AUTOMATION & ROBOTICS (18ME732)

MODULE – 2 : AUTOMATED PRODUCTION LINES

LESSON CONTENTS: Fundamentals of automated production lines, application of
automated production lines, analysis of transfer lines, automated assembly systems,
fundamentals of automated assembly systems, quantitative analysis of assembly systems,
automatic identification methods, barcode technology, radio frequency identification, other
AIDC technologies

2.1 Fundamentals of automated production lines

 An automated production line consists of multiple workstations that are automated and
linked together by a work handling system that transfers parts from one station to the
next, as depicted in Figure 2.1.
 A raw work part enters one end of the line, and the processing steps are performed
sequentially as the part progresses forward (from left to right in the drawing).
 The line may include inspection stations to perform intermediate quality checks. Also,
manual stations may be located along the line to perform certain operations that are
difficult or uneconomical to automate. Each station performs a different operation, so
all operations must be performed to complete each work unit.
 Multiple parts are processed simultaneously on the line, one part at each station. In the
simplest form of production line, the number of parts on the line at any moment is equal
to the number of workstations, as in the figure.
 In more complicated lines, provision is made for temporary parts storage between
stations, in which case there are more parts than stations.
 An automated production line operates in cycles, similar to a manual assembly line.
 Each cycle consists of processing time plus the time to transfer parts to the next station.
The slowest workstation sets the pace of the line, just as in an assembly line.

Fig. 2.1 General configuration of an automated production line. Key: Proc =

processing operation, Aut = automated workstation.

Page 1

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

2.1.1 Work Part Transport

 The work part transport system moves parts between stations on the line. Transport
mechanisms used on automated production lines are usually either synchronous or
asynchronous but rarely continuous.
 Synchronous transport has been the traditional means of moving parts in a transfer
line.
 However, asynchronous transport provides certain advantages over synchronous
transport:
 They are more flexible,
 They permit queues of parts to form between workstations to act as storage
buffers and
 It is easier to rearrange or expand the production line.
 These advantages come at a higher first cost. Continuous work transport systems,
although widely used on manual assembly lines, are uncommon on automated lines
due to the difficulty in providing accurate registration between the station work heads
and the continuously moving parts.
 Depending on the geometry of the work part to be processed, the line may utilize
pallet fixtures for part handling.
 A pallet fixture is a work-holding device that is designed to
o (1) fixture the part in a precise location relative to its base and
o (2) be moved, located, and accurately clamped in position at successive
workstations by the transfer system.
 With the parts accurately located on the pallet fixture, and the pallet accurately
registered at a given workstation, the part itself is accurately positioned relative to the
processingoperation performed at the station.
 The location requirement is especially critical in machining operations, where
tolerances are typically specified in hundredths of a millimeter or thousandths of an
inch.
 The term palletized transfer line is sometimes used to identify a transfer line that uses
pallet fixtures or similar work-holding devices. The alternative method of work part
location is to simply index the parts themselves from station to station.
 This is called a free transfer line, and it has the obvious benefit that it avoids the cost of
the pallet fixtures. However, certain part geometries require the use of pallet fixtures to
facilitate handling and ensure accurate location at a workstation.
 When pallet fixtures are used, a means must be provided to deliver them back to the
front of the line for reuse.

SYSTEM CONFIGURATIONS.

 Although Figure 2.1 shows the flow of work to be in a straight line, the work flow can
actually take several different forms:
 (1) in-line,
 (2) segmented in-line, and

Page 2

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 (3) rotary.
 The in-line configuration consists of a sequence of stations in a straight line
arrangement, as in Figure 2.1.
 This configuration is common for machining big workpieces, such as automotive
engine blocks, engine heads, and transmission cases. Because these parts require a large
number of operations, a production line with many stations is needed.
 The in-line configuration can accommodate a large number of stations. In-line systems
can also be designed with integrated storage buffers along the flow path.
 The segmented in-line configuration consists of two or more straight-line transfer
sections, where the segments are usually perpendicular to each other.
 Figure 2.2 shows several possible layouts of the segmented in-line category.

