Automated Flow Lines: methods of work part transport, Transfer Mechanisms, buffer storage, automation for

machining operations, part feeding devices, Brief review of automated assembly systems and types.

Q1. (a) What do you mean by automated flow lines and methods of work part transport? 7½
(b) Explain past feeding devices in the materials handling system. 7½

Ans.(a) Automated production lines are examples of fixed automation, and it is generally difficult to alter the
sequence and content of the processing operations once the line is built.

The transfer mechanism of the automated flow line must not only move the partially completed work parts or
assemblies between adjacent stations, it must also orient and locate the parts in the correct position for processing
at each station. The general methods of transporting work pieces on flow lines can be classified into the following
three categories:
1. Continuous transfer
2. Intermittent or synchronous transfer
3. Asynchronous or power-and-free transfer

These three categories are distinguished by the type of motion that is imparted to the work piece by the transfer
mechanism.
The most appropriate type of transport system for a given application depends on such factors as:
 The types of operation to be performed
 The number of stations on the line
 The weight and size of the work parts
 Whether manual stations are included on the line
 Production rate requirements
 Balancing the various process times on the line

Continuous transfer

With the continuous method of transfer, the work parts are moved continuously at constant speed. This requires the
work heads to move during processing in order to maintain continuous registration with the work part.

For some types of operations, this movement of the work heads during processing is not feasible. It would be
difficult, for example, to use this type of system on a machining transfer line because of inertia problems due to the
size and weight of the work heads.

In other cases, continuous transfer would be very practical. Examples of its use are in beverage bottling operations,
packaging, manual assembly operations where the human operator can move with ‘the moving flow line, and
relatively simple automatic assembly tasks.

In some bottling operations, for instance, the bottles are transported around a continuously rotating drum. Beverage
is discharged into the moving bottles by spouts located at the drum’s periphery.

The advantage of this application is that the liquid beverage is kept moving at a steady speed and hence there are no
inertia problems. Continuous transfer systems are relatively easy to design and fabricate and can achieve a high rate
of production.
Intermittent transfer

In this method the workpieces are transported with an intermittent or discontinuous motion. The workstations are
fixed in position and the parts are moved between stations and then registered at the proper locations for
processing. All work parts are transported at the same time and, for this reason, the term “synchronous transfer
system” is also used to describe this method of work part transport.

Examples of applications of the intermittent transfer of work parts can be found in machining operations, press
working operations or progressive dies, and mechanized assembly. Most of the transfer mechanisms provide the
intermittent or synchronous type of work part transport.

Asynchronous transfer

This system of transfer, also referred to as a “power-and-free system,” allows each work part to move to the next
station when processing at the current station has been completed. Each part moves independently of other parts.
Hence, some parts are being processed on the line at the same time that others are being transported between
stations.

Asynchronous transfer systems offer the opportunity for greater flexibility than do the other two systems, and this
flexibility can be a great advantage in certain circumstances. In-process storage of work parts can be incorporated
into the asynchronous systems with relative ease. Power-and-free systems can also compensate for line balancing
problems where there are significant differences in process times between stations.

Asynchronous lines are often used where there are one or more manually operated stations and cycle-time
variations would be a problem on either the continuous or synchronous transport systems. Larger work parts can be
handled on the asynchronous systems.

A disadvantage of the power-and-free systems is that the cycle rates are generally slower than for the other types.

Q1. (b) Explain part feeding devices in the materials handling system. 7½
Or

Q3. (a) What are Part feeding devices? 10

In part feeding device a workstation accomplishes one or both of the following tasks:

(1) a component is delivered to the assembly work head and added to the existing base part in front of the work
head (at the first station in the system, the base part is often deposited onto a work carrier or pallet fixture), and

(2) a fastening or joining operation is performed at the station to permanently attach components to the existing
base part. In the case of a single-station assembly system, these tasks are carried out multiple times at the single
station.

The parts delivery system typically consists of the following hardware:

1. Hopper. This is the container into which the components are loaded at the workstation. A separate hopper is used
for each component type. The components are usually loaded into the hopper in bulk. This means that the parts are
randomly oriented in the hopper.

