09 Automated Assembly

Assembly
1. Fundamentals of Automated Production Lines

2. Applications of Automated Production Lines
24/04/2014 Manufacturing System
2
Automated Production Lines
High production of parts requiring multiple
processing operations
Fixed automation
Applications:
Transfer lines used for machining
Robotic spot welding lines in automotive final
assembly
Sheet metal stamping
Electroplating of metals
3
Where to Use Automated Production
Lines
High product demand
Requires large production quantities
Stable product design
Difficult to change the sequence and content of
processing operations once the line is built
Long product life
At least several years
Multiple operations required on product
The different operations are assigned to different
workstations in the line
4
Benefits of Automated Production
Lines
Low direct labor content
Low product cost
High production rates
Production lead time and work-in-process are
minimized
Factory floor space is minimized
5
Automated Production Line - Defined
Fixed-routing manufacturing system that consists
of multiple workstations linked together by a
material handling system to transfer parts from
one station to the next
Slowest workstation sets the pace of the line
Workpart transfer:
Palletized transfer line
Uses pallet fixtures to hold and move workparts
between stations
Free transfer line
Part geometry allows transfer without pallet fixtures
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Automated Production Line
7
General configuration of an automated production line consisting of
n automated workstations that perform processing operations
System Configurations
In-line - straight line arrangement of
workstations
Segmented in-line two or more straight line
segments, usually perpendicular to each other
Rotary indexing machine (e.g., dial indexing
machine)
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Segmented In-Line Configurations
9
L-shaped layout
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U-shaped layout
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Rectangular configuration
Two Machining Transfer Lines
12
Rotary Indexing Machine
13
Workpart Transfer Mechanisms
Linear transfer systems:
Continuous motion not common for automated
systems
Synchronous motion intermittent motion, all
parts move simultaneously
Asynchronous motion intermittent motion,
parts move independently
Rotary indexing mechanisms:
Geneva mechanism
Others
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Belt-Driven Linear Transfer System
15
Side view of chain or steel belt-driven conveyor (over
and under type) for linear transfer using work carriers
Walking Beam Transfer System
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Walking Beam Transfer System
17
Geneva Mechanism with Six Slots
18
Cam Mechanism to Drive Dial Indexing
Table
19
Storage Buffers in Production Lines
A location in the sequence of workstations where
parts can be collected and temporarily stored
before proceeding to subsequent downstream
stations
Reasons for using storage buffers:
To reduce effect of station breakdowns
To provide a bank of parts to supply the line
To provide a place to put the output of the line
To allow curing time or other required delay
To smooth cycle time variations
To store parts between stages with different
production rates
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Storage Buffer
21
Storage buffer between two stages of a production line
Control Functions in an Automated
Production Line
Sequence control
To coordinate the sequence of actions of the
transfer system and workstations
Safety monitoring
To avoid hazardous operation for workers and
equipment
Quality control
To detect and possibly reject defective work units
produced on the line
22
Applications of Automated Production
Lines
Transfer lines for machining
Synchronous or asynchronous workpart transport
Transport with or without pallet fixtures,
depending on part geometry
Various monitoring and control features available
Rotary transfer machines for machining
Variations include center column machine and
trunnion machine
23
System Design Considerations
Building block approach: machine tool companies
specialize in transfer lines and indexing machines
User contracts for custom-engineered line
Standard modules such as workheads, feed units,
transfer mechanisms, and bases
Called a unitized production line
Link line: uses standard machine tools connected by
specialized handling system
Specialized processes often engineered by the user
company
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Standard Feed Units used with In-Line
or Rotary Transfer Machines
25
(a) Horizontal feed drive unit, (b) angular feed drive
unit, and (c) vertical column feed drive unit
Standard Milling Head
26
Milling head unit that attaches to one of the feed drive
units in the previous slide
Rotary Transfer Machine (Plan View)
27
Center Column Machine (Plan View )
28
Analysis of Transfer Lines
Three problem areas must be considered:
1. Line balancing
To divide the total work load among workstations
as evenly as possible
2. Processing technology
Theory and principles about the manufacturing
or assembly processes used on the line
3. System reliability - two cases:
Transfer lines with no internal parts storage
Transfer lines with internal storage buffers
29
Lines with No Storage Buffers
As the number of workstations increases
Line efficiency and production rate are adversely
affected
As reliability of individual workstations
decreases
Line efficiency and production rate are adversely
affected
30
Lines with Storage Buffers
If E
0
and E
are nearly equal

Then little advantage is gained by adding a storage
buffer
If E
is much greater than E

