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Part III *A!ERIA -AN IN+ ANI EN!I(I/A!I N !E/-N +IES

/ apters10. *aterial !ransport S#ste"s

. Storage S#ste"s2. Auto"atic Identi&ication and ata /apture

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*aterial -andling !ec nologiesin t e Production S#ste"

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/ 0 *aterial !ransport S#ste"s

Sections1. Introduction to *aterial -andling E3uip"ent

2. *aterial !ransport E3uip"ent

4. Anal#sis o& *aterial !ransport S#ste"s

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*aterial -andling e&ined

5! e "ove"ent, storage, protection and control o&"aterials t roug out t e "anu&acturing and distri'utionprocess including t eir consu"ption and disposal6

7! e *aterial -andling Industr# o& A"ericaEsti"ated to represent 2092:; o& total "anu&acturingla'or cost in US

! e proportion varies depending on t#pe o&

production and degree o& auto"ation

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*aterial -andling

-andling o& "aterials "ust 'e per&or"edSa&el#E&&icientl#

At lo$ costIn a ti"el# "anner

Accuratel# 7t e rig t "aterials in t e rig t 3uantities tot e rig t locations

And $it out da"age to t e "aterials

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ogistics

/oncerned $it t e ac3uisition, "ove"ent, storage, anddistri'ution o& "aterials and products as $ell as t e planning andcontrol o& t ese operations to satis&# custo"er de"and

!$o categories o& logistics1External logistics 9 transportation and related activities t atoccur outside o& a &acilit# 7'et$een di&&erent geograp icallocations

(ive traditional "odes o& transportation1 rail truc), air, s ip,

and pipelineInternal logistics 9 "aterial andling and storage $it in a &acilit#

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E%ternal ogistics

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Internal ogistics

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/ategories o&*aterial -andling E3uip"ent

. *aterial transport e3uip"ent 9 to "ove "aterials inside a&actor#, $are ouse, or ot er &acilit#

2. Storage 9 to store "aterials and provide access to t ose"aterials $ en re3uired

4. Uniti<ing e3uip"ent 9 re&ers to7 containers to old "aterials, and72 e3uip"ent used to load and pac)age t e containers

=. Identi&ication and trac)ing s#ste"s 9 to identi&# and )eeptrac) o& t e "aterials 'eing "oved and stored

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esign /onsiderationsin *aterial -andling

*aterial c aracteristics(lo$ rate, routing, and sc edulingPlant la#out

Unit load principle

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*aterial / aracteristics

*aterial c aracteristics a&&ect t#pe o& transport and storagee3uip"ent re3uired

Solid, li3uid or gas

Si<e>eig tS ape 9 long, &lat, 'ul)#/ondition 9 ot, cold, $et, dirt#Ris) o& da"age 9 &ragile, 'rittle, sturd#Sa&et# ris) 9 e%plosive, &la""a'le, to%ic, corrosive

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(lo$ Rate, Routing, and Sc eduling

(lo$ rate 9 a"ount o& "aterial "oved per unit ti"eE%a"ples1 pieces? r, pallet loads? r, tons? r > et er t e "aterial "ust 'e "oved in individual units,

as 'atc es, or continuousl# 7pipe lineRouting 9 pic)9up and drop9o&& locations, "ove distances,routing variations, conditions along t e route 7sur&ace,tra&&ic, elevation

Sc eduling 9 ti"ing o& eac deliver#Pro"pt deliver# $ en re3uiredUse o& 'u&&er stoc)s to "itigate against late deliveries

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Plant a#out

*aterial andling e3uip"ent considerations "ust 'eincluded in t e plant la#out design pro'le"/orrelation 'et$een la#out t#pe and "aterial andling

e3uip"ent1 Plant la#out t#pe *aterial andling e3uip"ent (i%ed9position /ranes, oists, industrial truc)s Process -and truc)s, &or)li&t truc)s, A+@s

Product /onve#ors &or product &lo$!ruc)s to deliver parts to stations

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Unit oad Principle 7uniti<ing

In general, t e unit load s ould 'e as large as practical &ort e "aterial andling s#ste" t at $ill "ove and store it

A unit load is t e "ass t at is to 'e "oved or ot er$iseandled at one ti"e

Reasons &or using unit loads in "aterial andling1*ultiple ite"s andled si"ultaneousl#Re3uired nu"'er o& trips is reduced

oading?unloading ti"es are reducedProduct da"age is decreased

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Unit oad /ontainers

7a >ooden pallet, 7' pallet 'o%, 7c tote 'o%

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*aterial !ransport E3uip"ent

