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Materials handling in flexible manufacturing systems
1. Introduction
The term material handling is used in defining an integrated system that involves activities like moving, storing, handling, and the control of materials using grav-
ity, manual, or machine power. Moving materials is work and requires time and space. To move a material, it is important to focus on analyzing the path of movement regardless of the material's size, shape, weight, and condition. Storage is a good way of creating a buffer to materials from one operation to another. It is key to the efficiency of people and machines in the provision of an efficient material organization. In designing a material system, the following should be considered; size,
weight, condition, and ability to a stack of materials. This is required in all types of designs. Thinking about building design for example it is important to consider the floor loading, condition of the floor, and spacing of columns among others. Materials should be protected from all forms of deterioration. Protection of materials cov- ers packaging, safeguarding from theft, and protection against mishandling. Information about the use of a machine should be provided to all authorized people to prevent situations of machine mishandling. It is important to have both physical and status control. Controls should also cover misappropriate use and misplacement of materials. The sequence and space of material movement are defined as physical control. In status control, one needs to know the physical location of mater-
ial, origin, destination, ownership, and material schedule. However, it is difficult to maintain control of materials because it is affected by things like organizational cul- ture and the character of people handling the functions associated with the material. To ensure that an organization has a flexible manufacturing system, it is import- ant to focus on material handling. A material can spend 80% of its time on the floor of a shop waiting or in transportation activities that do not add value to an organ- ization. It is therefore important to have efficient material handling to avoid situations of congestion, shorten the delivery time, reduce the number of hours a
machine is idle and non-available, or accumulate materials at workstations. It is important to focus on safe material handling to reduce wastage, breakage, situ-
ations of loss, scrapes, and fixes. 1. Material handling principles
In material handling, some principles give fundamentals of practices for material handling and give guidance to designers of all material handling systems. The
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following list shows the applicable principles in material handling; 2.1 Planning principle
Planning is important in material handling. The result of material handling is inclined to set performance objectives and performing specific functions. It is important to plan and define material functions and the modes of operations. Key questions include; what, when, where, how, and who. 2.2 Standardization principle
This is key to the flexibility of handling materials. In all possible situations handling methods should be standardized. Limits set should assist in achieving all set per- formance objectives with flexibility, modularity, and considering the future changes of the materials. 2.3 Ergonomic principle
This is inclined to respecting the capabilities of humanity in the design of material handling tasks and equipment. This should is key to attaining safe and effective op- erations. The design process should consider making equipment that does away with repetitive and manual labor which can strain people. This is a good way of in- creasing the effectiveness of material handling. 2.4 Flexibility principle
This is associated with the use of material with the ability to perform a variety of tasks and can be exposed to different conditions of operations. 2.5 Simplifica-
tion
This is a principle that reduces and eliminates unnecessary movements and equipment. 2.6 Gravity
The use of gravity in moving material should be considered in all possible situations. 2.7 Layout
All viable systems should have a well-selected system of configuration with well know the operating sequence. 2.8 Cost
The expenses associated with material handling should be considered. Cost-effective alternatives should be considered. 2.9 Maintenance
In material handling, it is important to keep a schedule of preventive maintenance. 2.10 Unit load principle
The load that can be stored or moved at a time is known as a unit load. This can include things like a pallet or a container. A unit size should always have the ap-
propriate size and be in a way helping organizations achieve the flow of material and objectives of an organizational inventory system at different stages of the supply chain. 2.11 Principle of space utilization
Material handling should consider effective and efficient use of available space. Transport of material within a facility should consider overhead space utilization.
2.12 System principle
The movement of material and storage should be well-coordinated and integrated.
