capacity and the product’s nomenclature
...
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Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
1
Automation & Robotics: An
Optimized Loudspeaker
Assembly for a Mechanized
Serial Production Line
1
...
The purpose is usually to reduce and replace as much as possible labour
intensive and dangerous assembly operations with automated ones
...
Many current production processes involve computerised assembly using robots or
flexible automated production systems where manual assembly operations are completely replaced by
machines [1]
...
This usually
widely involves industrial robots and handlers
...
Recently, latest assembly techniques for simpler or more
complicated products in engineering, device manufacturing and electronics involve computer-aided
automated assembly means in Flexible Automated Production Lines or other types of automated conveyor
lines, which provide full automation and human labour replacement [1]
...
Regardless of the wide variety of
loudspeaker types and dimensions, this product is of average and even low complexity: it comprises 15
to 30 component parts
...
This data is used to calculate current assembly and
conveyor parameters and eventually, assembly and conveyor parameters after the modifications and
improvements in organisation
...
com
8
Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Figure 1 Initial organisation diagram
The work stations are positioned along the conveyor and various types and loudspeakers variants can be
manufactured either in parallel time or consecutively in time (consecutive manufacturing of individual
variants, individual production lots are run consecutively) [2]
...
Therefore, it is equipped
with fewer and simpler attachments and assembly equipment
...
In the alternative “b” individual workstations included in the assembly unit (section) are supposed to be
highly specialised and equipped with the necessary assembly means required to manufacture all variants
of loudspeaker types
...
From Figure 1 it is understood that the alternative “a” is not applicable in our case since if only a single
product type is to be manufactured at a time, assembly units designed for other products will be idle
this being unacceptable
...
com
9
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Automation and Robotics
Assembly line output & conveyor operation
For the initial arrangement, 120 000/month – 6 variants (product types), the time required to manufacture
a single loudspeaker assembly (T1a ) will be:
(1)
T1a =
TM
, where
NM
TM – operational time for 1 month [hours], and
NM – the number of products manufactured per month
...
4
120000
200
120000
0
...
T1a = 0
...
3600 = 6[sec/ 1unit ]
Thus, with the initial line rate, six (6) seconds will be required to assemble a single loudspeaker unit
...
4
...
2
Developing a dolly removal strategy
1
...
1
Loudspeaker arrangement
In general, every loudspeaker features the type of design illustrated in Figure 2
...
3
Membrane – conical shape
1
Composites
4
Packing – dust cap
1
Composites
5
Oscillator – corrugated, centring
1
Composites
6
Collar – corrugated, together with the conical membrane
1
Composites
7
Voice coil oscillator
1
Constituent assembly with coil
8
Electrical wiring – terminals and cable wiring for the coil
1
Electrical assembly made
up of several components
9
Bonding and connecting elements (materials)
1
Glues, etc
...
38–0
...
com
10
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Automation and Robotics
δ
δ1
Figure 2
1
...
2 Operation
The electrical pulse transmitted via 8 to the coil 7 causes vertical oscillations as a result of the interaction
between the electrical magnetic field of the coil and permanent magnets of 2
...
38 ÷ 0
...
1
...
3
Description of assembly and characteristic features
The body 1, which is usually made of stamped steel or aluminium sheet is connected to the rest of the
component parts by means of glue applied on its contact surfaces (only rarely by means of welding or
riveting)
...
For the purpose of all said above, sub-assembly 2 (motor unit) could be pre-assembled separately and
then in turn assembled with the body 1
...
The last parts to be assembled should be the
cone 3 and the cover 4 and the wiring from the coil 7 to the terminals 8 and point a located on the cone
3
...
If the cone 3 and the corrugated oscillator 5 are assembled at the same time, there is a risk of changing
the gap d after the dolly is removed because of the relatively heavier weight and higher “toughness” of
the cone 3 when it has not been manufactured sufficiently precisely
...
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...
2
...
2
...
1 The motor unit assembly
This comprises 4 separate parts usually round in shape (Fig
...
D, d, d1 are positioned concentric with
each other and d1 – d = 2d2, where d2 is sufficient to insert the coil of the voice oscillator (item 7 in
Figure 2) and leave a radial gap of d = 0
...
7
...
1 – central stud; 2
...
3 – top plate; 2
...
Component 2
...
4 and 2
...
2 and 2
...
The diameter D also serves to
centre the sub-assembly in the body 1 (Figure 2) during the assembly operation
...
2
...
2 Voice coil and suspension
It comprises 2 parts (Figure 4):
Oscillator, corrugated, centring (5 – Figure 4);
6
...
d3 < d1 (Figure 3) and d2 < d (Figure 3)
d2 – d = d and d = 0
...
7[mm]
...
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...
2
...
3 Cone and dust cap (Figure 2)
This comprises 2 parts and is glued to 1 and to the voice coil and suspension with the glue applied to
d4 (Figure 4)
...
com/Mitas
www
...
com
Ma
Month 16
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...
2
...
35 ÷ 0
...
35 ÷ 0
...
Figure 5 1
...
Loudspeaker body (chassis); 3
...
Oscillator, corrugated, centering; 5
...
1
...
1 Voice coil – constituent part of Item 4
...
The bottom section of the loudspeaker comprising the magnetic motor assembly is not shown
in this arrangement but this is replaced by a simulation attachment, item 1
...
1, centred along D to item 2
...
Figure 5 shows the operation of gluing the oscillator 4 to 2, applying the glue on the flange M and pressing
on it using the force F, with the dolly, item 3, carefully pre-inserted in d2 of the coil and then or at the
same time installed over d
...
1
are also assembled (glued) on N
...
1
...
6
Recommendation for mechanisation of the manual operation for the Dolly removal
A considerable number of methods and schematic diagrams for Dolly removal are possible using the
movement of the conveyor in the area of this specific assembly work station
...
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...
Conveyor; 2
...
Product (loudspeaker); 4
...
Horizontal arm; 6
...
Guide;
8
...
Gear drive; 10
...
Spring – vertical; 12
...
Actuating lever; 14
...
Pedal; S – Spherical hinges; D – Gap between rests item 12 – pitch
...
2
...
1 Structure of the device and mode of operation
The device comprises the component parts as listed in Figure 6
...
The dolly is hung to
the arm 5 by means of the hanger hook and the arm moves vertically along the guide 7 installed on the
assembly device
...
The screw is seated on the pin II (z) and is driven by the gear drive
9 – pin I to pin II
...
The entire lever 13 rotates at a specific angle around the pin I, for example at
± 90° (in the X0Y plane)
...
The lever 13 is kept horizontal and parallel to the X0Y plane by the
spring 11 and it is kept in its starting position “a” by the spring 10
...
com
15
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Automation and Robotics
The mode of operation of the device involves pressing by hand of the lever 13 in the Z direction or
pressing the pedal 15 by operator’s foot until the end section of 13 moves from position “a” to position
“a1“with the rest 12 installed on the side of the conveyor, resting against 13 and rotating it in position
“b”, where it becomes disengaged from 13
...
Springs 10 and 11 restore the starting position of the hanger hook 4 ready for the next product, retracting
the lever 13 in its “a” position
...
2
...
2 Involvement of the conveyor
According to the arrangement described above, the conveyor moves the device and pulls out the dolly
in the +Z direction by means of the rests 12 installed at a specific pitch L along the conveyor
...
This movement can be performed
manually or by the foot using the pedal 15
...
Another alternative exist for the pedal 15 to move the screw 8 or 5 directly, but the use of the
conveyor is then eliminated [5]
...
ie
...
admissions@ie
...
Experience: 1 YEAR
Language: ENGLISH / SPANISH
Format: FULL-TIME
Intakes: SEPT / FEB
55 Nationalities
in class
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3
General assembly strategy
1
...
1
Review of assembly operations and assessment of their mechanisation suitability
The assessment of the suitability of a given product to be assembled in series production condition –
conveyors, process flow lines and automated lines – should be made before introducing any sort of
mechanisation whatsoever
...
A large number of assembly operations in various types of manufacturing processes
currently involve manual labour since they are difficult to mechanise
...
There are also assembly operations where insufficient cost effectiveness makes them useless
and not applicable in practice
...
• When complex movements of the hand (manipulator) are performed to carry out the
assembly operations, such as rotations along more than 1–2 axes and movements along such
axes; insertions into tight spaces and gaps [8]
...
• Operations that are difficult to mechanise and automate are also gluing and sealing with
glue packings and pastes of a specified amount, running electrical wires or steel wire
through holes (such as the voice coil wires) [7]
...
• In general, the assembly characteristics of the product involve the analysis of all these
elements
...
In our specific case we make an assessment of all described
above relative to loudspeaker assembly processes
...
3
...
1) as a suitable
assembly unit for mechanisation – pole plate, magnet, top plate and a central stud
...
We considered a ready-made and assembled
loudspeaker motor unit assembly in series production [10]
...
com
17
Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
1
...
2
...
These are
sufficiently easy to grip and move using mechanised gripping means, such as manipulators, and robots
[11]
...
The material they are made of – iron and ferrous alloys, can also be used to transport them
by means of using their magnetic properties [12]
...
3
...
3
...
1 Component parts and features
The “motor unit assembly” comprises 4 individual sections
...
We must clarify here that more than one possible assembly techniques exist for this specific assembly
depending on the adopted assembly process pertaining to the “oscillator with voice coil” stage (5 in
Figure 2)
...
Central stud; 2
...
Magnet; 4
...
Loudspeaker body
...
Components 1, 2, 3, 4 (Figure 7) are assembled afterwards
...
This operation is performed after the oscillator is assembled
...
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...
In this specific case the dolly is pulled in the direction – Y (Figure 7)
...
3
...
2 An example for an assembly process
We draw up a process flow map (Table 1) in order to clarify the assembly process at the “motor unit“ stage
(A)
...
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...
No
...
No
...
8
Possible use of conveyor
Machine-M
Tool – T
Fixture – F
Robot – R
Manipulator – D
Baseline:
robot (CNC)
Feasibi
lity of
operati
on
mechanical
Description of stage,
operation, transition in
operating
condition a1, c1, d1
Item No in fig
...
n
Note: Column 1 – [sec] for mechanised arrangement
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...