(ive categories1. Industrial truc)s

2. Auto"ated guided ve icles

4. *onorails and ot er rail guided ve icles=. /onve#ors:. /ranes and oists

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Industrial !ruc)s

!$o 'asic categories1. Non9po$ered

-u"an $or)ers pus or pull loads

2. Po$eredSel&9propelled, guided or driven '# u"an/o""on e%a"ple1 &or)li&t truc)

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Nonpo$ered Industrial !ruc)s7-and !ruc)s

7a !$o9$ eel and truc), 7' &our9$ eel doll#, 7c and9operated lo$9li&t pallet truc)

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Po$ered !ruc)s1>al)ie !ruc)

> eeled &or)s insert into pallet openingsNo provision &or riding truc) is steered '# $or)er usingcontrol andle at &ront o& ve icle

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Po$ered !ruc)s1(or)li&t !ruc)

>idel# used in &actoriesand $are ouses 'ecausepallet loads are so

co""on/apacities &ro" =:0 )g7 000 l' up to =:00 )g7 0,000 l'

Po$er sources includeon9'oard 'atteries andinternal co"'ustion"otors

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Po$ered !ruc)s1!o$ing !ractor

esigned to pull one or "ore trailing carts in &actories and$are ouses, as $ell as &or airport 'aggage andlingPo$ered '# on9'oard 'atteries or I/ engines

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Auto"ated +uided @e icles

An Auto"ated +uided @e icle S#ste" 7A+@S is a"aterial andling s#ste" t at uses independentl#operated, sel&9propelled ve icles guided along de&inedpat $a#s in t e &acilit# &loor

!#pes o& A+@1riverless trains

Pallet truc)sUnit load A+@s

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Auto"ated +uided @e icles1riverless Auto"ated +uided !rain

(irst t#pe o& A+@S to'e introduced around

B:=/o""on applicationis "oving eav#pa#loads over longdistances in$are ouses and

&actories $it outinter"ediate stopsalong t e route

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Auto"ated +uided @e icles1 A+@ Pallet !ruc)

Used to "ovepalleti<ed loads alongpredeter"ined routes

@e icle is 'ac)ed intoloaded pallet '#$or)er pallet is t enelevated &ro" &loor >or)er drives pallettruc) to A+@ guidepat and progra"sdestination

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Auto"ated +uided @e icles1Unit oad /arrier

Used to "ove unit loads &ro" station to station

&ten e3uipped &or auto"atic loading?unloading o& palletsand tote pans using roller conve#ors, "oving 'elts, or"ec ani<ed li&t plat&or"s

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A+@s Applications

1. Dri erless train operations 9 "ove"ent o& large 3uantitieso& "aterial over long distances

!. Storage and distri"ution 9 "ove"ent o& pallet loads

'et$een s ipping?receiving doc)s and storage rac)s#. Assem"ly line operations 9 "ove"ent o& car 'odies and"aCor su'asse"'lies 7"otors t roug t e asse"'l#stations

$. %lexi"le manufacturing systems 9 "ove"ent o& $or)parts'et$een "ac ine tools&. Miscellaneous 9 "ail deliver# and ospital supplies

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@e icle +uidance !ec nolog#

*et od '# $ ic A+@S pat $a#s are de&ined and ve icles arecontrolled to &ollo$ t e pat $a#s! ree "ain tec nologies1

I"'edded guide $ires 9 guide $ires in t e &loor e"it

electro"agnetic signal t at t e ve icles &ollo$Paint strips 9 optical sensors on9'oard ve icles trac) t e $ itepaint stripsSel&9guided ve icles 9 ve icles use a co"'ination o&

ead rec)oning 9 ve icle counts $ eel turns in given directionto "ove $it out guidanceDeacons located t roug out &acilit# 9 ve icle uses triangulationto co"pute locations

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@e icle +uidance Using +uide >ire

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@e icle *anage"ent

!$o aspects o& ve icle "anage"ent1!ra&&ic control 9 to "ini"i<e inter&erence 'et$een ve iclesand prevent collisions

. (or$ard 7on9'oard ve icle sensing2. one control@e icle dispatc ing

. n9'oard control panel

2. Re"ote call stations4. /entral co"puter control

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one /ontrol

one control to i"ple"ent 'loc)ing s#ste". ones A, D,and are 'loc)ed. one / is &ree. @e icle 2 is 'loc)ed

&ro" entering one A '# ve icle . @e icle 4 is &ree toenter one /.