0
Then adding a storage buffer may improve line
performance significantly
Storage buffers should be located so that production
rates of the stages are about equal
During operation, if any buffers are always empty or
always full, then the buffer is serving little purpose
31
Lines with Storage Buffers
The maximum possible efficiency is achieved by:
Setting the number of stages = number of stations
Using large buffer capacities
The law of diminishing returns operates in
multi-stage automated lines:
As the number of storage buffers is increased, line
efficiency improves at an ever-decreasing rate
As storage buffer capacity is increased, line
efficiency improves at an ever-decreasing rate
32
1. Fundamentals of Automated Assembly Systems
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Automated Assembly - Defined
The use of mechanized and automated devices to
perform the various assembly tasks in an
assembly line or cell
Fixed automation usually
Most automated assembly systems are designed to
perform a fixed sequence of assembly steps on a
specific product that is produced in very large
quantities
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Manufacturing System
Automated Assembly - Application
Characteristics
Where is automated assembly appropriate:
High product demand
Stable product design
The assembly consists of no more than a limited
number of components
The product is designed for automated assembly
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Typical Products
Alarm clocks
Ball bearings
Ball point pens
Cigarette lighters
Door mechanisms
Gear boxes
Light bulbs
Locks
Mechanical pencils
PCB assemblies
Small electric motors
Wrist watches
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Assembly Processes in Automated
Assembly
Adhesive bonding
Insertion of components
Placement of components
Riveting
Screw fastening
Snap fitting
Soldering
Spot welding
Stapling
Stitching
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System Configurations
In-line assembly machine
Dial indexing machine
Carousel assembly system
Single-station assembly cell
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In-Line Assembly Machine
A series of automatic workstations located along and in-line transfer system
Either synchronous or asynchronous work transfer used
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Dial Indexing Machine
Base parts are loaded onto
fixtures or nests attached to a
circular dial table, and
components are added at
workstations located around
the periphery of the dial as it
indexes from station to station
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Dial indexing assembly machine
(Bodine Corp.)
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Carousel Assembly System
A hybrid between circular work flow of dial indexing
machine and straight work flow of in-line system
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Single-Station Assembly Cell
Assembly operations are performed on a base part at a single location
A robot is sometimes used as the assembly machine
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Multi-Station vs. Single-Station
Multi-station assembly machine or line
Faster cycle rate
High production quantities
More operations possible
More components per assembly
Single-station assembly cell
Suited to robotic assembly
Intended for lower production quantities
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Parts Delivery at Workstations
Typical parts delivery system at a workstation
consists of the following hardware components:
Hopper - container for parts
Parts feeder - removes parts from hopper
Selector and/or orientor - to assure part is in
proper orientation for assembly at workhead
Feed track - moves parts to assembly workhead
Escapement and placement device - removes parts
from feed track and places them at station
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Parts Delivery System at Station
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Vibratory Bowl Feeder
Most versatile of hopper feeders for small parts
Consists of bowl and helical track
Parts are poured into bowl
Helical track moves part from bottom of bowl to
outlet
Vibration applied by electromagnetic base
Oscillation of bowl is constrained so that parts
climb upward along helical track
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Photo courtesy Syntron Inc.
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Selector and/or Orientor
Purpose - to establish the proper orientation of
the components for the assembly workhead
Selector
Acts as a filter
Only parts in proper orientation are allowed to
pass through to feed track
Orientor
Allows properly oriented parts to pass
Reorients parts that are not properly oriented
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Parts Selection and Orientation
a) Selector
b) Orientor
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Feed Track
Moves parts from hopper to assembly workhead
Categories:
Gravity - hopper and feeder are located at higher
elevation than workhead
Powered - uses air or vibration to move parts
toward workhead
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Escapement and Placement Devices
Escapement device
Removes parts from feed track at time intervals
that are consistent with the cycle time of the
assembly workhead
Placement device
Physically places the parts in the correct location
at the assembly workstation
Escapement and placement devices are
sometimes the same device, sometimes different
devices
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(a) Horizontal and (b) vertical devices for placement of
parts onto dial-indexing table
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Escapement of rivet-shaped parts actuated by work
carriers
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Two types of pick-and-place mechanisms for
transferring base parts from feeders to work carriers
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Analysis of Assembly Systems
The parts delivery system at each station must
deliver components to the assembly operation at a
net rate that is greater than or equal to the cycle rate
of the assembly workhead
Otherwise, assembly system performance is limited by
the parts delivery system rather than the assembly
process technology
Component quality has an important effect on
system performance - poor quality means
Jams at stations that stop the entire assembly system
Assembly of defective components in the product
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As the number of stations increases, uptime
efficiency and production rate are adversely
affected due to parts quality and station
reliability effects
The cycle time of a multi-station assembly
system is determined by its slowest station
By comparison with a multi-station assembly
system, a single-station assembly cell with the
same number of assembly tasks has a lower
production rate but a higher uptime efficiency
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Multi-station assembly systems are appropriate for high
production applications and long production runs
By comparison, single-station assembly cells have a
longer cycle time and are more appropriate for mid-
range quantities
Storage buffers should be used on partially automated
production lines to isolate the manual stations from
breakdowns at the automated stations
An automated station should be substituted for a manual
station only if it has the effect of reducing cycle time
sufficiently to offset negative effects of lower reliability
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09 Automated Assembly

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09 Automated Assembly

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Assembly

1. Fundamentals of Automated Production Lines

are nearly equal

is much greater than E

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