3
...
3
...
1 Basic assembly scheme resulting from the above analysis
According to the indications in Table 1, we can then draw up the following diagram – Figure 8
...
IV03 – assembly operations and transitions – 12 off
Figure 8: 1
...
Press; 3
...
Robot or CNCcontrolled manipulator; 5
...
1
...
4
...
The component parts to be assembled are picked up from feeder devices or pallets from a thru e in the
described sequence (Table 1) by a CNC controlled robot or industrial mechanical manipulator
...
Gluing and waiting for the glue to set is carried out in positions c1 and d1 to put together preassembled (mechanically) sub-assemblies 1+2 and 4+5
...
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...
3
...
3 End effector design
The design of the end effector is pre-defined by the proposed idea for mechanisation and automation
of the process
...
It performs all moving operations of components from the pallet (feeder device or cartridge bin), to
riveting or gluing work positions and for staving component 4 into component 5
...
The arm shall be widely universal or adjustable for several types
of component parts to allow handling of other product variants
...
A suitable method of transferring component parts is via
an electrical magnet built into the arm and providing reverse polarity (demagnetisation) or mechanical
ejectors to insert parts securely into working positions a1, c1 and d1
...
The jaws 2 (2 off) grip the outer diameter D of the component part and
the jaws 3 (2 off) – the inner diameter d of openings in component parts
...
The flat section of the arm A × B can also be an electrical magnet
with possibilities for demagnetisation
...
Jaw height h is of suitable size to handle the specific components and can be changed
by means of readjustment or replacement
...
com
22
Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Another significant element of the end effector unit are the assembly fixtures in a1, c1 and d1
...
They represent seats for inserting and locating at least one
component 1 thru 5 (Figure 7)
...
Moreover, it is possible to make one fixture capable of holding several
variants of shape and size of components or made readjustable as appropriate
...
Figure 10
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Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
The fixture used to insert component 1 to be riveted to component 2 can be used for 3 and more variants
of the size d2: d2, d21, d22, …d2n of component 1
...
3
...
4 Conveyor and its role in the organisation and mechanisation of the assembly process
The conveyor is used to provide transport of semi-finished products from the store in pallets or stacks
of components and auxiliary materials
...
According to the proposed mechanisation arrangement, no other
involvement of the conveyor in the assembly process for the “motor unit assembly” is envisaged [15]
...
3
...
5 Feeding and storage of parts
According to the above description of the proposed assembly arrangement parts are delivered in pallets
or preferably stacked into special cartridges
...
Parts 1–5 should be stacked in pallets a–e (Figure 8) only if a robot or manipulator
is available to pick them up from a specific location
...
When part feeder devices are employed, parts are stacked by the device itself and can then be loaded
into attached feed stacker bins
...
Additionally, parts can also be stored
in the assembly cell itself in quantities sufficient to meet the requirements for 1 work shift plus some
spare quantity
...
Parts are transported
within the assembly cell automatically by means of a robot or manipulator [13]
...
It is also possible to have a buffer stock quantity of finished assembled
motor units between individual assembly operations if this is required to facilitate the overall process
organisation and to improve the operational reliability of the assembly line [17]
...
If special feeders are provided for feeding parts 1 thru 5, the operations of the robot or manipulator will
be greatly facilitated
...
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...
4
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Feeder design
We assume the feeder(s) will be used to feed component parts comprising the motor unit assembly –
Item 2
...
These are described in more detail in Para 3
...
1 – Figure 3 and
Para 4
...
1 – Figure 7 above
...
e
...
The body of the loudspeaker, item 5 in Figure 7, which we also included in the assembly
operation, features considerably larger size and more complicated “conical” shape
...
We assume the following specific sample dimensions of parts for the initially required
provisions for part size and output data and re-filling cycle – Figure 11 (Note: designations and names
are identical to those given in Figure 7)
...
Figure 12 illustrates one design solution for feeding this type of component parts
...
4
...
The stacker
bin is supported freely on rollers 2 and can be moved to a certain extend in the ± y directions along the
guides 3 fixed in position
...
Connected detachable to the gap along the partition flange
I-I is a trough having an inner section area larger than the cross sectional area (across the diameter) of
the part being fed
...
An electrical sensor 11 and lock 10 are installed at the exit of the trough 5
...
Optionally, or as an auxiliary attachment, a working position
(a1, c1 and d1 – Figure 8) can be installed next to the exit of the trough 5 and the assembly fixture 7 for
the relevant assembly operation, transition and part size can be provided in this position
...
com
25
Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Figure 12: 1
...
Roller; 3
...
Component parts (of the 2, 3 and 4 type in Figure 11); 5
...
Roller; 7
...
Robot arm (manipulator); 9
...
Lock; 11
...
Connecting rod – crank mechanism; 13
...
Electrical wiring
...
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...
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Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
1
...
2 Operation
Parts are dumped in bulk into the stacker bin 1 and arranged and stacked in heights of 5 or 6 with
their flat side facing the bottom of the bin
...
In this end position the part 4 is
locked by the lock 10 and actuates the sensor 11
...
The motor can be either electrical, pneumatic or hydro, etc
...
The bin performs reciprocating movement along the ± Y under the action of the
crank mechanism which is in turn driven by the motor
...
Vibrations of the bin cause the parts to be
arranged in the right way and fall into the trough 5
...
As an option the device
allows installation close to a1 where the robot can move the part in the + X direction without lifting it
(direction Z), until it falls into a1
...
4
...
In other words, the next part shall be fed in position a1 after 22 seconds
...
1
...
4
Storage capacity
Considering the expected increase in output of the assembly line to 180000/month and increased
number of servicing workers Nwmax = 46, we can calculate the number of assembly cells, the cycle time
of operation of a single assembly cell and the minimum number of parts that must be assembled to
provide for continuous operation of the line and meeting the required production output
...
com
27
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Automation and Robotics
If we assume 15 assembly cell are located along the entire length of the conveyor (60 m) each served
by 3 workers as the product is assembled over three basic assembly stages (3 assemblies make up the
entire product), then:
(6) NW = NAC
...
3 = 45 and one worker will not be occupied in the assembly process for
the time being
...
From para 2
...
(2) above we have T2C = 4[sec]
(7)
\TAP = T2C
...
4 = 60 [sec], where TAP is the cycle time for a single assembly cell
...
From (7) above we can calculate the required number of parts to provide for normal production run
during one working shift:
(8)
QWS
10
...
From (8) above we can draw the conclusion that 600 parts of each specific type required for the motor
unit assembly (1, 2, 3 and 4 – Figure 11 and part 5 in Figure 7(body)) shall be delivered and be available
in each assembly cell for one working shift ( 10 hours)
...
4
...
With parts 2 and 4 stacked next to each other at
several layers (layers of H1), we calculate the dimensions A, B, H, H1 of the feeder device:
The volume of space occupied by a single part 2 (4) is V2max = h + D 2 (Figure 11)
( 4)
V2max = 0,3 x5 2 = 7 [cm3]
( 4)
from (8) above V2max
...
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...
B
...
40
...
The dimensions of the feeder are approximately as follows:
A = 400, B = 400, H1 = 100, A1 = 800, H = 400 [mm] and is capable of loading sufficient quantity of
parts to provide for one working shift production = 10 hours operation
...
QWS
V3max
...
375 [cm3]
2025 [cm3] V3
...
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...
4
...
This can be done when parts are delivered in
a pallet in bulk (not arranged and stacked in the pallet) and these pallets are dumped into the stacker
bin 1of the feeder device
...
A modified feeder device for these two parts is
illustrated and they shall be fed by means of stacked cartridges for parts 1 and 3 or through modification
of the bottom and trough of 1 in the feeder device
...
4
...
Instead, we could use the stacker bin 1 as illustrated in Figure 13 still keeping the rest of the
feeder mechanism unchanged to stick to the basic idea (unified with the idea adopted in Figure 12)
...
4
...
1 Arrangement
Figure 13: 1
...
Spring; 3
...
Parts; 5
...
Rubber rope or band; 7
...
Cover; f, F – Pressure forces; k – points of attaching 6
...
com
30
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Automation and Robotics
The stacker bin has a slightly tilted bottom (∠ a1 < ∠ a – Figure 12)
...
Parts 4 are stacked and arranged in the bin in a single layer
...
The trough 5 starts from “a” and represents a pipe of diameter d2 > d1(of the part)
...
4
...
2 Operation
Parts 4 are stacked and arranged in the bin 1 under the action of gravity and bin vibrations cause them
to move tightly stacked from the band 6 to the end of trough 5 – the opening in point “a” and they
fall inside one at a time and move down to the rest “b1” of the gate lock 3 held in this position by the
spring 2
...
2, which falls into the trough and reaches the seat a1 – position 4
...
Meanwhile, part 4
...
2 after 4
...
The “tooth” b ensures part 4
...
2 is released
...
The area of bin occupied by a single type 1 part (Figure 11) is:
S1max ≤ d12 = 1
...
25
711 600 parts
Method of re-filling
Parts are stacked manually and arranged in the proper way, as shown in Figure 13
...
5 minutes in the beginning or end of each work shift
...
4
...
3 Other applications of the device
The feeder mechanism for part 1 (Figure 11) illustrated in Figure 13 II can also be implemented as an
almost horizontal alternative, the X0Y plane, with the trough 5 having a rectangular cross-section
...
In this case we do not need the gate lock 3 and
other elements that go with it
...
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...
5
Assembly cell design
1
...
1
Initial provisions
From the assumed basic assembly stages in the production of the loudspeaker “General strategy”: 1a, 2, 3,
we can assume that their duration is approximately identical
...
The assembly stage B involving the voice coil and suspension assembly
comprises less operations and transitions involving mainly manual operations because of the nature and
characteristic features of these operations
...
The cone and dust cap are glued together and the cables from the coil are soldered to the appropriate
terminals
...
...
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32
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Automation and Robotics
Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
From what we discussed above we assume that each individual assembly cell has three basic working
positions where the operations and transitions involved in the three basic assembly stages which we
designated as A, B and C are performed
...
5
...