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This should not limit the operating system responsible for receiving, selection, transportation, and returns handling. This should also consider the organizational sup- ply chain with manufacturers, suppliers, distributors, and consumers. 2.13 Principle of automation
In improving the efficiency of material handling, it is important to mechanize/ automate operations to increase effectiveness, consistency, and predictability. 2.14
Principle of Environment
Impacts on the environment and energy consumption should be considered when designing equipment and material handling systems. 2.15 Principle of
life cycle cost
The life cycle of machine handling should have a proper analysis of its economy. This should consider investment capital, installation, material/machine setup
and equipment programming, any training needed, testing of system and acceptance, the associated operations and maintenance, repair, reuse value, and at the end ultimate disposal. 3.Material Transport Equipment
Equipment has been classified by the International materials management society as; conveyors, cranes, elevators, and hoists. There are positioning con-
trol, and weighing equipment, Vehicles for industries, railroad cars, marine carriers, aircraft, containers, and support. Details of material transport equipment are
provided as below; 3.1 Conveyor Systems
In cases where there is very frequent movement of material between two specific points, it is important to use a conveyor. The conveyor system is combined with modern identification and recognition system and plays a critical role in an organizational production line. The common types of conveyors used include; rollers,
skate-wheel conveyors, in-floor towline conveyors, and overhead trolley conveyors. 3.1.1 Roller conveyor
This is a conveyor whose part is made up of a series of rollers perpendicular to the direction in which the load travels. The load in this type of conveyor should
have a flat bottom to be able to span several rollers. Rollers can be powered or non-powered. Powering a roller conveyor helps in driving the loads forward.
Fig. 1. Roller conveyor 3.1.2 Skate-wheel conveyor
This has a similar operation as the roller conveyor. The difference is that it uses skate wheels instead of rollers which are lighter and non-powered. They
can be built as portable units for loading and unloading truck trailers.
Fig. 2. Skate-wheel conveyor 3.1.3 Conveyor belt
This is a continuous loop that is made to have a forward path of moving loads. The characteristic belt is made up of an elastomeric support slider or even rollers
supporting the loop. They can be of two types; Flat belts and V-shaped for very heavy materials.
Fig. 3. Belt conveyor 3.1.4 In-Floor two-line conveyor
This is a cart that is four-wheel powered by a moving chain or cable in trenches in the floor. Carts are made to use steel pins that project below the level of the floor
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and engage a chain in tow.
Fig. 4. In-floor two-line conveyor.
3.1.5 Overhead Trolley conveyor It is a wheeled carriage that runs on an overhead track. This track is used in suspending loads. Trolleys are connected and
moved by the chain or cable forming a complete loop.
Fig. 5. Over-head trolley conveyor
3.1.6 Cart-on Track conveyor
This is made up of a cart that rides on a track that is above the floor level and using a spinning tube to drive it. A drive wheel is used in controlling the forward
motion.
Fig. 6. Cart-on-track conveyor. 3.2 Cranes and Hoists
Transfer of materials with heavyweight requires the use of a crane for the intermittent flow of material. Loads moved by cranes have varying shapes and weights. Craned can be operated manually, electrically, or pneumatically. A crane uses a hoist making up a combination of both. They can be used in providing vertical
and horizontal transport.
Fig. 7. (a) Sketch of the hoist (b) diagram to illustrate mechanical advantage 3.2.1 Bridge Crane
This is a crane that consists of one or two horizontal girder/beams which are suspended on a fixed rail on both ends and connected to a structure of a building.
They have used the fabrication of heavy machinery because of their ability to carry loads not exceeding 100 tons.
Fig. 8. Bridge crane 3.2.2 Half-gantry crane
The difference between this and bridge crane is that this crane has one or two vertical support elements providing support to a horizontal girder.
Fig. 9. Half gantry crane
3.2.3 Jib Crane
This kind of crane has a rotating arm and a hoist running across its length. The arm revolves on a fixed axis held by a grounded mounted post. They are convenient in lifting areas which characteristic circular arcs.
Fig. 10. Jib Crane
3.2.4 Stacker Crane
This is very similar to a bridge crane. This crane uses a mast with forks. It can also use platforms for handling the unit loads. This crane is used in storing and re-
trieving unit loads in raised store racks. 1. Automated Retrieval and storage equipment
This can be in form of shelves, racks, drawers, or bins. Racks are the most common storage equipment used. Racks have different configurations depending on
the facility and mode of operations.
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1. Automated guided vehicles (AGV) This system of handling material uses independently operated self-driven vehicles which move on guided pathways.
This system of material handling is automated. Key parts of the system include; the drive, steering power, and computer control. 5.1 Types of AGV
5.1.1 Driverless Automated Guided Train
This type of AGV was introduced in 1954. It is used in moving heavy payloads over distances in warehouses and factories without stopping along the route.
Fig. 11. Driverless automated guided vehicle 5.1.2 AGV pallet truck
They are applied in moving palletized loads in predetermined routes. Workers back vehicles into loaded pallet which is then elevated from the floor.