Figure 2.2 Several possible layouts of the segmented in-line configuration of an automated
production line: (a) L-shaped, (b) U-shaped, and (c) rectangular. Key: Proc = processing
operation, Aut = automated workstation, Wash = work carrier washing station.

Page 3

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 There are a number of reasons for designing a production line in these configurations
rather than in a pure straight line:
 (1) available floor space may limit the length of the line,
 (2) a workpiece in a segmented in-line configuration can be reoriented to
present different surfaces for machining, and
 (3) the rectangular layout provides for swift return of work-holding fixtures to
the frontof the line for reuse.
 Figure 2.3 shows two transfer lines that perform metal machining operations on
automotive castings.
 The first line, on the left-hand side, is a segmented in-line configuration in the shape of
a rectangle. Pallet fixtures are used in this line to position the starting castings at the
workstations for machining. It is a palletized transfer line.
 The second line, on the right side, is a conventional in-line configuration. When
processing on the first line is completed, the parts are manually transferred to the second
line, where they are reoriented to present different surfaces for machining. In this line
the parts are moved individually by the transfer mechanism, using no pallet fixtures. It
is a free transfer line.

Figure 2.3 Two machining transfer lines. On the left is a segmented in-line configuration that
uses pallet fixtures to locate the work parts. The return loop brings the pallets back to the
front of the line. On the right, the second transfer line is an in-line configuration. The manual
station between the lines is used to reorient the parts, represented as ovals. Pallet fixtures are
represented as rectangles.

 In the rotary configuration, the work parts are attached to fixtures around the
periphery of a circular worktable, and the table is indexed (rotated in fixed angular
amounts) to present the parts to workstations for processing.
 A typical arrangement is illustrated in Figure 2.4. The worktable is often referred to as
a dial, and the equipment is called a dial-indexing machine. Although the rotary
configuration does not seem to belong to the class of production systems called
“lines,” its operation is nevertheless very similar.

Page 4

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 By comparison with the in-line and segmented in-line configurations, rotary indexing
systems are commonly limited to smaller work parts and fewer workstations, and they
cannot readily accommodate buffer storage capacity.
 On the positive side, the rotary system usually involves a less expensive piece of
equipment and typically requires less floor space.

Figure 2.4 Rotary indexing machine (dial-indexing machine).

Key: Proc = processing operation, Aut = automated workstation.

 Work part transport mechanisms can be divided into two categories:

 (1) linear transport systems for in-line and segmented in-line systems, and
 (2) rotary indexing mechanisms for dial-indexing machines.
 Some of the linear transport systems provide synchronous movement, while others
provide asynchronous motion.
 The rotary indexing mechanisms all provide synchronous motion.

LINEAR TRANSFER SYSTEMS.

 Most of the material transport systems provide a linear motion, and some of these are
used for parts transfer in automated production lines.
 These include powered roller conveyors, belt conveyors, chaindriven conveyors, and
cart-on-track conveyors.
 Figure 2.5 illustrates the possible application of a chain driven or belt conveyor to
provide continuous or intermittent movement of parts between stations.
 Either a chain or flexible steel belt is used to transport parts using work carriers
attached to the conveyor. The chain is driven by pulleys in either an “over-and-under”
configuration, in which the pulleys turn about a horizontal axis, or an “around-the-
corner” configuration, in which the pulleys rotate about a vertical axis.
 The belt conveyor can also be adapted for asynchronous movement of work units
using friction between the belt and the part to move parts between stations.

Page 5

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 The forward motion of the parts is stopped at each station using pop-up pins or other
stopping mechanisms.

Figure 2.5 Side view of chain or steel belt driven conveyor (“overand- under” type)
for linear work part transfer by using work carriers.