1 – (1) T1a = 6 sec
...
With the total number of assembly cells NAC = 15 and nWP = 3, as calculated in Para 5
...
Figure 15
Each individual assembly cell AC No
...
15 comprises 3 working positions: WP 1, 2 and 3, where
assembly stages A, B and C are carried out
...
215 are assembly cells AC1
to AC 15; 3 working (assembly) positions WP 1, 2,3: 4 is the auxiliary assembly table (reserve stock)
with parts required for the assembly operation; S1, 2 is the movement of parts or pallets (cartridges) with
parts arriving at the assembly station
...
The parts required for each of these working positions arrive as follows: WP2 – from
WP 1 and 4, and WP 3 – from WP 2 and 4 and the finished product Sp, loudspeaker, is then placed on
the conveyor to be transported to the store
...
5
...
1 Cycle time of the assembly cell (AC1 … AC15) – TAC
(12) TAC = 1
...
T 1a
\TAC = 15
...
3600
=
= 120000 parts/month),
T1a
6
Download free eBooks at bookboon
...
5
...
2 Dimensions of AC (1 … 15)
The area of space occupied (available) by one assembly cell is:
S = lmax x h
...
1
...
3
Alternative organisational arrangement of the assembly line for the suggested
mechanisation – NMmax = 180000/month
According to the developed “General strategy”, (Task 2) above and the organisational arrangement
illustrated in Figure 8, a mechanised assembly cell can be introduced into the assembly line as illustrated
in Figure 16
...
mastersopenday
...
com
34
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Automation & Robotics: An Optimized Loudspeaker
Assembly for a Mechanized Serial Production Line
Automation and Robotics
All assembly cells are located in one line next to the conveyor and one double automated assembly
cell MAC1 serves two neighbouring “manual” cells (work stations: AC1 and AC2, etc
...
MAC1 … up to MAC11 are as illustrated
in Figure 8, Para 4
...
1, with the only difference that they have been doubled to be symmetrical and to
provide better organisation in servicing the other (second) “manual” assembly cell
...
Figure 16: P1 … 22 – product (loudspeaker)
SMAC1 … C11 – pallets (cartridges) carrying parts for MAC1 … 11
...
1; 4
...
5
...
1
Operation and features of the introduced flexible mechanised assembly cell MAC
(MAC1 ÷ MAC11) – Figure 16
All parts required for MAC and AC cells are delivered by the assembly conveyor and re-filled with new
pallets or cartridges at feed positions: a, b, c, d, e and robots item 4 also transfer assembled sub-assembles
to AC1 and AC2 … (up to AC 21 and AC 22)
...
The use of a second robot M1 is also considered to perform
some of the assembly operations carried out at WP31… over the auxiliary tables f
...
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...
1
...
3
...
T2a [from para 6
...
1; (2), (2), para 2
...
1]
TAC1 = 22
...
3600
=
= 180000 units (TM is the working time = 200 hours/month)
4
T2 a
NM = 180000 units
...
This is also achieved by
performing some of the assembly operations using robot No
...
The cycle
time for MAC = 22 [sec], as indicated in Table 1, column 12 and the cycle time for 2 manually operated
assembly cells is = 44 [sec] (AC1 + AC2)
...
TAC1 – 44 = 44[sec]
...
1
...
3
...
5
...
3
...
5 min = 90 sec, then for the minimum volume of assembled products per
hour Nhmin = 40, the time required to make one product T1 is calculated as follows:
(13) T1
T
min
Nh
3600
40
90 [sec],
where: T – is the time period = 1 hour and Nh – is the number of products produced for a time of T
...
b) For Nhmax = 1000 [units/hour] and from (13) above:
(14) T1 =
3600
= 3
...
1000
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...
3,6 = 79,2 [sec])
...
2 = 88 – 79
...
8[sec] (TAC1 is 88 [sec] from para 6
...
2)
...
3
...
To allow for an output of Nhmax = 1000 [units/hour] we shall have to use this spare reserve of 44[sec]
with robots 1 and 2 performing some of the operations at stages B and C
...
8 [sec]
and these operations are performed by the mechanised automated assembly cell ½ MAC, which has a
spare reserve of unused operational time
...
5
...
4 Required investment – K
The required investment to incorporate the flexible automated assembly cell illustrated in figure 16 and
made up of MAC, can be calculated as the sum of the required funds for inst constituent elements:
these include feeder devices, cartridges, etc
...
If we assume: K1 = a
...
NAC
K = 13 200
...
1
...
4
Analysis and assessment of the assembly cell AO24
The assembly cell AO 24, Appendix 2, is illustrated schematically in Figure 17
...
It is equipped with
4 robots operating in a set sequence
...
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...
These work positions are equipped with special assembly fixtures to facilitate the assembly
process
...
Conveyor – 1 off; 2, 3, 4 and 5 – Robots – 4 off; 6
...
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...
The assembly operations involved in stages A, B and C (as described in the previous
paragraphs) are distributed among robots 2, 3, 4 and 5 relevant to their individual capabilities
...
1
...
4
...
Robot 3 here replaces M1 (robot 2)
...
1
...
4
...
6
...
This time coincides (flows in parallel) with the time of operation of
robots
...
5 min
...
3 [sec]
1
...
4
...
For TM = 200 hours
T1 =
TM
200
...
6 sec, where:
200000
NS
NS – is the number of loudspeakers, and
TM – is the monthly amount of working time
...
6 [sec],
(16) N AO 24
max
T AO 24
T1
67
...
6
18
...
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...
5
...
4 Conclusion
With the given data and described conditions, the number of AO24 required to produce a volume of
200000 units/month is 18
...
1
...
4
...
18
...
M
...
Applied Ergonomics, Volume 15, Issue 1, March
1984, Pages 45–53
...
Abraham Seidmann, Ami Arbel, Reuven Shapira, A two-phase analytic approach to robotic
system design
...
3
...
D
...
R
...
Computers
in Industry, Volume 15, Issues 1–2, 1990, Pages 83–93
...
Jim Lee, Tzvi Raz
...
Computers &
Industrial Engineering, Volume 18, Issue 3, 1990, Pages 407–423
...
Nicholas Perrone, CAD/CAM, robotics and automated manufacturing and the connection to
FEM
...
6
...
Malakooti, A methodology for the automation of medium or small manufacturing companies
...
7
...
Dhinesh Kumar, L
...
T
...
Technovation, Volume 25, Issue 5, May 2005, Pages 477–488
...
com
40
Automation and Robotics
8
...
M
...
A
...
Journal of Manufacturing Systems, Volume 9, Issue 3, 1990,
Pages 181–193
...
Zhao Xiaobo, Katsuhisa Ohno, Properties of a sequencing problem for a mixed model assembly
line with conveyor stoppages
...
10
...
11
...
J
...
Y
...
Applied Soft Computing, Volume 11, Issue 1, January 2011,
Pages 605–613
...
Christian Becker, Armin Scholl A survey on problems and methods in generalized assembly
line balancing
...
13
...
European Journal of Operational Research, Volume 168,
Issue 3, 1 February 2006, Pages 880–904
...
Zhao Xiaobo, Katsuhisa Ohno, A sequencing problem for a mixed-model assembly line in a JIT
production system
...
Need help with your
dissertation?
Get in-depth feedback & advice from experts in your
topic area
...
helpmyassignment
...
uk for more info
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...
1 Introduction
Modern production techniques for medium to large series products or mass production usually involve
assembly conveyor lines
...
The aim is to have monotonous
and similar in type operations or such causing fatigue, stress and production traumas, gradually replaced
by automated assembly cycles, means and techniques
...
Higher productivity, lower cost and higher quality of assembled products are usually required
here
...
2
...
2
...
It consists of the following parts: (Figure 1)
Figure 1: 1
...
Magnet system; 3
...
Collar with
corrugated concentric folds of the conical diaphragm; 5
...
Voice coil, oscillator;
7
...
Download free eBooks at bookboon
...
Ω
÷0,6=δ
Figure 2
ItemNo
...
com
43
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
ItemNo
...
Already today, SKF’s innovative knowhow is crucial to running a large proportion of the
world’s wind turbines
...
These can be reduced dramatically thanks to our
systems for on-line condition monitoring and automatic
lubrication
...
By sharing our experience, expertise, and creativity,
industries can boost performance beyond expectations
...
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...
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...
2
...
The collar rim 2 and conical diaphragm 4 are
glued to item 3 by means of an adhesive in a ring-shaped groove provided in the upper section of the
speaker body
...
3 through holes are provided on the terminal strip 20, one for the rivet 22 and
two for threading the connection wires 5 to the terminals 21
...
On the other hand, the terminals 21 are riveted to
the strip 20 by means of the protrusions provided on them
...
This together with the coil 16 and the conical diaphragm 4 is glued in the
position 15 (along its ring)
...
A small section along axis of the pin 11 of the driving magnet
9, 10, 19 and 11 enters the opening d3 of the coil during the assembly process allowing for a very small
gap of d3 – d2
...
The
wire ends of the winding 17 provided on the 16 run up along the axis over the coil, glued and insulated,
and come out from the inside of the cone of the diaphragm 4, between the cover 8 and 4, reaching the
position 6 where they are soldered together with 5, insulated and glued to 4 by means of 7
...
The protrusion is fixed (1) to the upper plate (washer) 9 of
the magnet 10 by means of a D6/r6-tight connection
...
The centering pin 11 of the magnet system is riveted to 12 along d1 by means of the three deformed
sections 25 provided in it
...
The correct performance requirement for the loudspeaker is ensured during the assembly of the gap d =
0
...
6mm, which is (d5 – d4)/2
...
e
...
This is due to the fact that the coil moves axially in both directions during operation and
enters deeper between 11
...
com
45
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
3
Analysis of the assembly operation ensuring the gap “d”
It can be seen from the particular design of a modern loudspeaker examined above that the assembly
“dolly” to be removed after the operation should be installed over the winding 17 inside the opening d5,
in other words the nylon thickness is = 0
...
When the magnet is in assembled state 1+9+10+11+12 the “dolly” cannot be removed in the upward
direction section A-A, Figure 2), as the coil 16 has to be glued to the corrugated diaphragm 14
...