Fig. 12. AGV pallet truck 5.1.3 Unit Load carrier
In moving unit loads from one station to another this carrier is used. They are equipped for automatic loading/unloading of pallets.
Fig. 13. Unit load carrier 5.1.4 Light load AGV
This can be used for light loads. They are commonly applied in electronics assembly and offices. 5.1.5 Assembly AGV
In assembly platforms like in the automotive industry, this can be used. They are used to transport parts in an assembly station. 5.1.6 Forklift AGV
This could pick up and drop off palletized loads. Can be used to pick loads at floor level or on stands. 5.1.7 Rail-Guided vehicles
They are made to be self-propped vehicles moving on a fixed rail. They have an independent operation and maybe overhead monorail or on-floor- parallel fixed rails.
Fig. 14. Rail guided vehicle 5.2 Management of AGVS system
This should consider the following parameters; guide-path layout, AGVs required, and operational/transportation control. 5.2.1 Guide-path layout
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This defines the vehicle movement path. This dictates the pick-up and drop-off points, areas of maintenance, and intersections. The guide paths can be uni-
directional, bi-directional, multi-guided, or even mixed guided paths. 5.2.2 Number of AGVs required
The maximum number of AGVs in a system should be properly estimated. This is a good move towards reducing congestion and idle times in a working station.
5.2.3 Operational and transportation control
This consists of vehicle dispatching, traffic control, and routing vehicles. Once a demand rises for an AGV a choice should be made on the vehicle to be dispatched. Proper AGV utilization results in justification of the utilization economy. 1. Industrial robots
These are useful material handling devices that are automated. They are programmed to perform various tasks like moving materials, parts, tools m or devices
by variable programmed motions. They operate at a certain degree of freedom and are automatically controlled. 6.1 Robot Components
The basic components of an industrial robot are listed as below;- 6.1.1 Manipulator
This is a mechanical unit that provides characteristic motion similar to the human arm and hand. 6.1.2 End effector
This is attached with the end of the wrist in a robot. It is used to enable a robot to undertake a particular task. The end effector may be equipped with the
following; gripper, hooks, vacuum cups, spray gun, or attachments used for welding purposes. 6.1.3 Control system
This gives commands to the robot. It is used in data storage and manipulates the robot. 6.1.4 Power supply
Used in supplying power to the control system. 6.2 Robot types
The classification of robots is Cartesian, cylindrical, and polar. 6.2.1 Pick and place robots
This is a fixed sequence robot that is programmed for specific operation with movements from point to another. 6.2.2 Playback robot
This is a robot with the ability to learn the work and motion of operation activities and repeats them as guided by the operator. 6.2.3 Numerically controlled ro-
bot
This type of robot is programmed and works as a numerical control machine. 6.2.4 Intelligent robot
This robot can perform tasks done by human beings. It is equipped with sensors and has tactile capabilities. 6.3 Applications of robots in material handling
The main applications of robots in material handling include; 1. They are used in industries in loading/unloading materials. 1. Transfer of material from one con-
veyor to the other. 1. In palletizing and de-palletizing materials that are taken from conveyor and loaded into a pallet. 1. They are used in an automotive as-
sembly where repetitive work is needed. 1. The use of intelligent robots is used in automatically picking the right workpiece without the interference of the operator.
7. References M.P. Groover. “Automation, Production systems and computer integrated manufacturing” Second edition. Pearson-Prentice Hall, 2008. K.
Sareen and C. Grewal.”CAD/CAM: Theory and concepts” S. Chand & Co. 2009. C. R. Alavala. “ CAD/CAM: Concepts and applications” Prentice-Hall, 2008. P. N.
Rao. “ CAD/CAM: Principles and applications” McGraw-Hill, 2004. C. R. Asfahl. “Robots and manufacturing automation” Second edition, John-Wiley and
sons.1992. M. P. Groover and E. W. Zimmers. Jr. “ CAD/CAM: Computer added design and manufacturing” Pearson-Prentice Hall, 2009. G. Chryssol-
ouris, “Manufacturing systems: Theory and Practice
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Materials handling in flexible manufacturing systems
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Materials handling in flexible manufacturing systems
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The term material handling is used in defining an integrated system that involves activit- ies like moving, storing, handling, and the control of materials using gravity, manual, or machine power. Moving materials is work and requires time and space.