Figure 2.6 Operation of walking-beam transfer system: (1) work

parts at station positions on fixed station beam, (2) transfer beam is
raised to lift work parts from nests, (3) elevated transfer beam moves
parts to next station positions, and (4) transfer beam lowers to drop
work parts into nests at new station positions. Transfer beam then
retracts to original position shown in (1)

Page 6

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 Cart-on-track conveyors also provide asynchronous parts movement and are designed
to position their carts within about ±0.12 mm (±0.005 in ), which is adequate for
many processing situations.
 Many machining type transfer lines utilize walking-beam transfer systems, in which
the parts are synchronously lifted up from their respective stations by a transfer beam
and moved one position ahead, to the next station.
 The transfer beam lowers the parts into nests that position them for processing at their
stations. The beam then retracts to make ready for the next transfer cycle. The action
sequence is depicted in Figure 2.6.

ROTARY INDEXING MECHANISMS.

 Several mechanisms are available to provide the rotational indexing motion required
in a dial-indexing machine that might be used for processing or assembly operations.
A representative type is the Geneva mechanism, which uses a continuously rotating
driver to index the table through a partial rotation, as illustrated in Figure 4.7.

Figure 4.7 Geneva mechanism with six slots.

2.1.2 Storage Buffers

 Automated production lines can be designed with storage buffers. A storage buffer is
a location in the production line where parts can be collected and temporarily stored
before proceeding to downstream workstations.
 The storage buffers can be manually operated or automated. When it is automated, a
storage buffer consists of a mechanism to accept parts from the upstream workstation,
a place to store the parts, and a mechanism to supply parts to the downstream station.
 A key parameter of a storage buffer is its storage capacity, that is, the number of work
parts it can hold. Storage buffers may be located between every pair of adjacent
stations, or between line stages containing multiple stations.
 There are several reasons why storage buffers are used on automated production lines:

Page 7

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 To reduce the impact of station breakdowns. Storage buffers between stages

on a production line permit one stage to continue operation while the other
stage is down for repairs. This situation is analyzed in Appendix 16A.
 To provide a bank of parts to supply the line. Parts can be collected into a
storage unit and automatically fed to a downstream manufacturing system.
This permits untended operation of the system between refills.
 To provide a place to put the output of the line.
 To allow for curing time or other process delay. A curing time is required for
some processes such as painting or adhesive application. The storage buffer is
designed to provide sufficient time for curing to occur before supplying the
parts to the downstream station.
 To smooth cycle time variations. Although this is generally not an issue in an
automated line, it is relevant in manual production lines, where cycle time
variations are an inherent feature of human performance.
 Storage buffers are more readily accommodated in the design of an in-line transfer
machine than a rotary indexing machine.
 In the latter case, buffers are sometimes located
 (1) before a dial-indexing system to provide a bank of raw starting work parts,
 (2) following the dial-indexing machine to accept the output of the system, or
 (3) between pairs of adjacent dial-indexing machines.

2.1.3 Control of the Production Line

 Controlling an automated production line is complex, owing to the sheer number of
sequential and simultaneous activities that occur during its operation. This section
covers
 (1) the basic control functions that are accomplished to run the line and
 (2) controllers used on automated lines.

CONTROL FUNCTIONS.
 Three basic control functions can be distinguished in the operation of an automated
production line:
 (1) sequence control,
 (2) safety monitoring, and
 (3) quality control.
 The purpose of sequence control is to coordinate the sequence of actions of the
transport system and associated workstations.
 The various activities of the production line must be carried out with split-second
timing and accuracy.
 On a transfer line, for example, theparts must be released from their current
workstations, transported, located, and clamped into position at their respective next
stations.

Page 8

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 Then the work heads must be actuated to begin their feed cycles, and so on. The
sequence control function in automated production line operation includes both logic
control and sequence control.
 The safety monitoring function ensures that the production line does not operate inan
unsafe manner.
 Safety applies to both the human workers in the area and the equipment itself.
 Additional sensors must be incorporated into the line beyond those required for
sequence control, in order to complete the safety feedback loop and avoid hazardous
operation.
 For example, interlocks must be installed to prevent the equipment from operating
when workers are performing maintenance or other duties on the line.
 In the case of machining transfer lines, cutting tools must be monitored for breakage
and/or excessive wear to prevent feeding a defective cutter into the work.
 In the quality control function, certain quality attributes of the work parts are
monitored.
 The purpose is to detect and possibly reject defective work units produced on the line.
 The inspection devices required to accomplish quality control are sometimes
incorporated into existing processing stations.
 In other cases, separate inspection stations are included in the line for the sole purpose
of checking the desired quality characteristic.

