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Miltiadis A. Boboulos Automation and Robotics Download free ebooks at bookboon.com 2 Automation and Robotics © 2010 Miltiadis A. Boboulos & Ventus Publishing ApS ISBN 978-87-7681-696-4 Download free ebooks at bookboon.com 3 Contents Automation and Robotics Contents Abstract 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 3. 3.1 3.2 3.3 3.4 4. 4.1 4.2 9 Chapter 1: Automation & robotics: an optimized loudspeaker assembly for a mechanized serial production line Introduction Developing a dolly removal strategy Loudspeaker arrangement Operation Description of assembly and characteristic features Assemblies (sub-assemblies) Involvement of the dolly in the coil assembly operation, motor unit assembly and dust cap cone Recommendation for mechanisation of the manual operation for the Dolly removal General assembly strategy Review of assembly operations and assessment of their mechanisation suitability Selection of an assembly unit Stage: Assembly of motor unit – Figure 7 Recommendation for most suitable form of mechanisation and automation Feeder design Description – Figure 12 Operation 10 10 12 12 13 13 13 15 16 19 19 19 20 23 27 28 29 Please click the advert The next step for top-performing graduates Masters in Management Designed for high-achieving graduates across all disciplines, London Business School’s Masters in Management provides specific and tangible foundations for a successful career in business. This 12-month, full-time programme is a business qualification with impact. In 2010, our MiM employment rate was 95% within 3 months of graduation*; the majority of graduates choosing to work in consulting or financial services. As well as a renowned qualification from a world-class business school, you also gain access to the School’s network of more than 34,000 global alumni – a community that offers support and opportunities throughout your career. For more information visit www.london.edu/mm, email mim@london.edu or give us a call on +44 (0)20 7000 7573. * Figures taken from London Business School’s Masters in Management 2010 employment report Download free ebooks at bookboon.com 4 Contents Automation and Robotics 4.3 4.4 4.5 4.6 4.7 5. 5.1 5.2 5.3 5.4 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 Cycle time Storage capacity Basic dimensions (Figure 12) Method of re-filling Stacker bin for feeding type 1 parts stacked and properly arranged Assembly cell design Initial provisions Organisational arrangement of the assembly line for the current production output Alternative organisational arrangement of the assembly line for the suggested mechanisation – NMmax = 180000/month Analysis and assessment of the assembly cell AO24 References Chapter 2: Design of speakers production: assembly line of capacity 180,000/month, 15 product variants Introduction Strategy for the “dolly” removal Speaker design analysis Design description of RSW 401, Figure 2 Analysis of the assembly operation ensuring the gap “” Assembly technique sequence for coil 16 and center oscillator, corrugated flat diaphragm 14 in body 1 Concept for mechanised “dolly” removal, Figure 4 Using conveyor movement for the removal of the “dolly” (Figure 4) 29 29 31 31 32 35 35 35 37 40 43 45 45 45 45 48 48 50 52 53 Please click the advert Teach with the Best. Learn with the Best. Agilent offers a wide variety of affordable, industry-leading electronic test equipment as well as knowledge-rich, on-line resources —for professors and students. We have 100’s of comprehensive web-based teaching tools, lab experiments, application notes, brochures, DVDs/ CDs, posters, and more. See what Agilent can do for you. www.agilent.com/find/EDUstudents www.agilent.com/find/EDUeducators © Agilent Technologies, Inc. 2012 u.s. 1-800-829-4444 canada: 1-877-894-4414 Download free ebooks at bookboon.com 5 Contents Automation and Robotics 3. 3.1 3.2 Please click the advert 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5. 5.1 5.2 5.3 5.3 5.4 5.5 Possible organisation of work posts No.1 and No.2 and mounting of the “dolly” and the conveyor (Figure 5) General strategy Analysis of the assembly process techniques Recommendation for a suitable automation process for stage A (components group A) Feeder design Description of Figure 7 Operation, Figure 7 Basic dimensions (Figure 7) Storage capacity (Figure 7) Cycle time Tc Method of re-filling Feeder of component part 10 (Figure 2) to the fixture Item No.4, Figure 7 Feeder for part No. 11 (Figure 2) Feeder of component part 12 (Item 12 in Figure 2) Feeder of component part 1 (item 1 in Figure 2) Evaluation of the assembly unit Structure and functioning of the assembly operation unit Transportation of component parts and sub-assemblies, Figure 13 Arrangement layout of assembly operation units along the conveyor, Fig. 14 Production capacity of the assembly line Investment required to achieve Q = 180000 units/month Operation sequence using assembly robots “Fanuc” or “Pragma” References 54 55 55 61 64 66 67 68 68 69 70 70 72 74 74 79 79 80 82 83 84 85 86 You’re full of energy and ideas. And that’s just what we are looking for. © UBS 2010. All rights reserved. 