Assignment No 02

(ASSEMBLY LINE AUTOMATION)

Q.1) Differentiate between following

a) Mechanization and Automation

b) Hard automation and flexible automation

c) Capital intensive vs Low cost automation

Q2) What is need of automated assembly system. How it is different from automated
assembly line.

Q.3) Classify and explain types of automated assembly system.

Q.4) Sketch and explain functions of parts delivery system.

Q.5) enlist and explain recommendations for automated assembly system.

Q.6) Explain performance measures of storage system.

Q.7) Note on conventional storage methods.

Q.8) Note on Basic AS/RS system and Basic Carousel storage system, compare.

Q.9) Note on 10 principles of storage system.

Q.10) Summarize applications of material handling equipment’s.

Q.11) Note on AGVS and conveyors.

Q,12) Note on automation using cams and Geneva mechanism.

Solution

Mechanization Automation

Saves human muscle Saves human muscle as well as human

judgement

Replace craft work Replace human thinking

Jobs for unskilled labor also Jobs for skilled labor

Affect one or two industries at a time Affect many industries at a time

Used for short term job production Used for long term job production

Low cost automation Capital intensive automation

Some degree of automation around Complete integrated automation

existing set up

Use of standard components available in Specially designed components used

market

Short payback period Comparatively long payback period

Reduce manual content without disturbing Complete change in production/ assembly

existing setup system

Low investment Comparatively higher investments

Smaller batch size Bigger batch size

Mechanisms used for automation

Mechanism is a system of rigid elements arranged and connected to transmit motion in a

predetermined fashion. Indexing mechanisms generally converts a rotating or oscillatory motion
to a series of step movements of the output link or shaft. In machine tools the cutting tool has to
be indexed in the tool turret after each operation. Also in production machines the product has to
be indexed from station to station and need to be stopped if any operation is being performed in
the station. Such motions can be accomplished by indexing mechanisms. Indexing mechanisms
are also useful for machine tool feeds. There are several methods used to index but important
types are ratchet and pawl, rack and pinion, Geneva mechanism and cam drive.
1. Ratchet and pawl mechanism

A ratchet is a device that allows linear or rotary motion in only one direction. Figure 4.5.1 shows
a schematic of the same. It is used in rotary machines to index air operated indexing tables.
Ratchets consist of a gearwheel and a pivoting spring loaded pawl that engages the teeth. The
teeth or the pawl, are at an angle so that when the teeth are moving in one direction the pawl
slides in between the teeth. The spring forces the pawl back into the depression between the
next teeth. The ratchet and pawl are not mechanically interlocked hence easy to set up. The
table may over travel if the table is heavy when they are disengaged. Maintenance of this system
is easy.

2. Rack and pinion mechanism

A rack and pinion gear arrangement usually converts rotary motion from a pinion to linear
motion of a rack. But in indexing mechanism the reverse case holds true. The device uses a
piston to drive the rack, which causes the pinion gear and attached indexing table to rotate (Fig.
4.5.2). A clutch is used to provide rotation in the desired direction. This mechanism is simple but
is not considered suitable for high-speed operation.
3. Geneva mechanism

The Geneva drive is also commonly called a Maltese cross mechanism. The Geneva mechanism
translates a continuous rotation into an intermittent rotary motion. The rotating drive wheel has a
pin that reaches into a slot of the driven wheel. The drive wheel also has a raised circular blocking
disc that locks the driven wheel in position between steps (Fig. 4.5.3). There are three basic types
of Geneva motion mechanisms namely external, internal and spherical. The spherical Geneva
mechanism is very rarely used. In the simplest form, the driven wheel has four slots and hence
for each rotation of the drive wheel it advances by one step of 90°. If the driven wheel has n slots,
it advances by 360°/n per full rotation of the drive wheel.

In an internal Geneva drive the axis of the drive wheel of the internal drive is supported on only
one side (Fig. 4.5.4). The angle by which the drive wheel has to rotate to effect one step rotation
of the driven wheel is always smaller than 180° in an external Geneva drive and is always greater
than 180° in an internal one. The external form is the more common, as it can be built smaller
and can withstand higher mechanical stresses.
Because the driven wheel always under full control of the driver, impact is a problem. It can be
reduced by designing the pin in such a way that the pin picks up the driven member as slowly as
possible. Both the Geneva mechanisms can be used for light and heavy duty applications. Generally,
they are used in assembly machines.

Intermittent linear motion from rotary motion can also be obtained using Geneva mechanism (Fig.
4.5.5). This type of movement is basically required in packaging, assembly operations, stamping,
embossing operations in manufacturing automation.

Fig. 4.5.5 Linear intermittent motion using Geneva mechanism

4. Cams mechanism

Cam mechanism is one of the accurate and reliable methods of indexing. It is widely used in
industry despite the fact that the cost is relatively high compared to alternative mechanisms. The
cam can be designed to give a variety of velocity and dwell characteristics. The follower of the
cams used in indexing mechanism has a unidirectional rotary motion rather than oscillating rotary
motion which is usually the case of axial cams. The cam surface geometry is more complicated in
a cross over indexing type of cam as shown in Figure
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