LINE CONTROLLERS.
 Programmable logic controllers (PLCs) are the conventional controllers used on
automated production lines today.
 Personal computers (PCs) equipped with control software and designed for the factory
environment are also widely used.
 Computer control offers the following benefits:
 Opportunity to improve and upgrade the control software, such as adding
specific control functions not anticipated in the original system design
 Recording data on process performance, equipment reliability, and product
quality (in some industries product quality records must be maintained for
legal reasons)
 Diagnostic routines to expedite maintenance and repair when line breakdowns
occur and to reduce the duration of downtime incidents
 Generation of preventive maintenance schedules to reduce the frequency of
downtime occurrences
 A PC provides a more convenient interface than a PLC between the operator
and the automated line.

Page 9

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

2.2 APPLICATIONS OF AUTOMATED PRODUCTION LINES

 Machining is one of the most common processing applications and is the focus of
most of the discussion in this section.
 Other processes performed on automated production lines and similar systems include
sheet metal forming and cutting, rolling mill operations, spot welding of automobile
car bodies, painting, plating operations, and assembly

2.2.1 MACHINING SYSTEMS

 Many applications of machining transfer machines, both in-line and rotary
configurations, are found in the automotive industry to produce engine and drive-train
components.
 In fact, the first transfer lines can be traced to the automobile industry
 Machining operations commonly performed on transfer lines include milling, drilling,
reaming, tapping, grinding, and similar rotational cutting tool operations.
 It is possible to perform turning and boring on transfer lines, but these applications are
less common.
TRANSFER LINES.
 In a transfer line, the workstations containing machining work heads are arranged in
an in-line or segmented in-line configuration and the parts are moved between
stations by transfer mechanisms such as the walking-beam system.
 The transfer line is the most highly automated and productive system in terms of the
number of operations that can be performed to accommodate complex work
geometries.
 It is also the most expensive of the systems discussed in this section. Machining type
transfer lines are pictured in Figure 2.3.
 The transfer line can include a large number of workstations, but reliability of the
system decreases as the number of stations is increased.
 Today, many transfer lines are being designed for flexibility and ease of changeover
so that
 (1) different but similar work parts can be produced on the same system and
 (2) workstations from obsolete lines can be used on new lines
 Thus, there is a trend in transfer lines in the direction of flexible manufacturing
systems.
 Indeed, the term flexible transfer line is sometimes applied to these systems.
 The workstations in these lines consist of both fixed tooling and CNC machines, so
that differences in work parts can be accommodated by the CNC stations while the
common operations are performed by stations with fixed tooling.
 Some of the CNC machine tools are new, while others are equipment that has been
redeployed from previous lines and reconfigured for the new products.
 The opportunity to use redeployed stations represents a significant saving for the user
company when compared to the purchase of new machine tools.

Page 10

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

ROTARY TRANSFER MACHINES AND RELATED SYSTEMS.

 A rotary transfer machine consists of a horizontal circular worktable, upon which are
fixtured the parts to be processed, and around whose periphery are located stationary
work heads.
 The worktable is indexed to present each part to each work head to accomplish the
sequence of machining operations.
 An example is shown in Figure 2.8. By comparison with a transfer line, the rotary
indexing machine is limited to smaller, lighter work parts and fewer workstations.

Figure 2.8 Plan view of a rotary transfer machine.

