UNIT V Prepared by Dr.K.S.Badrinathan 1 IMPLEMENTATION AND ROBOT - - PDF document

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UNIT V Prepared by Dr.K.S.Badrinathan 1 IMPLEMENTATION AND ROBOT - - PDF document

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13 10 2017 UNIT V Prepared by Dr.K.S.Badrinathan 1 IMPLEMENTATION AND ROBOT ECONOMICS Automated Guided Vehicle System (AGVS), RGV Implementation of Robots in Industries Safety Considerations for Robot Operations

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UNIT ‐ V

Prepared by Dr.K.S.Badrinathan 1

IMPLEMENTATION AND ROBOT ECONOMICS

  • Automated Guided Vehicle System

(AGVS), RGV

  • Implementation of Robots in Industries
  • Safety Considerations for Robot

Operations

  • Economic Analysis of Robots.

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Automated Guided Vehicle System (AGVS)

  • An AGVS is a material handling system that uses

independently operated, self‐propelled vehicles guided along defined pathways.

  • Powered by on‐board batteries that allow many hours
  • f operation (8‐16 hours)
  • Pathways are unobtrusive.
  • Suitable for automating material handling in batch

production & mixed model production

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Types of AGV vehicles

  • Driverless trains
  • Pallet trucks
  • Unit load carriers

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Driverless AG train

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Driverless AG train

  • A towing vehicle pulling one or more trailers to

form a train

  • To move heavy payloads over long distances in

warehouses or factories with or without intermediate pickup and drop‐off points along the route

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Pallet Trucks

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Pallet trucks

  • To move palletized loads along predetermined

routes

  • Human worker steers the truck and loads the

pallet & puts it in is guidepath

  • Forklift AGV – can have vertical movement of its

forks to reach loads on racks and shelves

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Unit Load Carriers

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Unit Load Carrier

  • To move unit loads from one station to another
  • Equipped for automatic loading and unloading of

pallets or tote pans by means of :

– Powered rollers – Moving belts – Mechanized lift platforms – Other devices built into the vehicle deck

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Applications of AGVS

  • Driverless train operations
  • Storage and distribution
  • Assembly line applications
  • FMS

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Vehicle Guidance Technology

  • Method by which AGVS pathways are defined and

vehicles are controlled to follow the pathways Technologies used:

  • Imbedded guide wires
  • Paint strips
  • Self‐guided vehicles

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Wire Guided AGV

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Wire Guided AGV

  • Electrical wires are placed in a small channel cut into

the surface of the floor

  • The channel is filled with cement to eliminate the

discontinuity in the floor surface

  • Guide wire is connected to a frequency generator,

which emits low‐voltage, low‐current signal (1‐15kHz)

  • The induced magnetic field is followed by sensors on

board each vehicle

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Paint Strip AGV

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Paint Strip AGV

  • Vehicle uses an optical sensor system capable of

tracking the paint

  • Strips are taped, sprayed or painted on the floor
  • Paint strips contain fluorescent particles that

reflect an UV light source from the vehicle

  • On‐board sensor detects the reflected light in the

strip and controls the steering mechanism

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Self‐guided Vehicle

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Self‐guided Vehicle

  • Operate without continuously defined pathways
  • Uses a combination of dead reckoning and

beacons located throughout the plant that can be identified by on‐board sensors

  • Dead reckoning: capability of vehicle to follow a

given route in the absence of a defined pathway in the floor

  • Accomplished by computing the required number
  • f wheel rotations
  • Computations are performed by the vehicle’s on‐

board computer

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Self‐guided Vehicle ‐ Beacons

  • Positioning accuracy of dead reckoning decreases
  • ver long distances.
  • It must be periodically verified by comparing the

calculated position with one or more known positions.

  • Beacons are used for this throughout the plant
  • Barcoded or magnetic beacons

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RGV Rail Guided Vehicle

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Steps for Robot Implementation

  • Initial familiarization with the technology
  • Plant survey to identify potential applications
  • Selection of the application
  • Selection of the robot
  • Detailed economic analysis & capital

authorization

  • Planning and engineering the installation
  • installation

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Human Safety from Robots

  • During programming of the robot
  • During operation of the robot cell when

humans work in the cell

  • During maintenance of the robot

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Safety Sensors

  • Sensors indicate conditions or events that are

unsafe or potentially unsafe

  • Sensors should protect humans and also the

equipment in the cell

  • Simple limit switches to sophisticated vision

systems are needed to find intruders

  • Care must be taken in the workcell design to

anticipate all of the possible mishaps that might occur in the cell

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Levels of Safety Sensor Systems