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Material handling can be defined as an integrated system involving such activities as mov- ing, handling, storing and controlling of materials by means of gravity, manual effort or power activated machinery Moving materials utilize time and space
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size, weight, condition, and ability to a stack of materials.
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the size, weight, condition and stack ability of materials
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In status control, one needs to know the physical location of material, origin, destination, ownership, and material schedule.
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Status control is the real time awareness of the location, amount, destination, origin, ownership and schedule of material
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It is therefore important to have efficient material handling to avoid situations of conges- tion, shorten the delivery time, reduce the number of hours a machine is idle and non- available, or accumulate materials at workstations.
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Material handling efficiency is necessary to reduce traffic congestion, ensure timely deliv- ery, and reduce machine idle time due to non-availability or accumulation of materials at workstations
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It is important to focus on safe material handling to reduce wastage, breakage, situations of loss, scrapes, and fixes.
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Safe handling of materials is important in a plant as it reduces wastage, breakage, loss and scrapes etc
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Material handling principles
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of material handling principles
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In material handling, some principles give fundamentals of practices for material hand- ling and give guidance to designers of all material handling systems.
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The material handling principles provide fundamentals of material handling practices and provide guidance to material handling system designers
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2.2 Standardization principle
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0251124$@%@@@#@!!~$$ 2.2 Standardization principle
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2.3 Ergonomic principle
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2.3 Ergonomic principle
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2.4 Flexibility principle
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2.4 Flexibility principle
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2.5 Simplification
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2.5 Simplification
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2.6 Gravity
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2.7 Layout
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2.8 Cost
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2.9 Maintenance
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2.10 Unit load principle
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2.10 Unit load principle
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The load that can be stored or moved at a time is known as a unit load.
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A unit load is one that can be stored or moved as a single
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2.11 Principle of space utilization
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2.11 Space utilization principle
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2.12 System principle The movement of material and storage should be well-coordinated and integrated.
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2.12 System principle Material movement and storage activities should be fully integrated to form a coordinated, operational system
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2.13 Principle of automation
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2.13 Automation principle
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2.14 Principle of Environment
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2.14 Environmental principle
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Impacts on the environment and energy consumption should be considered when designing equipment and material handling systems.
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Environment Environmental impact and energy consumption should be considered while designing or choosing alternative equipment and material handling systems
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2.15 Principle of life cycle cost
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2.15 Life cycle cost principle
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This should consider investment capital, installation, material/machine setup and equip- ment programming, any training needed, testing of system and acceptance, the associ- ated operations and maintenance, repair, reuse value, and at the end ultimate disposal.
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Life cycle costs include capital investment, installation, setup and equipment program- ming, training, system testing and acceptance, operating (labor, utilities, etc.), mainten- ance and repair, reuse value, and ultimate disposal
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3.Material Transport Equipment
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Material Transport Equipment
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Equipment has been classified by the International materials management society as;
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International Materials Management Society has classified equipment as (1)
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conveyors, cranes, elevators, and hoists.
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Cranes and Hoists
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Details of material transport equipment are provided as below;
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details of material transport equipment
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3.1 Conveyor Systems
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3.1 Conveyor Systems
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The common types of conveyors used include;
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Some of common types of conveyors are
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3.1.1 Roller conveyor
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3.1.1 Roller Conveyor
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This is a conveyor whose part is made up of a series of rollers perpendicular to the direc- tion in which the load travels.
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The path of a roller conveyor is made up of a series of rollers that run perpendicular to the direction of motion
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Rollers can be powered or non-powered.
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Conveyors can be either powered or non-powered
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Roller conveyor 3.1.2 Skate-wheel conveyor
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3.1.2 Skate-Wheel Conveyor
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This has a similar operation as the roller conveyor. The difference is that it uses skate wheels instead of rollers which are lighter and non-powered.
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are similar in operation to roller conveyor but use skate wheels instead of rollers and are generally lighter weight and non-powered
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They can be built as portable units for loading and unloading truck trailers.
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Sometimes, these are built as portable units that can be used for loading and unloading truck trailers in shipping and receiving
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Skate-wheel conveyor 3.1.3 Conveyor belt
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3.1.3 Belt Conveyor
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This is a continuous loop that is made to have a forward path of moving loads. The char- acteristic belt is made up of an elastomeric support slider or even rollers supporting the loop.