 Two variants of the rotary transfer machine are the center-column machine and the
trunnion machine.
 In the center-column machine, vertical machining heads are mounted on a center
column in addition to the stationary machining heads located on the outside of the
horizontal worktable, thereby increasing the number of machining operations that can
be performed.
 The center-column machine, depicted in Figure 2.9, is considered to be a high
production machine that makes efficient use of floor space.

Figure 2.9 Plan view of the center-column machine.

Page 11

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

 The trunnion machine gets its name from a vertically oriented worktable, or trunnion,
to which are attached work holders to fixture the parts for machining.
 Since the trunnion indexes around a horizontal axis, this provides the opportunity to
perform machining operations on opposite sides of the work part. Additional work
heads can be located around the periphery of the trunnion to increase the number of
machining directions.
 Trunnion machines are more suitable for smaller work parts than the other rotary
machines discussed here

2.2.2 SYSTEM DESIGN CONSIDERATIONS

 Most companies that use automated production lines and related systems turn the
design of the system over to a machine tool builder that specializes in this type of
equipment.
 The customer (company purchasing the equipment) must develop specifications that
include design drawings of the part and the required production rate.
 Typically, several machine tool builders are invited to submit proposals. Each
proposal is based on the machinery components comprising the builder’s product line
and depends on the ingenuity of the engineer preparing the proposal. The proposed
line consists of standard work heads, spindles, feed units, drive motors, transfer
mechanisms, bases, and other standard modules, all assembled into a special
configuration to match the machining requirements of the particular part.
 Examples of these standard modules are illustrated in Figures 2.10 and 2.11.

Figure 2.10 Standard feed units used with in-line or rotary transfer machines:
(a) horizontal feed drive unit, (b) angular feed drive unit, and (c) vertical column unit.

 The controls for the system are either designed by the machine builder or sublet as a
separate contract to a controls specialist.
 Transfer lines and indexing machines constructed using this building-block approach
are sometimes referred to as unitized production lines.

Page 12

Availaible at VTU HUB (Android App)

AUTOMATION & ROBOTICS (18ME732)

Figure 2.11 Standard milling head unit. This unit

attaches to the feed drive units in Figure 2.10.
 An alternative approach in designing an automated line is to use standard machine
tools and to connect them with standard or special material handling devices.
 The material handling hardware serves as the transfer system that moves work
between the standard machines.
 The term link line is sometimes used in connection with this type of construction. In
some cases, the individual machines are manually operated if there are fixturing and
location problems that are difficult to solve without human assistance
 A company often prefers to develop a link line rather than a unitized production line
because it can utilize existing equipment in the plant.
 This usually means the production line can be installed sooner and at lower cost.
 Since the machine tools in the system are standard, they can be reused when the
production run is finished.
 Also, the lines can be engineered by personnel within the company rather than outside
contractors.
 The limitation of the link line is that it tends to favor simpler part shapes and therefore
fewer operations and workstations.
 Unitized lines are generally capable of higher production rates and require less floor
space.
 However, their high cost makes them suitable only for very long production runs on
products that are not subject to frequent design changes.

Page 13

Availaible at VTU HUB (Android App)

Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
Availaible at VTU HUB (Android App)
AUTOMATION & ROBOTICS (18ME732)

REFERENCES:

Name of the Edition and

Sl. No. Title of the Book Name of the Publisher
Author/s Year
Textbook/s
Computer Integrated Mikell P. 3rd edition,
1 Pearson
Manufacturing Groover 2009
Introduction to robotics 3rd edition,
2 John J. Craig Pearson
mechanics and control 2009
Reference Books
1st edition,
1 Robotics for Engineers Yoram Koren McGraw Hill International
1985.
2nd edition,
2 Industrial Robotics Weiss, Nagel McGraw Hill International 2012

Klafter, 1st edition,

Robotic Engineering - An
3 Chmielewski PHI 2009
Integrated approach
and Negin

2nd
Computer Based Industrial
4 Krishna Kant EEE-PHI edition,2010
Control

Tiess Chiu
An Introduction to Automated Chang &
5 Richard A.
Process Planning System
Wysk.

Page 38

Availaible at VTU HUB (Android App)