  • Level 1 – Perimeter penetration detection
  • Level 2 – Intruder detection inside the

workcell

  • Level 3 – Intruder detection in the immediate

vicinity of the robot

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Levels of Safety Sensor Systems

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Safety Monitoring Strategies

  • Complete shutdown of the robot upon

detection of an intruder

  • Activation of warning alarms
  • Reduction in the speed of the robot to a ‘safe’

level

  • Directing the robot to move its arm away from

the intruder to avoid collision

  • Directing the robot to perform tasks in

another region of the workcell away from the intruder

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Other Safety Measures

  • Emergency stop buttons also called ‘panic

button’ are located on the main control panel and the robot teach pendant.

  • ‘Deadman switch’ – is a trigger or toggle

switch device located on the teach pendant. The switch is ‘ON’ when it is pressed against a

  • spring. When the pressure is removed the

switch automatically goes to ‘OFF’ mode.

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ECONOMIC ANALYSIS

  • f

ROBOTS

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Basic Data Required

  • Type of project
  • Cost of robot installation
  • Production cycle time
  • Savings & Benefits

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Types of Robot Installation

  • New application – no existing facility
  • To replace the current method of operation;

i.e. the manual method is replaced with robot

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Cost Data Required

  • Investment cost

– Cost of robot: purchase price – Engineering cost: planning and design – Installation cost: labour & materials – Special tooling: end effector, fixtures & tools – Miscellaneous: other equipment needed

  • Operating cost

– Direct labour: operator – Indirect labour: supervisor, programming – Maintenance: – Utilities: electricity etc. – Training:

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Life cycle of cash flow

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Methods of Economic Analysis

  • Payback (or payback period) Method
  • Equivalent Uniform Annual Cost (EUAC)

Method

  • Return On Investment (ROI) Method

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Payback Method

  • Time required for the net accumulated cash

flow to equal the initial investment in the project

n =

  • n = pay back period

IC = Investment Cost NACF = Net Annual Cash Flow

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Payback Method…

  • Total Investment = Rs.30 lacs
  • Anticipated revenue = Rs.18 lacs/year
  • Operating cost = Rs.6 lacs/year
  • NACF = Revenue – operating cost

= 18 – 6 = Rs.12 lacs/year n =

  • =

= 2.5 years

Note: revenue is assumed to be same in all the years

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Disadvantage of Payback method

  • Ignores the time value of money
  • It does not consider the objective of the

company to derive a certain minimum rate of return from its investments.

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Equivalent Uniform Annual Cost (EUAC) Method

  • Converts all the present and future

investments and cash flows into their equivalent uniform cash flows over the anticipated life of the project.

  • Done by making use of the various interest

factors associated with engineering economy calculations.

  • A minimum attractive rate‐of‐return (MARR),

20‐50, should be selected to decide whether a investment project should be funded.

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Equivalent Uniform Annual Cost (EUAC) Method

  • Total Investment = Rs.30 lacs
  • Anticipated revenue = Rs.18 lacs/year
  • Operating cost = Rs.6 lacs/year
  • Service life of robot = 5 years
  • MARR = 30%
  • EUAC = ‐30,00,000 (A/P,30%,5) +18,00,000 ‐

6,00,000 = ‐30,00,000 (0.41058) + 12,00,000 = ‐31,740 Note: if EUAC is positive, then project can be funded

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Return On Investment (ROI) Method

  • Determines the rate of return (RoR) for

the proposed project based on the estimated costs and revenues.

  • This RoR is compared with the company’s

MARR to decide whether the investment is justified.

  • Determination of RoR involves setting up

an EUAC equation.

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Return On Investment (ROI) Method…

  • Total Investment = Rs.30 lacs
  • Anticipated revenue = Rs.18 lacs/year
  • Operating cost = Rs.6 lacs/year
  • Service life of robot = 5 years
  • MARR = 30%

EUAC = ‐30lacs(A/P,i,5) + 18lacs‐6lacs=0 (A/P,i,5) = 12lacs/30lacs = 0.4 For i=25% (A/P,25%,5)= 0.37185 For i=30% (A/P,30%,5)= 0.41058 Rate of return = 30%

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END OF UNIT ‐ V

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