2.7 Looking for a career where your ideas could really make a difference? UBS’s Graduate Programme and internships are a chance for you to experience for yourself what it’s like to be part of a global team that rewards your input and believes in succeeding together. Wherever you are in your academic career, make your future a part of ours by visiting www.ubs.com/graduates. www.ubs.com/graduates Download free ebooks at bookboon.com 6 Contents Automation and Robotics 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Please click the advert 1. 1.1 1.2 2. 2.1 2.2 2.3 Chapter 3: Strategic approaches to resource husbandry and recovery: the superwash combo case study Introduction The team’s work The performers Quality Market & production line Environmental impact Machines Process technology & management Raw materials & component parts Conclusions References 88 88 89 92 93 94 97 98 100 101 102 103 Chapter 4: Software engineering and data communications: an automatic laminating plant Enviromental model Context diagram [1] Event list for press controller (pc) Behavioural model Low level data / control flow diagrams Low level state transition diagrams Top level data/control flow diagram [10] References 104 104 104 106 108 108 116 122 123 360° thinking . 360° thinking . 360° thinking . Discover the truth at www.deloitte.ca/careers © Deloitte & Touche LLP and affiliated entities. Discover the truth at www.deloitte.ca/careers © Deloitte & Touche LLP and affiliated entities. Download free ebooks at bookboon.com Discover the truth7at www.deloitte.ca/careers © Deloitte & Touche LLP and affiliated entities. © Deloitte & Touche LLP and affiliated entities. D Contents Automation and Robotics 1. 2. 3. 4. 5. Chapter 5: Robot grip mechanism: control loop design considerations Introduction Open loop system Closed loop control system Other control loop design considerations Conlcusion References 124 124 124 125 130 131 132 Download free ebooks at bookboon.com 8 Abstract Automation and Robotics Abstract In this book for the optimisation of assembly conveyor lines we are dealing with series part production featured by a medium complexity degree and a medium number of individual components and assembly technique alternatives. Modern production techniques for medium to large series products or mass production usually involve assembly conveyor lines. They still use hand labour more or less automated. The aim is to have monotonous and similar in type operations or such causing fatigue, stress and production traumas, gradually replaced by automated assembly cycles, means and techniques. This usually widely involves industrial robots and handlers. Higher productivity, lower cost and higher quality of assembled products are usually required. Recently, latest assembly techniques for simpler or more complicated products in engineering, device manufacturing and electronics involve computer-aided automated assembly means in Flexible Automated Production Lines or other types of automated conveyor lines, which provide full automation and human labour replacement. Assembly alternatives involving automation, and mechanisation, programmable and adaptive control have been analyzed in Chapters 3-5. Practically, this means no large investment in the modernisation and expansion of the production capacity and the product’s nomenclature. Download free ebooks at bookboon.com 9 Automation & robotics: an optimized loudspeaker assembly for a mechanized serial production line Automation and Robotics Chapter 1: Automation & robotics: an optimized loudspeaker assembly for a mechanized serial production line 1. Introduction Modern manufacturing of products in small and large scale series production utilise conveyors and automated assembly lines. The purpose is usually to reduce and replace as much as possible labour intensive and dangerous assembly operations with automated ones. Thus, productivity and quality can also be increased. Many current production processes involve computerised assembly using robots or flexible automated production systems where manual assembly operations are completely replaced by machines [1]. The aim is to have monotonous and similar in type operations or such causing fatigue, stress and production traumas, gradually replaced by automated assembly cycles, means and techniques. This usually widely involves industrial robots and handlers. Higher productivity, lower cost and higher quality of assembled products are usually required here. Recently, latest assembly techniques for simpler or more complicated products in engineering, device manufacturing and electronics involve computer-aided automated assembly means in Flexible Automated Production Lines or other types of automated conveyor lines, which provide full automation and human labour replacement [1]. In this loudspeaker production case study, we have a typical example of a series production, which provides opportunities for improved and automated assembly. Regardless of the wide variety of loudspeaker types and dimensions, this product is of average and even low complexity: it comprises 15 to 30 component parts. These can be assembled using mechanised assembly means with only a limited number of manually performed operations [2]. This data is used to calculate current assembly and conveyor parameters and eventually, assembly and conveyor parameters after the modifications and improvements in organisation. Download free ebooks at bookboon.com 10