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Is a continuous loop with forward path to move loads in which the belt is made of rein- forced elastomeric support slider or rollers used to support
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Belt conveyor 3.1.4 In-Floor two-line conveyor This is a cart that is four-wheel powered by a moving chain or cable in trenches in the floor. Carts are made to use steel pins that pro- ject below the level of the floor and engage a chain in tow.
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3.1.4 In-Floor Tow-Line Conveyor These are four-wheel carts powered by moving chains or cables in trenches in the floor Carts use steel pins (or grippers) to project below floor level and engage the chain (or pulley) for towing
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In-floor two-line conveyor.
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In-floor two-line conveyor
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3.1.5 Overhead Trolley conveyor It is a wheeled carriage that runs on an overhead track.
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3.1.5 Overhead Trolley Conveyor A trolley is a wheeled carriage running on an overhead track from which loads can be suspended
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Trolleys are connected and moved by the chain or cable forming a complete loop.
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Trolleys are connected and moved by a chain or cable that forms a complete loop and are often used to move parts and assemblies between major production areas
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Over-head trolley conveyor
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Over-head trolley conveyor
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3.1.6 Cart-on Track conveyor
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3.1.6 Cart-On-Track Conveyor
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A drive wheel is used in controlling the forward motion.
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The forward motion of cart is controlled by a drive wheel
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Cart-on-track conveyor.
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· Cart-on-track conveyor
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3.2 Cranes and Hoists
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3.2 Cranes and Hoists
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Craned can be operated manually, electrically, or pneumatically.
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They can be operated manually, electrically, or pneumatically
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(a) Sketch of the hoist (b) diagram to illustrate mechanical advantage 3.2.1 Bridge Crane
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(a) Sketch of the hoist (b) diagram to illustrate mechanical advantage
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This is a crane that consists of one or two horizontal girder/beams which are suspended on a fixed rail on both ends and connected to a structure of a building. They have used the fabrication of heavy machinery because of their ability to carry loads not exceeding 100 tons.
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A bridge crane consists of one or two horizontal girders or beams suspended between fixed rail on either end which are connected to the structure of the building They have the ability to carry loads up to 100 tons
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Bridge crane 3.2.2 Half-gantry crane The difference between this and bridge crane is that this crane has one or two vertical support elements providing support to a horizontal girder.
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3.2.2 Half-gantry crane Half gantry crane is distinguished from bridge crane by the pres- ence of one or two vertical supporting elements which support horizontal girder
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Half gantry crane
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Half gantry crane
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3.2.3 Jib Crane
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3.2.3 Jib Crane
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3.2.4 Stacker Crane
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3.2.4 Stacker Crane
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This crane uses a mast with forks.
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The stacker crane uses a mast with forks or a platform to
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Automated Retrieval and storage equipment
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Automated Retrieval and storage equipment
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This can be in form of shelves, racks, drawers, or bins.
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Storage equipments can be in the form of racks, shelves, bins and drawers
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Automated guided vehicles (AGV) This system of handling material uses independently operated self-driven vehicles which move on guided pathways.
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Automated Guided Vehicles An Automated Guided Vehicle System (AGVS) is a material handling system that uses independently operated, self-propelled vehicles guided along defined pathways in the facility floor
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This system of material handling is automated.
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Automated material handling
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5.1 Types of AGV 5.1.1 Driverless Automated Guided Train
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5.1 Types of AGV 5.1.1 Driverless Automated Guided Train
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It is used in moving heavy payloads over distances in warehouses and factories without stopping along the route.
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Common application is moving heavy payloads over long distances in warehouses and factories without intermediate stops along the route Automated guided pellet trucks
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Driverless automated guided vehicle 5.1.2 AGV pallet truck
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5.1.2 AGV Pallet Truck
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They are applied in moving palletized loads in predetermined routes.
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Palletized loads are transported along predetermined routes
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Workers back vehicles into loaded pallet which is then elevated from the floor.
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pallet is then elevated from floor
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AGV pallet truck 5.1.3 Unit Load carrier
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5.1.3 Unit Load Carrier
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In moving unit loads from one station to another this carrier is used.
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This type of AGVS is used to move unit loads from one station to another station
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They are equipped for automatic loading/unloading of pallets.
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often equipped for automatic loading/unloading of pallets
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Unit load carrier 5.1.4 Light load AGV
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5.1.4 Light load AGV
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5.1.5 Assembly AGV
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5.1.5 Assembly AGV
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5.1.6 Forklift AGV
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5.1.6 Forklift AGV
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This could pick up and drop off palletized loads.