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@e icle Sa&et#

!ravel velocit# o& A+@ is slo$er t an t#pical $al)ing speedo& u"an $or)er

Auto"atic stopping o& ve icle i& it stra#s &ro" guide pat

Ac3uisition distance'stacle detection s#ste" in &or$ard directionUse o& ultrasonic sensors co""on

E"ergenc# 'u"per 9 'ra)es ve icle $ en contact is "ade

$it &or$ard o'Cect>arning lig ts 7'lin)ing or rotating red lig ts>arning sounds o& approac ing ve icles

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Rail9+uided @e icles

Sel&9propelled ve icles t at ride on a &i%ed9rail s#ste"@e icles operate independentl# and are driven '#electric "otors t at pic) up po$er &ro" an electri&ied rail

(i%ed rail s#ste"ver ead "onorail 9 suspended over ead &ro" t e

ceilingn9&loor 9 parallel &i%ed rails, trac)s generall#

protrude up &ro" t e &loor Routing variations are possi'le1 s$itc es, turnta'les,and ot er special trac) sections

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ver ead *onorail

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/onve#or S#ste"s

arge &a"il# o& "aterial transport e3uip"entdesigned to "ove "aterials over &i%ed pat s, usuall#in large 3uantities or volu"es

. Non po$ered‑

*aterials "oved '# u"an $or)ers or '# gravit#2. Po$ered

Po$er "ec anis" &or transporting "aterials is

contained in t e &i%ed pat , using c ains, 'elts,rollers or ot er "ec anical devices

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/onve#or !#pes

Roller S)ate $ eel‑

Delt

In &loor to$line‑ver ead trolle# conve#or

/art9on9trac) conve#or

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Roller /onve#or

Pat $a# consists o& aseries o& rollers t at areperpendicular to directiono& travel

oads "ust possess a &lat'otto" to span severalrollersPo$ered rollers rotate todrive t e loads &or$ardUn9po$ered rollerconve#ors also availa'le

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S)ate9> eel /onve#or

Si"ilar in operation toroller conve#or 'ut uses)ate $ eels instead o&rollers

ig ter $eig t andunpo$eredSo"eti"es 'uilt asporta'le units t at can 'eused &or loading andunloading truc) trailers ins ipping and receiving

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Delt /onve#or

/ontinuous loop $it&or$ard pat to "oveloadsDelt is "ade o& rein&orced

elasto"er Support slider or rollersused to support &or$ardloop!$o co""on &or"s1

(lat 'elt 7s o$n@9s aped &or 'ul)"aterials

7Support &ra"e not s o$n

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In9(loor !o$9 ine /onve#or

(our9$ eel carts po$ered'# "oving c ains or ca'lesin trenc es in t e &loor /arts use steel pins 7orgrippers to proCect 'elo$&loor level and engage t ec ain 7or pulle# &or to$ing! is allo$s t e carts to 'edisengaged &ro" to$line&or loading and unloading

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ver ead !rolle# /onve#or

A trolle# is a $ eeledcarriage running on anover ead trac) &ro" $ icloads can 'e suspended!rolle#s are connected and"oved '# a c ain or ca'let at &or"s a co"plete loop

&ten used to "ove partsand asse"'lies 'et$een"aCor production areas

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/art9 n9!rac) /onve#or

/arts ride on a trac)a'ove &loor level/arts are driven '# aspinning tu'e(or$ard "otion o&cart is controlled '# adrive $ eel $ oseangle can 'ec anged &ro" <ero7idle to =: degrees7&or$ard

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Po$ered /onve#orperations and (eatures

!#pes o& "otions. /ontinuous 9 conve#or "oves at constant velocit#

2. As#nc ronous 9 conve#or "oves $it stop9and9go"otion

! e# stop at stations, "ove 'et$een stations Anot er classi&ication o& conve#ors1

. Single direction

2. /ontinuous loop4. Recirculating

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7a Single9 irection /onve#or and7' /ontinuous oop /onve#or

7a Single directionconve#or

7' /ontinuous loopconve#or

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/ranes and -oists

-andling devices &or li&ting, lo$ering and transporting"aterials, o&ten as eav# loads/ranes

Used &or ori<ontal "ove"ent o& "aterials-oists

Used &or vertical li&ting o& "aterials/ranes usuall# include oists so t at t e crane9and9 oist

co"'ination provides-ori<ontal transport@ertical li&ting and lo$ering

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-oist

-oist $it "ec anicaladvantage o& &our1

7a s)etc o& t e oist

7' diagra" toillustrate "ec anicaladvantage

7a 7'

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Dridge /rane

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+antr# /rane

A al&9gantr# crane

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Ji' /rane

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Anal#sis o&*aterial !ransport S#ste"s

Anal#sis o& ve icle9'ased s#ste"s(ro"9to c arts and net$or) diagra"s!#pes o& s#ste"s1 industrial truc)s, A+@S, rail9guided

ve icles, and as#nc ronous conve#or operations/onve#or anal#sis

Single9direction conve#ors/losed loop conve#orsRecirculating conve#or s#ste"s

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Net$or) iagra" S o$ing eliveries'et$een oad?Unload Stations