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Lecture Dated 22 October, 2024 - Material Handling

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Mohit Suaradkar
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7 views

Lecture Dated 22 October, 2024 - Material Handling

Uploaded by

Mohit Suaradkar
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Lecture dated 22 October, 2024

Rail guided vehicles


• The third category of material transport equipment consists of
motorized vehicles that are guided by a fixed rail system.
• The rail system consists of either one rail, called a monorail, or two
parallel rails.
• Monorails in factories and warehouses are typically suspended
overhead from the ceiling.
• In rail-guided vehicle systems using parallel fixed rails, the tracks
• generally protrude up from the floor.
• Unlike AGVs, which are powered by their own on-board batteries, rail-
guided vehicles pick up electrical power from an electrified rail
(similar to an urban rapid transit rail system).
Conveyors
• A conveyor is a mechanical apparatus for moving items or bulk
materials, usually inside a facility.
• Conveyors are generally used when material must be moved in
relatively large quantities between specific locations over a fixed
path, which may be in the floor, above the floor, or overhead.
Conveyors are either powered or nonpowered.
Types of Conveyors: (a) Roller conveyor, (b) skate-wheel conveyor, (c)
belt (flat) conveyor
(support frame not shown), (d) in-floor towline conveyor, and (e)
overhead trolley conveyor.
How to choose
• Roller conveyors. In roller conveyors, the pathway consists of a series
of tubes (rollers) that are perpendicular to the direction of travel.
Loads must possess a flat bottom surface of sufficient area to span
several adjacent rollers.
• Belt conveyors. Belt conveyors consist of a continuous loop, with half
its length usedfor delivering materials and the other half for the
return run. The belt is made of reinforced elastomer (rubber), so
that it possesses high flexibility but low extensibility.
• Chain conveyors. The typical equipment in this category consists of
chain loops in an over-and-under configuration around powered
sprockets at the ends of the pathway.
• In-floor towline conveyor. These conveyors use four-wheel carts
powered by moving chains or cables located in trenches in the floor,
Cranes and hoists
• The fifth category of transport equipment in material handling is
cranes and hoists.
• Cranes are used for horizontal movement of materials in a facility,
and hoists are used for vertical lifting.
• A crane invariably includes a hoist; thus, the hoist component of the
crane lifts the load, and the crane transports the load horizontally to
the desired destination.
• This class of material handling equipment includes cranes capable of
lifting and moving very heavy loads, in some cases over 100 tons.
Three types of cranes: (a) bridge crane, (b) gantry crane
(a half gantry crane is shown), and (c) jib crane.
Analysis
• Quantitative models are useful for analyzing material flow rates,
delivery cycle times, and other aspects of system performance. The
analysis may be useful in determining equipment requirements—for
example, how many forklift trucks will be required to satisfy a
• specified flow rate.
• Material transport systems can be classified as vehicle-based systems
• or conveyor systems.
Vehicle based systems
From-To Chart Showing Flow Rates, loads/hr (Value Before the
• Equipment used in Slash), and Travel Distances, m (Value After the Slash),Between
vehicle-based material Stations in a Layout
transport systems
includes industrial trucks ,
automated guided
vehicles and rail-guided
vehicles. Two graphical
tools that are useful for
displaying and analyzing
data in these deliveries
are the from-to chart and Network diagram showing material
the network diagram. deliveries between load/unload stations.
Nodes represent the load/unload stations,
and arrows are labeled with flow rates,
loads/hr, and distances m.
Equation
• The time for a typical delivery cycle in the operation of a vehicle-based
transport system consists of (1) loading at the pickup station, (2) travel
• time to the drop-off station, (3) unloading at the drop-off station, and
(4) empty travel time of the vehicle between deliveries. The total cycle
time per delivery per vehicle is given by

• where Tc = delivery cycle time, min/del; TL = time to load at load


station, min; Ld = distance the vehicle travels between load and
unload station, m (ft); vc = carrier velocity, m/min ; TU = time to
unload at unload station, min; and Le = distance the vehicle travels
empty until the start of the next delivery cycle, m .
• This ignores any time losses due to reliability problems, traffic
congestion, and other factors that may slow down a delivery. In
addition, not all delivery cycles are the same.
Equations
• The available time per hour per vehicle can now be expressed
• As
•
• where AT = available time, min/hr per vehicle; A = availability; Ft=traffic
factor, and Ew = worker efficiency.
• Equations for the two performance parameters of interest can now be
written. The rate of deliveries per vehicle is given by

• where Rdv = hourly delivery rate per vehicle, deliveries/hr per vehicle;
Tc = delivery cycle time in min/del; and AT = the available time in 1
hour, adjusted for time losses, min/hr.
Equations
• The total number of vehicles (trucks, AGVs, trolleys, carts, etc.)
needed to satisfy a specified total delivery schedule Rf in the system
can be estimated by first calculating the total workload required and
then dividing by the available time per vehicle. Workload is defined
as the total amount of work, expressed in terms of time, that must
be accomplished by the material transport system in 1 hr. This can
be expressed as
• where WL = workload, min/hr; Rf = specified flow rate of total
deliveries per hour for the system, deliveries/hr; and Tc = delivery
cycle time, min/del.
• Now the number of vehicles required to accomplish this workload
can be written as
• Consider the AGVS layout . Vehicles travel
counterclockwise around the loop to deliver Example
loads from the load station to the unload
station.
• Loading time at the load station = 0.75 min, and
unloading time at the unload station = 0.50 min.
The following performance parameters are
given: vehicle speed = 50 m/min, availability =
0.95, and traffic factor = 0.90. Operator
efficiency does not apply, so Ew = 1.0.
• Determine
(a) travel distances loaded and empty,
(b) ideal delivery cycle time, and
• (c) number of vehicles required to satisfy the
delivery demand if a total of 40 deliveries per
hour must be completed by the AGVS
Solution
• The AGVS includes load station 1 where Calculating Ld
raw parts enter the system for delivery
to any of three production stations 2, 3,
and 4.
• Unload station 5 receives finished parts
from the production stations. Load and
unload times at stations 1 and 5 are
each 0.5 min. Production rates for each
workstation are indicated by the
delivery requirements table. A
complicating factor is that some parts
must be transshipped between stations
3 and 4. Vehicles move in the direction
indicated by the arrows in the figure.
Determine the average delivery
distance, Ld.
• Consider the case of a single direction Single line conveyor
powered conveyor with one load station at
the upstream end and one unload station at
the downstreamend. Materials are loaded at
one end and unloaded at the other. The
materials may be parts, cartons, pallet loads,
or other unit loads. Assuming the conveyor
operates at a constant speed, the time
required to move materials from load
station to unload station is given by

where Rf = material flow rate, parts/min; RL =


loading rate, parts/min; sc = center To center
spacing of materials on the conveyor, m/part ; and
TL = loading time, min/part.

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