Above considerations define the assembled position of the body 1 at the time of “dolly” removal in the
axial direction
...
Another alternative is to leave the bottom
section of the speaker open until the time when the coil 16 is centered and the “dolly” removed
...
2
...
4
Assembly technique sequence for coil 16 and center oscillator, corrugated flat diaphragm
14 in body 1
The sequence of individual assembly operations could be the following:
Designation
Item No
...
Stage
Description
Fixture or
manually
Time
[sec]
Remarks
1
2
3
4
5
6
7
1
I
01
Positioning diaphragm 14
with the coil 16 in the work
station
fixture
3
Specialised work post
No
...
1
3
I
03
Applying the adhesive 26
on d10
manually
10
Specialised work post
No
...
1
5
II
01
Moving 1 with 14 and 16
horizontally along with the
dolly until dolly engages
with mechanical jig
fixture
3
Work post No
...
com
46
Using conveyor
movement
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
4
...
1
...
Fixture in work post No
...
Parts 14 + 16; 3
...
Surface with applied
glue; 5
...
1
...
com
47
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Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
Operation I Stage 04
Position 3 is fixed – to be held manually until inserted through opening d5 into part No
...
Pressed to
be glued along 4
...
2
...
1 (Figure 2) could be
carried out by means of exerting axial pull action (+Z) using a special pulling device
...
1 or close to it
...
1 and No
...
2 used
for subsequent assembly operations in the assembly process sequence
...
2
...
1 Description and operation (Figure 4)
When assembly operation I 04 is complete we proceed with operation II 01 with the fixture F01, item 2
moved along with parts 1, 14, 16 and the “dolly” installed over them to Z1- until inserted into the
opening of the horizontal arm 1b of the pulling device
...
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...
A reel is installed on
a pin in the bottom section of the column 1e such that the column 1e slides into two guides 1d, which
are in turn fixed to 1c
...
2
...
6
Using conveyor movement for the removal of the “dolly” (Figure 4)
The lever, column 1e moves vertically in the +Z direction after the reel 1f contacts the slanted “lifter”
plane 5 mounted on the conveyor’s side
...
Figure 4: 1
...
Assembly fixture for items 1, 14 and 16 of the loudspeaker
3
...
Conveyor (assembly line)
5
...
Support along the Z axis
1a to 1g are components constituting the removal device (Item 1 above)
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...
2
...
1 and No
...
Work table between 3 and 4
2
...
Work post and operator No
...
Work post No
...
Dolly removal device according to item 1
...
Conveyor or assembly line
1a, 6a – parts from 1 and 6
Download free eBooks at bookboon
...
2
...
1 Description of operation
Operator No
...
The conveyor provides angular
movement of 1 – a Geneva stop 1 along with the parts and (F01) 2 via the yokes 1a and reels 6a
...
2 to proceed
...
3
General strategy
2
...
1
Analysis of the assembly process techniques
In order to be able to assess the suitability of the conveyor assembly technique for a specified product,
such as the loudspeaker in this case, and the automation possibilities available for the particular process it
is necessary to first make more detailed differentiation of individual assembly operations [3]
...
It is
a well-known fact that for many products significant portion of assembly operations is still hard to be
automated or assisted by robotics [4]
...
Using industrial assembly
equipment, handling machines or robots makes many operations impossible or hard to perform or such
automation proves to be economically inefficient and is therefore considered groundless and useless [4]
...
There are also a number of
components requiring some additional operation, such as holding the component in place, deburring
of edges, welding or soldering in hard to access locations [5]
...
From the above
differentiating analysis of the subject, i
...
assembly components, we could draw up a preliminary general
but still very necessary evaluation of their suitability for automated assembly techniques
...
General requirements could also comprise the following: the design of the product
should allow for the assembly to be performed in complete interchange ability of individual components
and on a continuous basis [6]
...
Some fragile and tender elements are also considered hard to be
involved in automated assembly techniques, as is the case of the oscillator coil
...
Download free eBooks at bookboon
...
A detailed consideration
of all required assembly operations and additional handling transitions could help us in our precise and
good-quality selection of the types of operations, which are most suitable for automated assembly [7]
...
This analysis provides
grounds for drawing up an organisational chart and a work post layout diagram for the location of
individual workstations along the conveyor
...
2
...
1
...
Selecting a suitable assembly stage, which can be
efficiently automated
The assembly process flow model, which was selected for the Mod
...
The process stage in Table 2 and the described above in p
...
1, which is the most suitable to involve some
automated assembly techniques is stage A (group A)
...
Moreover, handling units
will feature very simple design
...
The stage, which is considered most unsuitable for automation in this particular case is the stage B (group
B components) and this is due to the high precision required in the positioning of the components
being assembled and possible damage of coil winding
...
Vacuum grips could be used
here but the applied adhesive or adhesive plastics could lead to unreliable automated operation cycles [9]
...
com
52
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
Assembly analysis chart
Legend:
yes +; no -; 9+10 sub-assembly of part items 9 and 10 or other part Nos
...
duration sec
...
handler
+
+
+
No3
-
No1
3
Possible to transfer
it to No
...
A3
Assembling 1 and
9+10 along the H6/
r6 connection
16
17
9
10
11
12
13
15
16
17
No2
-
4
No2
-
5
Group consisting of
part Nos
...
9+10
and 11+12)
1
2
3
4
5
6
7
8
9
III
01
Picking 9+10 from
pallet (or conveyor)
and position it in the
press
+
+
+
Fixture based
on d9 and the
plane
Picking 1 from pallet
and position it on
9+10
+
02
13
to
3
III
12
Remarks and
additional data
2
10
11
Transport
linkmovement
between
work posts
from
workpost
9
after
7
simult
...
com
53
Time needed for
the glue to set is
not included in the
duration time
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
11
III
03
Plastic deformation
of 1 till
-
+
-
Press tool,
hydr
...
motor,
air, etc
...
com
54
No2
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
VII
STAGE C Assembly of
cone and dust cover
4, 2, 8 and 1
23
VII
01
Picking 1 from pallet
and positioning in
work post
+
+
+
Fixture,
oriented
along the
102 sq
...
3
...
3
...
1 Concept for a general diagram of the automated assembly process A (stage A)
Components are assembled (according to the example technique in Table 2) in 3 separate sub-stages; first parts
9 and 10 are glued together to form one unit and this is stage A1, then parts 11 and 12 are subsequently or in
parallel with A1 riveted together and this is sub-stage A2; and finally, sub-assembly 9+10 is installed in the body
1 in the third sub-stage A3
...
3 using three
separate fixtures
...
One final sub-stage is also carried out apart from sub-stages A1, A2 and A3, sub-stage A4
...
Due to the specific overall assembly operation sequence this sub-stage is actually
carried out in a different work post No
...
Download free eBooks at bookboon
...
Therefore, they can be fed to the specified location, the
assembly fixture, and inserted into it automatically (without any manual actions) using two simple and
conventional methods
...
Alternatively, them could be
arranged in a column along the trough’s length, one after the other
...
a)
End actuator
The components being thus fed to the assembly fixtures should be inserted in regular small time intervals
into the specified number of specific type (stage A1, A2 and A3) assembly fixtures moving underneath
...
Once substages A1, A2 and A3 are completed the assembly fixtures can then be further transferred to feed their
sub-assemblies into the next work post, WP 2 in this case
...
Parts 9+10 should have before that
been released or fed to assembly fixture No
...
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...
Additionally, he will have to manually load assembly
fixture No
...
b)
Involvement and function of the flat linear conveyor belt
The conveyor belt may in this case be only used for some additional auxiliary actions, such as to provide
the transportation link between individual work posts in relation to their location along the conveyor and
the assembly cell itself
...
The conveyor belt could therefore be used to transport finished loudspeakers to the
end of its length ready to be transferred into the finished products store
...
A similar idea was discussed in p
...
c)
Feeding and storage of individual component parts
As we mentioned earlier, component parts are normally supplied in individual pallets in quantities
sufficient to provide for feeding a specified duration of an operation cycle
...
The movement between work posts WP1, 2 and 3 is through an auxiliary
transportation turntable providing automation to the whole process
...
d)
Possibilities to speed up assembly operations
Apart from the general assembly diagram discussed above and involving continuously or step-moving
fixtures with nests or bases for performing the required assembly operations involved in sub-stages A1,
A2 and A3, this concept also allows for another assembly arrangement involving multi-station fixtures
for a single stage of each assembly operation
...
Download free eBooks at bookboon
...
2
...
Ω
Figure 6: 1
...
Turntable; 3
...
Pallets filled with component parts 1, 9, 10, 11 and 12;
5
...
Feed-in bins (2 off ) and trough for parts 11 and 12 towards D2; 7
...
Feed-in bin and trough for part 1 towards D; 9
...
Adhesive
applicator (for D3); 11
...
or for the installation of
F01 (fixture for “dolly”)
...
The operator
at WP3 fills in the bins 5, 6, 7 and 8 from pallets 4 with component parts 9, 11, 12, 10 and 1 respectively
(designations are according to Figure 2)
...
Device 10 applies the adhesive and
device 7 feeds in the other component part 10 in an identical or similar way
...
The part 1 and bin 8 are positioned on D1 and sub-assembly 9+10 is taken
from D3 and positioned into part 1
...
Download free eBooks at bookboon
...
4
Feeder design
Para 2 above describes the basic principal elements of feeder mechanisms
...
Therefore, we shall need to consider design ideas and details for each individual feeding device intended
for each of these 5 different component parts
...
β
δ2
δ2
δ1
δ
α1
α1
δ1
Figure 7: Direction of the arrows shows: – direction of movement of component parts; – direction of movement of
mechanisms; – compressed air fed to the pneumatic cylinders
...
Figure 7 shows the design idea of such type of feeding mechanism
...
com
59
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
SPECIFICATION
for Figure 7
No
...
1
1
2
Description
Qu-ty
Notes
Bin for component parts (part 9)
1
1
...
2
Vertical partition
5
4
2
Column
4
5
3
Pusher
1
6
3
...