2. Parts feeder. This is a mechanism that removes the components from the hopper one at a time for delivery to the
assembly work head. The hopper and parts feeder are often combined into one operating mechanism. A vibratory
bowl feeder, is a very common example of the hopper-feeder combination.

3. Selector and/or orientor. These elements of the delivery system establish the proper orientation of the
components for the assembly work head. A selector is a device that acts as a filter, permitting only parts in the
correct orientation to pass through. Incorrectly oriented parts are rejected back into the hopper.
4. Feed track. The preceding elements of the delivery system are usually separated from the assembly work head by
a certain distance. A feed track moves the components from the hopper and parts feeder to the location of the
assembly work head, maintaining proper orientation of the parts during the transfer.

There are two general categories of feed tracks: gravity and powered.

5. Escapement and placement device. The escapement removes components from the feed track at time intervals
that are consistent with the cycle time of the assembly work head. The placement device physically places the
component in the correct location at the workstation for the assembly operation. These elements are sometimes
combined into a single operating mechanism.

Q2. (a) Differentiate among various types of automated assembly systems. 10

(b) How will you design an automated assembly? 10

Ans.(a) The term automated assembly refers to mechanized and automated devices that perform various assembly
tasks in an assembly line or cell. Much progress has been made in the technology of assembly automation in recent
years. Some of this progress has been motivated by advances in the field of robotics. Industrial robots are sometimes
used as components in automated assembly systems.

Automated assembly systems can be classified according to physical configuration. The principal configurations are
(a) in-line assembly machine,
(b) dial-type assembly machine,
(c) carousel assembly system, and
(d) single-station assembly machine.
(a)In-line assembly machine
The in-line assembly machine, is a series of automatic workstations located along an in-line transfer system. It is the
assembly version of the machining transfer line.
Synchronous and asynchronous transfer systems are the common means of transporting base parts from station to
station with the in-line configuration.

(b) Dial-type assembly machine

In the typical application of the dial-type machine, base parts are loaded onto fixtures or nests attached to the
circular dial. Components are added and/or joined to the base part at the various workstations located around the
periphery of the dial. The dial-indexing machine operates with a synchronous or intermittent motion, in which the
cycle consists of the service time plus indexing time.
Dial-type assembly machines are sometimes designed to use a continuous rather than intermittent motion. This is
common in beverage bottling and canning plants, but not in mechanical and electronics assembly.
(c) Carousel assembly system
The carousel assembly system represents a hybrid between the circular work flow of the dial-type assembly machine
and the straight work flow of the in-line system.
The carousel configuration can be operated with continuous, synchronous, or asynchronous transfer mechanisms to
move the work around the carousel. Carousels with asynchronous transfer of work are often used in partially
automated assembly systems.

(D) single-station assembly machine.

In the single-station assembly machine, assembly operations are performed on a base part at a single location. The
typical operating cycle involves the placement of the base part at a stationary position in the workstation, the
addition of components to the base, and finally the removal of the completed assembly from the station. An
important application of single-station assembly is the component placement machine, widely used in the
electronics industry to populate components onto printed circuit boards.
Q2. (b) How will you design an automated assembly?
Ans. “The aim of DESIGN FOR ASSEMBLY (DFA) is to simplify the product so that the cost of assembly is reduced.”
To design the automated assembly types of assembly method
1. Manual assembly
2. Automatic assembly
3. Robotic assembly
1. Manual assembly
A Manual assembly line is a production line that consists of a sequence of workstations. At each workstation Product
are assembled by human workers as they move along the line.
At each station, a portion of the total work is performed on each unit.
The common practice is to "launch" base parts onto the beginning of the line at regular intervals.
Each base part travels through successive stations and workers add components that progressively build the
product.
A mechanized material transport system is typically used to move the base part along the line as it is gradually
transformed into the final product.
The production rate of an assembly line is determined by its slowest station.