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Used to pick up and drop off palletized loads both at floor
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Can be used to pick loads at floor level or on stands.
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It can pick up and drop off palletized loads both at floor level and on stands
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5.1.7 Rail-Guided vehicles
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5.1.7 Rail-Guided Vehicles
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Rail guided vehicle 5.2 Management of AGVS system
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5.2 AGVS System Management
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guide-path layout, AGVs required, and operational/transportation control.
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Guide-path layout Number of AGVs required Operational and transportation control
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5.2.1 Guide-path layout
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5.2.1 Guide-path layout
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This defines the vehicle movement path.
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defines the possible vehicle movement path
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This dictates the pick-up and drop-off points, areas of maintenance, and intersections.
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Pick-up and drop-off points, maintenance areas, and intersections represent the route
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5.2.2 Number of AGVs required
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5.2.2 Number of AGVs required
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5.2.3 Operational and transportation control This consists of vehicle dispatching, traffic control, and routing vehicles. Once a demand rises for an AGV a choice should be made on the vehicle to be dispatched.
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5.2.3 Operational and Transportation Control The operation and transportation consists of vehicle dispatching, vehicle routing and traffic control issues Once a demand arises for an AGV, a choice needs to be made regarding the vehicle to be dispatched among the pool of vehicles available
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These are useful material handling devices that are automated.
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Industrial robots are very useful material handling devices in an automated environment
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6.1 Robot Components
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6.1 Robot components
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The basic components of an industrial robot are listed as below;- 6.1.1 Manipulator
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6.1 Robot components The following are basic components of an industrial robot
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This is a mechanical unit that provides characteristic motion similar to the human arm and hand.
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It is a mechanical unit that provides motions similar to those of human arm and hand
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6.1.2 End effector
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6.1.2 End effector
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This is attached with the end of the wrist in a robot.
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It is attached with the end of wrist in a robot
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The end effector may be equipped with the following;
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Depending on the type of work, end effector may be equipped with any of the following
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6.1.3 Control system
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6.1.3 Control system
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6.1.4 Power supply
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6.1.4 Power supply
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6.2 Robot types
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6.2 Robot Types
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6.2.1 Pick and place robots
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6.2.1 Pick and place robot
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This is a fixed sequence robot that is programmed for specific operation with movements from point to another.
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It is also called fixed sequence robot and is programmed for a specific operation
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6.2.2 Playback robot
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6.2.2 Playback robot
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6.2.3 Numerically controlled robot
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6.2.3 Numerically controlled robot
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This type of robot is programmed and works as a numerical control machine.
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It is a programmable type of robot and works same as the numerical control machines
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6.2.4 Intelligent robot
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6.2.4 Intelligent robot
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6.3 Applications of robots in material handling The main applications of robots in material handling include;
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6.3 Robot applications in Material handling Major applications in material handling include
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Transfer of material from one conveyor to the other.
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These are used to transfer the material from one conveyor to another
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In palletizing and de-palletizing materials that are taken from conveyor and loaded into a pallet.
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· These are used in palletizing and de-palletizing so that components and materials are taken from the conveyor and loaded into a pallet in the proper pattern and sequence, and vice versa
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References M.P.
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References M.P
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“Automation, Production systems and computer integrated manufacturing” Second edi- tion. Pearson-Prentice Hall, 2008.
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“Automation, Production systems and computer integrated manufacturing” Second edi- tion Pearson-Prentice Hall, 2008
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Sareen and C. Grewal.”CAD/CAM: Theory and concepts” S.
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Sareen and C Grewal.”CAD/CAM Theory and concepts” S
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Concepts and applications” Prentice-Hall, 2008.
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Concepts and applications” Prentice-Hall, 2008
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Principles and applications” McGraw-Hill, 2004.
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Principles and applications” McGraw-Hill, 2004
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“Robots and manufacturing automation” Second edition, John-Wiley and sons.1992.
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“Robots and manufacturing automation” Second edition, John-Wiley and sons.1992
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Groover and E.
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Groover and E
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Computer added design and manufacturing” Pearson-Prentice Hall, 2009.
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Computer added design and manufacturing” Pearson-Prentice Hall, 2009
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Chryssolouris, “Manufacturing systems:
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Chryssolouris, “Manufacturing systems
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Theory and Practice
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Theory and Practice” Springer-