2
Profile groove
2
8
4
Assembly fixture
12
On 5
9
5
Work table
1
Turntable
10
6
Cylinder, horizontal
1
Along X-axis, pneumatic
11
6
...
1
Guide, top
1
14
7
...
3
End plate
2
16
7
...
5
Spring
2
18
8
Cylinder, vertical
1
Along Z axis, pneumatic
19
8
...
2
Assembly punch
1
21
9
Electrical circuit breaker
3
A, b, a1 b1 – end positions of 6 and 8
...
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...
4
...
9 (Figure 2) is shown in Figure 8 underneath:
Figure 8: Washer (top plate); Material: Steel
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61
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Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
A feed mechanism provides for the movement of component parts from the parts feeder bin 1 towards
the assembly fixture 4, which performs the assembly with part 10 (Fig
...
A hopper bin for component
parts 1 is located on 4 (up to n-number) vertical columns, d1 inner diameter tubes and the hopper bin
bottom is positioned at an angle of b
...
5mm
...
A knife-shaped pusher 3 is positioned horizontally
in the lower section of the columns 2, underneath them
...
The
columns 2 are supported above the guide trough 7 transferring component parts towards the axis of the
fixture 4
...
2 underneath and by end plate
7
...
The assembly punch 8
...
1 and 9
...
2 are provided along the x axis of 3 and guide reels
3
...
Cylinder 6 is connected to 3 by means of the slide 6
...
2
...
2
Operation, Figure 7
Component parts 9 are filled into the bin 1 from a pallet positioned and located independently
...
1, the diameter of the openings being slightly larger
...
2 acting as side stops (along the y-axis)
...
The horizontal pusher 3
with cam grooves 3
...
1 moves along +x at a distance of l in the bottom section of the
columns 2 in accordance with the cycle of feeding component parts to 4
...
Under this action the parts cannot lift up and go back to 2 once they move to the distance –y held there
by the side guide 7
...
The parts are further guided along the trough by its side walls, supported on the
bottom side by the guides 7
...
When the cylinder 8 actuates it presses down part 9 by means of the punch 8
...
The moving sections
7
...
5 to compress to an angle of a 1 (2 × a 1) and the
component part thus descends into the – Z direction entering the seat provided for it in 4
...
02 A (Figure 8)
...
5+0
...
The cylinder 8 actuates as the worktable 5
rotates in a position where the axis of 4 is coincident with the axes of the punch 8
...
Circuit breakers 9 and the cam of 6, the switch 8
...
The circuit breakers control respective electromagnetic control pneumatic
and hydraulic valves depending on the operation fluid selected
...
com
62
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
3
Basic dimensions (Figure 7)
Dimensions are determined by the necessary number of component parts (part 9) held into the columns
2; by the stroke and size of power cylinders 6 and 8 and other parts and mechanisms involved in their
operation; the length of the trough 7 and the distance between the outer diameter D of the turntable and
D3 = (D – D3) × ½
...
n, where d = 2
...
1; n is ¼ of necessary parts for 8-hour operation
...
3 (WP3) is the sum of times in column 16, i
...
≈ 51 sec
...
1 where the final assembly and test of the loudspeaker is performed
...
/(TA1 + TA1 + TA1) = 8
...
is the operation time fund for 8-hours operation (single shift)]
For column 1, Item 2 n1 = 566/4 = 141
...
9 and d = 2
...
Therefore, H1min ≥ 142
...
d
...
4
...
The dimensions thus defined are valid for the particular loudspeaker discussed
...
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...
4
...
3
...
The bin 1 is capable of holding almost twice the number of component parts of the
specified dimensions held in the columns 2 and the trough 7 and therefore the actual possible minimum
set quantity of part 9 will be:
5) Nstor
...
n – 1132 parts – from (2) above we have n – 566,
Where, Nstor
...
This quantity is sufficient to provide 16 hours continuous conveyor operation
...
4
...
25 sec, where
TA is the time necessary to perform Stage A or ≈ operation I 01;
m is the number of positions provided on the turntable 5 (Fig
...
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64
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Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
5
...
Tc
Tc6 = 4
...
, where nc is the number of columns 2 (Figure 7)
...
4
...
2 Cycle time for power cylinder 8 – Tc8
8) Tc8 = Tc = 4
...
4
...
4
...
1 Time for re-filling
Re-filling is performed every 16 hours of continuous conveyor operation or once in every 2 shifts and
this necessitates some additional time of around 2 minutes
...
Time for re-filling is in this sense per every 15 hours and 58 minutes
when there are still some parts in the unit [11]
...
4
...
2 Re-filling technique (Figure 7)
Re-filling is performed by gradually filling 1132 component parts into the bin 1 (parts 9, Figure 2)
...
1 and the columns 2 parts are stirred in by hand when filled into the
hopper bin
...
2
...
7
Feeder of component part 10 (Figure 2) to the fixture Item No
...
Prior to this stage, the glue applicator unit Item 10 in Figure
6 has applied glue to the upper surface of part 9 (not shown in Figure 7)
...
4
...
1 Design
Part No
...
2)
...
3 above
...
Download free eBooks at bookboon
...
It is also possible
for the entire storage and feeder unit to be manufactured of such materials with the only exception of
the feeder cylinders 6 and 8
...
2 and the fixture 4 itself it is mandatory to avoid sticking
to the part 10 for magnetic reasons
...
4
...
2 Dimensions
If we assume that parts 10 will be filled once for every work shift, then the number of component parts
filled into the unit will be:
9) Nstor
...
/ 2, where Nstor
...
10 = 566 parts
As part 10 is slightly larger in size: d10 = 8
...
d10 /d
...
5 mm and Hmin = 755 mm from (3)
H10min ≥ 755
...
½ = 1283
...
d10,
where d10 = 45h9 (from Fig
...
45 = 720 mm
The size across the width B10 is:
12) B10min ≥ Bmin
...
d10 /d, where
Bmin = 640 (from (4); and d = 40
B10min ≥ 640
...
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...
2
...
7
...
10= 566 parts
2
...
7
...
Tc10 = Tc = 4
...
5
...
5
...
25 sec
...
sylvania
...
Fascinating lighting offers an infinite spectrum of
possibilities: Innovative technologies and new
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...
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Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
7
...
6 above for every 8 hour operation
...
4
...
11 (Figure 2)
2
...
8
...
11 “Central pin” (magnet core system) is shown on Figure 10
...
One basic
difference is the method of feeding the component into the tubes, columns 2 (Figure 7), where 11 should
enter with its 10R10 dia pointing upwards (=Z), as shown in Figure 10
...
1 (Fig
...
Arrangement of parts 11 in the tray on a
single level
towards the columns 1
Figure 11
2
...
8
...
14) Height H11min = Hmin = 755 mm;
from (3) H = 755 mm
15) Length L11
from (4) Lmin = 640 mm
min
=L
min
= 640 mm;
16) Width B11min ≥ Bmin = 180 mm;
Bmin = 180 mm
Download free eBooks at bookboon
...
4
...
3 Storage capacity Nstor
...
11= Nstor
...
= 1132 parts from (5)
2
...
7
...
25 sec;
Tc = 4
...
4
...
5 Method of re-filling
Re-filling should be done every 16 hours of continuous conveyor operation, Tf , which is the time needed
to arrange the parts in the bin 1 tray (Figure 7)
...
In other words, re-filling is performed
every 15 hours and 45 minutes
...
2
...
9
Feeder of component part 12 (Item 12 in Figure 2)
The feeder bin item 6, Figure 6 for component part 12 is identical to the one shown in Figure 7 because
all external (datum) dimensions and the shape of component 12 are identical to those of part 9
...
2
...
10
Feeder of component part 1 (item 1 in Figure 2)
Used for performing assembly operations III 01…04 as in Table 2
...
4
...
1 esign description and operation (according to Figure 7 and others)
D
Component part 1, “Body”, is the most complex in shape and as a manufacturing technique part of
the loudspeaker
...
Therefore, the feeder mechanism cannot use the same bin 1 and columns 2 (Fig
...
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...
One column of “Body” parts is provided instead of 2 and the parts are stacked one on top of the other
not in the feeder device but in a special removable cartridge “a magazine”, which is removed when empty
and replace by a re-filled one during operation
...
The feeder mechanism operated on a single cycle, i
...
it feeds 1 component part towards 4 (Figure 7) for
every cycle of the turntable (which we estimated at 4
...
)
Figure 12 shows the principal design diagram for this type of feeder mechanism
...
com
70
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
SPECIFICATION
for Figure 12
No
...
1
1
2
Description
Qu-ty
Notes
Cartridge for component parts
1
120 parts (part 1, Fig
...
1
Guide
1
Towards push bar of 6
8
7
Pusher
1
9
7
...
1
...
1
11
7
...
3
Vertical plane
2
Part of 7, parallel to X0Z
13
7
...
1
Sleeve for positioning lock, with guide
2
16
8
...
3
Split pin
2
180
Note: 7
...
3 and 7
...
Parts are stacked one on top of the other as shown in Figure 12, with their tapered section pointing
towards cartridge 1 bottom and are positioned in place (around the Z axis) by mean of pins 2 fixed to
the cartridge
...
The cartridge 1 is rotated at 180° around the axis, which is parallel to x or y during
transportation, such that component parts (part 1 in Fig
...
Located
in the bottom section of 1 at a distance of t/2 from its end are 2 positioning locks 8, Figure 12, which
are being held against the centre of the (pallet) cartridge 1 by means of the spring 8
...
3
...
The cartridge 1 is secured to the base plate
7
...
7 from fig
...
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...
1
...
1 guided by the bracket 7
...
1 (or some
other guides in the ±x direction)
...
While travelling the distance l1, initially 7
contacts the sleeves 8
...
2 thus lifting them up to
a distance of Z1
...
The piston rod of the cylinder 6 then moves backwards, which causes the pusher
7 to retract to position a, which repeats the whole cycle
...
4
...
2 Dimensions
17) Length L1
L1min = 640 mm;
18) Width B1
B1min = 250 mm;
19) Height H1
H1
min
= 560 mm;
360°
thinking
...
360°
thinking
...