GENERAL DESIGN GUIDELINES FOR MANUAL ASSEMBLY

• The process of manual assembly can be divided into two separate areas:
1. Handling (acquiring, orienting, and moving the parts)
2. Insertion and Fastening (mating a part to another part or group of parts)

2. AUTOMATED ASSEMBLY
“The use of mechanized and automated devices to perform the various assembly tasks in an assembly line or cell”
Most automated assembly systems are designed to perform a fixed sequence of assembly steps on a specific product
that is produced in very large quantities.
Where is automated assembly appropriate:
1. High product demand
2. Stable product design.
3. The assembly consists of no more than a limited number of components.
4. The product is designed for automated assembly.

GENERAL DESIGN GUIDELINES FOR AUTOMATED ASSEMBLY

1. Use self-aligning and self-locating features.
2. Avoid screws/bolts.
3. Use the largest and most rigid part as the assembly base and fixture.
4. Perform assembly in a layered, bottom-up manner.
5. Use standard components and materials.
6. Avoid parts that require orientation.
7. Use parts that can be fed automatically.
8. Design parts with a low center of gravity.
3. Robotic Assembly
Production volume is higher than that of a manual assembly system but lower than that of an automatic assembly
system (Fixed automation).

Two very important and crucial considerations that have to be taken into account when designing components for
robotic assembly:
1. Design a component so that it can be grasped, oriented, and inserted by that robot's end effector. Failure to do so
will result in the need for an additional robot and, consequently, higher assembly cost.
2. Design parts so that they can be presented to the robot's arm in an orientation appropriate for grasping. Also,
eliminate the need for reorienting assemblies (or subassemblies) during the assembly operation.

Q3. (a) What are Part feeding devices? 10

(b) Discuss the analysis of a single station assembly machine. 10
Or
Q4. (a) How will you control and analyse operation of a single-station assembly machine? 10
(b) Write short note on part feeding devices. 10
Ans.(b) (D) single-station assembly machine.
Analysis of Single-station assembly system.
It consists of a single work head, with several components feeding into the station to be assembled to a base part.
Let ne = the number of distinct assembly elements that are performed on the machine.
Each element has an element time, Tej , where j = 1, 2, p , ne. The ideal cycle time for the single-station assembly
machine is the sum of the individual element times of the assembly operations to be performed on the machine,
plus the handling time to load the base part into position and unload the completed assembly.
The ideal cycle time can be expressed as

where Th = handling time, min. Many of the assembly elements involve the addition of a component to the existing
subassembly. As in the analysis of multiple-station assembly, each component type has a certain fraction defect rate,
qj , and there is a certain probability that a defective component will jam the workstation, mj. When a jam occurs,
the assembly machine stops, and it takes an average Td to clear the jam and restart the system.
The inclusion of downtime resulting from jams in the machine cycle time gives

For elements that do not include the addition of a component, the value of qj = 0 and mj is irrelevant. This might
occur, for example, when a fastening operation is performed with no part added during element j.
In this type of operation, a term pj Td would be included in the above expression to allow for a downtime during that
element, where pj = the probability of a station failure during element j. For the special case of equal q and equal m
values for all components added, Equation (17.19) becomes

Determining yield (proportion of assemblies that contain no defective components) for the single-station assembly
machine makes use of the same equations as for the multiple station systems, Equations (17.5) or (17.7). Uptime
efficiency is computed as E = Tc >Tp using the values of Tc and Tp from Equations.
Q5.(a) What are the essential resources for Automated Flow Lines ? Illustrate its operational features with the
help of an example. 10
(b) Discuss the significance of Buffer storage incorporated in Machining Centre. 5
Ans.(a) Automated production lines are examples of fixed automation, and it is generally difficult to alter the
sequence and content of the processing operations once the line is built.
Their application is therefore appropriate only under the following conditions:
• High demand, requiring high production quantities
• Stable product design, because frequent design changes are difficult to accommodate on an automated production
line
• Long product life, at least several years in most cases
• Multiple operations performed on the product during its manufacture.
(b) BUFFER STORAGE
It is just a temporary storage connected between the two or more workstation
When a breakdown occurs on an automated flow line, the purpose of the buffer storage zone is to allow a portion of
the line to continue operating while the remaining portion is stopped and under repair