Discover the truth at www
...
ca/careers
© Deloitte & Touche LLP and affiliated entities
...
deloitte
...
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72
Click on
© Deloitte & Touche LLP and affiliated entities
...
4
...
3 Storage capacity
Nstor
...
4
...
4 Cycle time
Tc1
Tc1 = 4
...
4
...
5 ethod of re-filling
M
The cartridges 1 come from the storage area filled and arranged and the operator only has to remove
the empty cartridge and replace it with a new one
...
5 minutes of
continuous feeder operation, in other words every 2 hours of continuous operation of the assembly unit
(work posts No
...
2 and No
...
2
...
• The number of basic equipment involved and its position within the assembly unit,
interrelation between individual devices and work posts
...
• The overall fund of required operation time Top necessary for the assembly of one
loudspeaker of the selected example type
...
• The role of the currently available conveyor in relation to the assembly units configuration
thus formed
• Possibilities for mechanisation and automation of operations from the A stage aimed at
increasing production capacity and reaching the required level of parameters; loudspeakers/
month
...
• Work posts and assembly operations suitable for the use of robots
...
com
73
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
1
Structure and functioning of the assembly operation unit
Three work posts have been defined all serviced by a single operator each: WP No
...
2 and WP
No
...
These are positioned around the auxiliary turning worktable, which is located on the sideways
next to the linear flat conveyor with work posts No
...
1 closer to the linear conveyor
...
2
...
1
...
3
...
• Assembly operations for the terminal strip are carried out in work post WPNo
...
-- Stage D includes the assembly of component parts 20, 21, 22, 23, 5 and 1
...
-- Stage C includes the assembly of the cone and dust cover
...
Involved assembly operations and transition sub-stages are
VII 01 … 07
...
1
...
• Additional assembly (final) of the loudspeaker
-- Stage A4, component parts: 1 with the parts already assembled to it 11+12; 6 and control
[15]
...
5
...
2 Duration of operations performed in the individual work posts – T WP (Table 2)
Duration is defined as the sum of individual duration of all assembly operations and transitional substages in the relevant work posts
...
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...
5
...
1, 2
and 3
Figure 13
Figure 13 shows the transportation flow for individual components and sub-assembles
...
Parts 5, 20, 21, 22 and 23 as well as 2, 4 and 8 are fed to WP2
from pallets
...
The pallets with component
parts required for the continuous operation of individual work posts and conveyor are transported
from the store to the corresponding work post by means of the conveyor and in between individual
work posts WP1, 2 and 3 – by means of the turntable 3
...
The rotation of 3 is interrupted and alternated by idle time necessary for the assembly operations
of the machine to be carried out in every working position
...
The rotation of 3 around the axis O is synchronised with the conveyor movement with
the driving click 2 (a mechanism similar to a Geneva wheel) travelling the distance l between positions
a and a1 thus moving the reel on the arm 2 (of the table 3) for as much time as is required to rotate 3 at
an angle of 30°, which is < 5 seconds
...
com
75
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
2
...
3
Arrangement layout of assembly operation units along the conveyor, Fig
...
Send us your CV
...
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www
...
com
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...
Each operation unit produces (finally assembles) 1 particular type of loudspeaker
...
From 4
...
2 above it can be seen that when
WP1, WP2 and WP3 operate simultaneously in each assembly unit, the time required to assemble one
loudspeaker of a particular size and type (or model with only slight design differences), Tass
...
is:
n
21) Tass
...
sp =
57 s
3
Tass
...
sp is the time required to assemble one loudspeaker;
TWPi is the time required for work post i, and
N is the number of working positions included in the assembly unit
...
For ease and convenience to
operators we could assume that Tass
...
In other words, the operation unit, which comprises
WP1, 2 and 3 and a turntable will produce one loudspeaker on every 1 minute not involving the
automation in WP3
...
5
...
un
...
T
Qass
...
4 = 200 hours
Q = 60
...
200 = 180000 units/month, where:
Qass
...
Download free eBooks at bookboon
...
5
...
1
Production capacity of the assembly unit following the automation of assembly operations
involved in WP3 – QWP3
If the mechanisation and automation techniques suggested in para 2 and 3 earlier are adopted, the time
required to carry out all assembly operations in this particular work post will then be T WP3 = 5 sec
...
It is not impossible to include all operations involved in
the A stage on WP3 within this time of TWP3 = 5 sec because they are performed by all 5 automatic part
feeders in parallel (Figure 6)
...
Thus, we will have a large reserve available for increasing the production capacity of the line, or:
QWP3 = 720 units/hour ( = 12
...
Therefore, work post WP3 will only have to operate for 40 minutes per shift to produce this number
when automation is adopted (the is due to its production capacity, which increases 12 times as a result
of the automation)
...
40 min
...
25
WP3 work posts from all the 15 assembly units discussed above (we could round this to 2 WP3 work
posts)
...
This will also result in reduction of 13 basic operators throughout the line
...
2
...
4
Investment required to achieve Q = 180000 units/month
23) I = M
...
15 + 25000 = 77500 £, where
I is the investment required (in £);
M is the funds needed to equip the assembly unit (automation of WP3 is not included here) (in £);
N is the number of operation units;
AS is additional expense involved in the assembly line (in £)
I assume M = 5500 £ per one turntable (one table for each assembly unit);
Download free eBooks at bookboon
...
I = 77500 < 100000£
100000£ have been initially calculated for a capacity of Q = 180000 units/month
2
...
4
...
For example, ≈ 4000 £ will be required
for all 5 feeder devices or totally 15 × 4000 = 60000 £ for all 15 operation units [16]
...
5
...
On the other hand, it would be hard for the robot to reach the set requirement with the
other mechanised attachments involved in WP3 due to the exceptionally short time = 5 sec required
to feed component parts 1, 9, 10, 11 and 12 in all 5 working positions
...
In this case the time required to perform the operations
involved in Stage A will increase to 30 sec, or in average, 6 sec for each part [16]
...
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Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
The robot could carry out the following handling operations [17]:
• Picking component parts 1, 9, 10, 11 and 12 from a pallet or parts storage rack and position
them in sequence into the assembly fixtures with the grip (robot arm) being identical for
parts 9 and 12; magnetic grip for part 10 and a combined (more complex) grip for part 1
...
If assembly robots are selected to be used this could avoid the use of turntables thus producing a linear
work post arrangement diagram
...
5
...
1 Linear arrangement of work posts, Figure 15
(assembly fixtures
Conveyer
Figure 15:
...
Work table with assembly fixtures for parts 9+10, 11+12 and 1+9+10
3
...
Pallets containing parts for WP2
5
...
Up to assembly unit XV
6
...
2
...
5
...
ass
...
ass
...
Qass
...
5
...
3 Assembly line production capacity Qaut
Qass
...
This is due to the fact that the production capacity of WP3 is twice higher
...
com
80
Design of speakers production: assembly line of
capacity 180,000/month, 15 product variants
Automation and Robotics
Saving around 30 sec at WP3 would allow us to reduce the number of required assembly robots by two
(the number of working positions in WP3)
...
5
...
4
Required investment for an assembly line comprising 15 assembly robots and 30 operators
(15 assembly units × 2 operators each)
Iaut = Paut
...
15 + 4000 = 107500 £, where:
Iaut is the required investment (in £);
N is the number of assembly units;
AS1 is additional expense involved (in £)
...
Angeles, J
...
TWER 681
...
2
...
and Slotine, J
...
E
...
TCPW 681
...
51:007
...
3
...
, Theory of screws: a study in the dynamics of a rigid body, Hodges, Foster and Co
...
TWER 514 / BALL 1988
...
Bar-Shalom, Yaakov and Li, Xiao-Rong
...
TWER 681
...
01/BAR 1993
...
Brady, J
...
TELE 007
...
6
...
TWER 512/BRAN 1948
...
Canudas de Wit, C
...
and Bastin, Georges, (Eds
...
TWER
681
...
8
...
J, Introduction to Robotics: mechanics and control
...
3*I29/CRAI 1986
...
Crane, C
...
III and Duffy, J, Kinematic Analysis of Robot Manipulators
...
3*I29
...
Ginsberg, M, Essentials of Artificial Intelligence
...
3*I20/GINS 1993
...
Duffy, J, Statics and Kinematics with Applications to Robotics
...
8 / DUFF 1996
...
Kanal, L
...
and Lemmer, J
...
, (Eds), Uncertainty in Artificial Intelligence
...
3*I23/0045
...
Latombe, Jean Claude
...
TWER 681
...
14
...
Discrete Applied Mathematics, Volume 65, Issues 1–3, 7 March 1996, Pages 285–318
...
Advances in manufacturing
...
Download free eBooks at bookboon
...
M
...
Gupta, C
...
P
...
Balakrishnann, Expert scheduling system for a prototype
flexible manufacturing cell: a framework
...
17
...
Cutkosky, Paul S
...
, The design of a flexible machining cell for
small batch production
...
I joined MITAS because
I wanted real responsibili�
I joined MITAS because
I wanted real responsibili�
Real work
International
Internationa opportunities
al
�ree wo placements
work
or
�e Graduate Programme
for Engineers and Geoscientists
Maersk
...
discovermitas
...
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82
�e G
for Engine
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Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
3
Strategic approaches to resource
husbandry and recovery: the
superwash combo case study
3
...
A preliminary study of the company’s structure, activities and problems was used as an initial
database
...
The teams thus expanded ensure increased possibilities for
outlining and identifying to a maximum extend the wide range of problems that need to be solved
...
It will be necessary to go through the following stages in order to be
able to prepare this plan:
• Clarify the production situation in the DOMAPP factory
...
• Prepare a suitable process flow chart for the main material chains in the product, from
nature to consumers [2]
...
The techniques employed included the analytical synthesis method and the brain attack technique [1]
...
Participants were
allowed to swap sheets to give them more hints and generate additional suggestions
...
Download free eBooks at bookboon
...
2
The team’s work
The team advanced to the first objective: Identifying the factors that influence the Combo production
...
The cause and
consequence diagram was build up observing the following sequence:
• the basic problem is presented as a main horizontal arrow in the diagram;
• all influencing factors were identified;
• major junctions of basic factors were marked (Figure 2);
• sub-factors were also marked by corresponding arrows for each basic factor;
• The arrangement of the diagram appears as a well-branched tree or fishbone (Figure 3)
...
com
84
Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
Market and
production line
Performers
Environmental
impact
Quality
Increasing
the Combo
production
volume
Row materials
and components
Technique
Machines
Tools and jigs
Figure 2
The diagram was then split up into separate branches and an assessment of performance of individual
company activities was made to identify weaknesses
...
Market and production line
Performers
education
mobility
raw material
quality
electronic
Superwash
high employee
turnover
lack of motivation
(uncertainty about
current jobs)
machine reworking
(poor quality)
vertical drum
washer
low remuneration
low qualifications
(lack of skills)
Quality
washer/dryer
(twin tubs)
quality
of deliveries
(PCB)
Superwash
Combo
lack of
training
20% of UK market
quality of paint
work
55% of the
washer-dryer segment
Increasing
the Combo
production
volume
small share of
the European market
heater
electrical
components
maintenance
(repairs)
welders
visible
pollution
process
provisions
bearings
drum
(plastic)
energy
savings
presses
management
belt
drum
(steel)
motor
labour safety
requirements
production
department
organisation
toxic emissions
into the atmosphere
jigs
CNC machines
efficiency
housing
(case)
materials and parts
metal cutting
machines
machines
waste
presses
technique
Figure 3
Download free eBooks at bookboon
...
Examiner
Lecturer
conducting
the training
Personnel manager,
managerial
staff
Yes
Storing documentation
in personal dossiers
...
Therefore,
the team had to approach a realistic plan that could be implemented involving the minimum amount of
spending
...
Download free eBooks at bookboon
...
3
The performers
The lack of adequate training in the factory, low wages and lack of motivation in staff were identified as
most significant weaknesses
...
Explanation activities will have to be
undertaken to draw the workers attention to the fact that the increase in the Combo production will
guarantee they retain their jobs and will rescue the factory and maintain the economic infrastructure
in the region
...
The larger market share of the new washing machine would raise the image of the company and all its
employees [4]
...
ie
...
admissions@ie
...
Experience: 1 YEAR
Language: ENGLISH / SPANISH
Format: FULL-TIME
Intakes: SEPT / FEB
55 Nationalities
in class
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...
3
...
The main opinion was that elimination of re-working due to poor
quality would substantially increase production efficiency
...
Basic recommendations that were outlined were addressed to the need to increase the quality of PC boards
supplied by the Electro company, the painting process and the defects observed in the washing machines
...
Specialists have identified the painting process as a special process where quality results could not
be checked in a subsequent inspection and tests of the product
...
The team has outlined the following activities in order to
help improve the painting quality [4]:
• Preparing operation performance instructions that set out the process parameters, process
sequence, some special observations, adjustments and control;
• Employ or train adequately qualified personnel;
• Assess the suitability and applicability of equipment involved and quality of paint used
...
com
88
Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
To overcome the problem of occurring defects in finished washers and eliminate the need of reworking
one of the production managers suggested to employ the Paretto’s technique [6]
...
e
...
Additional studies will have to be conducted afterwards to identify the causes for these
defects and outline some corrective activities to eliminate these defects
...
3
...
This washer features modern design, saves energy thus contributing to environment
protection, it has compact size and saves space
...
One proof of this is the high sales volume and the need to increase
the production volume (Figure 5)
...
Download free eBooks at bookboon
...
The proposal presented to the Board
was backed up with a preliminary marketing analysis and identification of the life-cycle of the two older
washers (Figures 6 and 7) The life cycle analysis has also involved the value of profit from the sales of
these two products
...
Introduction
Growth
Figure 6
Download free eBooks at bookboon
...
Prices go down
Competition eliminated
...
The increased
production volume will allow for some reduction in expenditure involved leading to a reduction in cost
as a means to increase the sales volume
...
Download free eBooks at bookboon
...
6
Environmental impact
In finding solutions to the set task of increasing the production volume the team could not skip the issue
of environmental impact this would have
...
Looking at the problem from this aspect, the team concluded that the Combo meets modern requirements
for reduced energy consumption compared to similar products in the field [7]
...
Excellent Economics and Business programmes at:
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92
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Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
The quality improvement programme for component parts and complete products will affect the reliability
and life expectations of the Combo product
...
Faultless operation
and many years of exploitation will allow the Combo product to be subjected to recycling and re-use of
materials at the end of its life cycle
...
The aim is to make maximum use of all components and other resources
and materials that will result in the generation of products and not waste
...
3
...
The projected increase
in production volume will put additional load on the machines and equipment available and give rise
to possible machine failures
...
Some disastrous consequences in the
following spheres might be possible if a programme for maintaining and ensuring the life of machines
and equipment is not adopted [6]:
• Life and health of servicing personnel;
• environment;
• quantity and quality of manufactured washing machines;
• economic results
...
com
93
Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
• service time;
• intensity of usage;
• usage conditions and surroundings;
• method of usage (in accordance with technical provisions or allowing severe mistakes)
...
A problem area for possible failures was identified in the welding facility
...
Therefore, a preventive strategy in performing overhaul activities
is to be recommended for the machines in this production area
...
The involvement of a CNC machine was identified as one weakness in the operation of the available
machine inventory
...
CNC machines feature a rather complex design that employs high-level
electronic equipment
...
A special maintenance team will be necessary to be set up that should
include one mechanical engineer, a fitter and an electronic specialist
...
In order to solve the second problem with the CNC machine it will be necessary to employ in company
or train an operator-programmer to operate this machine
...
Proper operation of the
CNC machining centre will allow it to manifest its production efficiency capabilities
...
Lack of such machines
predetermines low production volume and high labour expenses (18% of sales volume) [6]
...
com
94
Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
3
...
This includes [8]:
• developing the documentation for various manufacturing processes;
• developing documentation for the specialized process machinery and equipment;
• developing the documentation for the required means of mechanisation and process automation;
• developing the specialised process machinery and equipment
...
An increase in Combo production volume will necessitate modifications to these
techniques to ensure maximum loading of manufacturing facilities
...
ligsuniversity
...
More info here
...
com
95
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Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
• developing single manufacturing technologies applicable to the entire group of compatible
products, assemblies and component parts;
• analysis of organisational forms of production;
• developing highly efficient process equipment and machinery;
• improving the organisational form of production of component parts, assemblies and products
...
Production planning and distribution is also an important element in increasing production efficiency
that involves:
• planning the annual production programme that includes all washing machine models
produced;
• distribution of the annual production programme;
• planning the required quantities of parts and assemblies;
• developing process route plan;
• calendar planning (developing network diagrams);
• preparing production orders;
• planning job positions loading;
• providing the equipment and documentation required for each job position
...
For example, the welding facility in the factory
needs special tooling and jigs that have to be taken out of the tool and jig store
...
It is necessary to consider some optimisation of the production department
distribution to allow easy access to tools and jigs
...
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...
Figure 9
3
...
Some of the
assemblies are delivered by other factories of the division, like for example the PC boards manufactured
by the Electro factory
...
One major priority
for the factory is to ensure the delivery of those materials without which the production process will not
start
...
The factory at Bournemouth does not supply
enough boards and does not take Swansea’s needs too seriously
...
Such an agreement will provide the legal commitment of the Electro factory
...
This change will make
the entire construction lighter and improve the material recycling possibilities but will on the other hand
reduce the work load in the pressing and welding facilities which might in turn result in personnel cut
downs and social tension
...
Thus, various customer requirements will be
met and the market situation will be used to establish the current Combo model
...
com
97
Strategic approaches to resource husbandry and
recovery: the superwash combo case study
Automation and Robotics
3
...
This summarises in the
order of priority the major problems that have to be solved very quickly and which will result in an
increase in Combo production volume:
1
...
2
...
3
...
4
...
References
1
...
M
...
S
...
Computers & Industrial Engineering, Volume 37, Issues 1–2, October 1999, Pages 111–115
...
Martin Rudberg, B
...
Omega, Volume 36, Issue 1, February 2008, Pages 91–106
...
Y
...
Shetty, Aiming high: Competitive benchmarking for superior performance
...
Download free eBooks at bookboon
...
Andrew Tobias, O
...
techniques for use in redesigning manufacturing and associated business
systems
...
5
...
Malakooti, A gradient-based approach for solving hierarchical multi-criteria production planning
problems
...
6
...
Blair, Kenneth D
...
Journal of Operations Management, Volume 4, Issue 1, November 1983,
Pages 1–10
...
W
...
Brachtendorf, L
...
Koch, Changes in the Role of Production Management in
the CIM-Era
...
8
...
Gunasekaran, T
...
Yli-Olli, Flexible manufacturing systems: An investigation for
research and applications
...
9
...
International Journal of Production
Economics, Volume 104, Issue 1, November 2006, Pages 179–190
...
D
...
N
...
Ansal, B
...
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...
1
Enviromental model
4
...
1
Context diagram [1]
Download free eBooks at bookboon
...
1
...
Press works
(press process enable)
Direct
C/D
2
...
AGV arrived
(start a press packets unloading)
Direct
C
4
...
com
101
Software engineering and data communications:
an automatic laminating plant
Automation and Robotics
5
...
Packet is correctly positioned
(instructs to close the safety guars)
Direct
C/D
2
...
Safety guards are closed
(instructs to close the press platens and set the appropriate hydraulic pressure)
Direct
C
2
...
Cycle is over – timer
(instructs to shut of the pressure)
Temporal
C
1
...
Temperature is setting
(control of steam valve)
Indirect
C
3
...
Platen’s temperature is normal
(instructs to close water valve and open press platens and safety guards)
Indirect
C
1
...
Conveyor is empty
(Instructs to unloading a laminate)
Direct
C
3
...
AGV arrived
(instructs to load the laminate on the AGV)
Direct
C
5
...
i – press shut down
(send message to AGVC)
Direct
C
2
...
Press packet is on the input conveyor
(send message to AGVC)
Direct
C
Safety guards system Viewpoint
Pressure Viewpoint
Temperature Viewpoint
i-Output Conveyor’s Viewpoint i=1,2,3,4
Maintenance Viewpoint
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...
2
Behavioural model
The basic sub-systems include [2]:
1
...
Pack loading control sub-system;
3
...
Safety guards control sub-system;
5
...
Temperature control sub-system;
7
...
The pressure and temperature control sub-systems are classical
type feedback systems
...
Download free eBooks at bookboon
...
4
...
1
Low level data / control flow diagrams
Sub-System Controlling Laminate Press Pack Positioning On The Input Conveyor
The sub-system controlling laminate press pack positioning on the input conveyor receives signals from
the following sensors and devices [2]:
• maintenance panel signal (press in use/out of use)
• sensor C (pack available/not available)
• sensor A (AGV available/not available)
The sub-system generates the following output signals:
• message to the AGV controller that AGV has been unloaded;
• instruction to unload pack from the AGV (this instruction is supplied to the AGV
unloading drives)
The events that control the process are [3]:
• AGV arrival;
• Press operating condition;
• Pack positioned on the conveyor
...
Figure 2
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...
The sub-system generates the following output signals [4]:
• message to the AGV controller to send an AGV loaded with press laminate packs;
• Instruction to load the pack from the conveyor into the press and simultaneously read the
bar code information;
The stored data are the temperature, pressure and pressing time
...
Figure 3 shows the data/control flow diagram
...
com
105
Software engineering and data communications:
an automatic laminating plant
Automation and Robotics
Safety Guards Control Sub-System
The safety guards control sub-system receives signals from the following sensors and sub-systems [5]:
• sensor F;
• temperature control sub-system (“shut safety guards” instruction);
• pack loading control sub-system (“shut safety guards” instruction);
The sub-system generates safety guards shut or open instructions
...
Figure 4 shows the data/control flow diagram
...
mastersopenday
...
com
106
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Software engineering and data communications:
an automatic laminating plant
Automation and Robotics
Figure 4
Temperature Control Sub-System
The Temperature control sub-system receives signals from the following sensors and sub-systems [4]:
• sensor Т;
• sub-system controlling loading of press packs into the press required press temperature,
down temperature and press time);
• system time timer
The sub-system generates the following output signals [4]:
• steam valve open/shut off instruction
• cold water valve open/shut off instruction;
• safety guards open instruction
...
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...
The sub-system generates the following signals [5]:
• pump control instruction;
Figure 6 shows the data/control flow diagram
...
com
108
Software engineering and data communications:
an automatic laminating plant
Automation and Robotics
Figure 6
AGV Traffic Control Sub-System During Maintenance Shutdowns
The AGV traffic control sub-system receives signals from the following sensors and devices [4]:
• signal from the maintenance panel (press in use/out of use);
• sensor А (a pack is in position/not available in the input conveyor);
• sensor В (a pack is in position/not available in the output conveyor)
...
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...
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...
Figure 8 shows the data/control flow
diagram
...
2
...
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...
Press work
wait
waiting
Press is empty
E generate instruction
D send message
loading
generating
Bar code
reading
Conveyor empty
E send message
D generate instruction
sending
D send message
Figure 10
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...
Close guards
Pack is positioned
Generate instruction ‘close’
Generating
Open guards
take down
Generate instruction ‘open’
Generating
Figure 11
Temperature Control Sub-System
The state transition diagram is shown in Figure 12 [8]
...
3
controlling
Temperature=press
temperature
start timer
starting
time out
E control 7
...
3
controlling
Temperature=down
temperature
E generate instruction
D control 7
...
com
113
Software engineering and data communications:
an automatic laminating plant
Automation and Robotics
Pressure Control Sub-System
Figure 13 shows the State transition diagram [8]
...
Find out what you can do to improve
the quality of your dissertation!
Get Help Now
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...
co
...
com
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Software engineering and data communications:
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Automation and Robotics
AGV TRAFFIC Control Sub-System During Maintenance Shutdowns
Figure 14 shows the state transition diagram [9]
...
Safety guards open
generate instr
...
load
Generating
Conveyor empty
generate message
Generating
Figure 15
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...
2
...
com
116
Software engineering and data communications:
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Automation and Robotics
References
1
...
Hubel, G
...
Colquhoun, A reference architecture for Engineering Data Control (EDC) in
capital plant manufacture
...
2
...
El-Nashar, Optimization of operating parameters of MSF plants through automatic
setpoint control
...
3
...
Carotti, G
...
Engineering
Structures, Volume 13, Issue 3, July 1991, Pages 242–252
...
Hassan Gomaa, Software design methods for the design of large-scale real-time systems
...
5
...
Journal
of Systems and Software, Volume 48, Issue 1, 1 August 1999, Pages 27–41
...
Sam C
...
Hayes, Donald E
...
Comparison of measurement efficiency for various test signal waveforms
...
7
...
Software Design Methodology, 2005,
Pages 299–334
...
Jeff Tian, Reliability Measurement, Analysis, and Improvement for Large Software Systems
...
9
...
Romeu, A simulation approach for the analysis and forecast of software productivity
...
10
...
Reid Turner, Alfonso Fuggetta, Luigi Lavazza, Alexander L
...
Journal of Systems and Software, Volume 49, Issue 1, 15 December 1999,
Pages 3–15
...
com
117
Automation and Robotics
Robot grip mechanism: control loop design considerations
5
Robot grip mechanism: control
loop design considerations
5
...
1:
A = 15, B = 15, C = 85
Input
A
s 2 + sB + C
Output
Figure 1
Brain power
By 2020, wind could provide one-tenth of our planet’s
electricity needs
...
Up to 25 % of the generating costs relate to maintenance
...
We help make it more economical to create
cleaner, cheaper energy out of thin air
...
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meet this challenge!
The Power of Knowledge Engineering
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...
skf
...
com
118
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Automation and Robotics
Robot grip mechanism: control loop design considerations
The closed-loop system shall have the following quality indicators for the transition process:
Peak time –
...
475 s
Percentage overshoot –
...
838%
Settling time –
...
533 s
Output value –
...
Showing the results of simulating the open loop system and the closed loop control system has been done
by employing CODAS (Matlab)
...
4 seconds while the other
parameters remain the same? What could you do about this? The problems this may cause and possible
solutions have been described
...
2
Open loop system
If we consider a standard second-order system [1]:
Y( s )
X( s )
(1)
2 2
T s
k
,
2 Ts 1
where:
k
T
A/ C
15 / 85 0
...
1085,
0
...
Figure 2 shows the step response of the
open loop system:
Figure 2
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...
3
Robot grip mechanism: control loop design considerations
Closed loop control system
If we close the system using a single feedback, as shown in Figure 3:
A
s 2 + sB + C
Figure 3
The transfer function is [2]:
W( s )
G( s )
1 G( s )
s
2
A
Bs C
A
s
2
15
...
15
...
(C + A)
A
A
s 2 + sB + C
Figure 4
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Automation and Robotics
Robot grip mechanism: control loop design considerations
The desired movement of the system (the parameters of the assignment) can be achieved adopting
various synthesis techniques – root locus, frequency domain compensator design techniques and other
methods but such techniques are essentially abstract by nature and too far from the physics of processes
taking place in real systems [3]
...
The algorithm synthesized employing the above method allows us to directly implement the parameters of
the desired movement into the control formula – the reference model will be defined using the following
second-order differential equation [5]:
2
y*
2 y*
y*
y0
...
The system (1) can be presented in the Koshi form [6]:
(3)
dy1
dt
dy 2
dt
y 2;
By 2
Cy1
Ax
...
com
122
Automation and Robotics
Robot grip mechanism: control loop design considerations
2
y2
1
x
x
A
+_
1
+_
s
Gain 3
y2
Integrator 1
1
s
y1
1
y1
Integrator
Gain 1
B
Gain 2
C
Figure 6
The object simulation model as controlled by (3) above is shown in Figure 7
...
τ
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...
4
s we will get the results shown in Figure 8 for coefficient k values of k = 0
...
Figure 8
It can be seen from Figure 8 that when coefficient k = 20 the reference movement defined by equation
(2) is coincident with system Output y
...
com
124
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Automation and Robotics
Robot grip mechanism: control loop design considerations
Since system (1) is a linear type of system we can achieve the desired quality of the transfer process for
any value of the quality indicators (settling time, overshoot, etc
...
However, this is not true when real systems have to be designed as we will then be limited by the energy
capabilities of the physical processes [6]
...
4
Other control loop design considerations
Real physical systems are non-linear and unsteady by nature
...
Despite of the fact that control loops are
usually synthesised based on linear models, it is necessary to check the results using computer simulation
on non-linear models or physical models [7]
...
When selecting the
suitable reference movement (2) we have to consider the energy capabilities of drive power units, which
are usually limited
...
When this condition is not met we cannot expect to meet the step
response quality criterion
...
For example, if we increased or reduces the values of A, B and C by 20%
...
Simulations are performed using a gain coefficient of k = 20
...
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...
This means that the loop thus synthesised shows adaptive properties when it comes to varying object
parameters [8]
...
5 Conlcusion
Other methods of control loop synthesis are also possible
...
References
1
...
Automatica, Volume 32, Issue 12, December 1996,
Pages 1659–1673
...
Yucai Zhu, Paul P
...
van den Bosch, Optimal closed-loop identification test design for internal
model control
...
3
...
Automatica, Volume 41,
Issue 3, March 2005, Pages 393–438
...
com
126
Automation and Robotics
4
...
Michiel Meeuse, Rob L
...
Computers & Chemical Engineering, Volume 26,
Issues 4–5, 15 May 2002, Pages 641–647
...
Jin-Hyung Kim, Neil A
...
CIRP Annals – Manufacturing Technology, Volume 54,
Issue 1, 2005, Pages 455–458
...
G
...
Barton, W
...
Chan, J
...
Perkins, Interaction between process design and process control:
the role of open-loop indicators
...
7
...
Atkinson, V
...
Dalvi Computer-aided design of parallel compensated closed-loop control
systems
...
8
...
Macgregor, Identification for robust multivariable control: The design
of experiments
...
9
...
Control and
Dynamic Systems, Volume 70, 1995, Pages 163–198