Questions:
PART A
A 1.1)ntroduction to machine vision systems and its applications:
1.2) Description of any one process incorporating machine vision system with justification Automobile Industry
PART B1
B1.1)Introduction to work cell arrangement in automated manufacturing industry:
1.2) Description of the functions carried out by the selected Robot work cell arrangement with block diagram:
1.3)Suggestion of an alternate layout for the Robot work cell with justification
PART B2
B 2.1)Discuss the role of material handling systems in the manufacturing industry:
B.2.2 Describe the adopted material handling system for the selected application in the manufacturing industry with a block diagram
ANSWERS:
A1.1. Introduction to machine vision systems and its applications:
Technology improvements in manufacturing system are increasing
day by day with scope for
automation implementation and robotics. It is necessary
to increase the productivity to meet the customer
requirement by implementing the automation.
Machine vision is a part of computer vision that gives
ability for computers to understand the surrounding
and give command for the system to operate depending on the information obtained.
Machine vision systems
rely on digital sensors protected
inside industrial cameras
with specialized optics to
acquire images, so that computer hardware and software can process, analyse, and measure various
characteristics for decision
making.
Application of machine
vision system in various sectors –
1.
Object detection – In packaging, assembly... etc.
2.
Measurement - Object
dimension and geometric dimension capture.
3.
Flaw detection - Abnormalities like surfaces defects,
scratches etc.
4.
Identification – printing
defect, identifying part and products.
5.
Locating – object
location for robotic
guidance.
6.
Counting – count of objects
etc.
Figure 1.1: Machine
vision system and frame work.
A1.2. Description of any one process
incorporating machine vision
system with justification Automobile Industry –
Automobile door handles are becoming increasingly more sophisticated as a greater need for
operator assistance and intelligence is built into each unit, coupled with the increased
demands for quality from automotive manufacturers driven by the need to
provide consumers with higher specifications
and performance.
Case study: Vision System Inspects Automotive Door Handles,
Industrial vision system Pvt. Lim.
The manufacturer required a machine to perform a number
of inspection tasks as part of the final
automatic quality control of the product. An automotive handle is made up of a
number of constituent parts including
the main body of the handle, closure and cap – all these parts are critical to the effective operation of
the handle in the application. Add to this the number of colour variants of each handle available along with the
variations in 2 door/4 door left hand/right
hand which go up to make a complete car handle pack; and it can be seen that
the final inspection is critical
to guarantee the correct components reach the customer
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PART –B
B.1.1
Introduction to work cell arrangement in automated manufacturing industry:
A
work cell is a logical
and strategic arrangement of resources in a manufacturing environment. These arrangements are put into place to organize
and improve process flow, increase efficiency, reduce costs, and eliminate wastage.
The concept of work cells is based
on the platform of lean
manufacturing, which focuses on value creation for the end customer and reduction of wastage. Work
cells, which are also referred to as work cells, are typically found in manufacturing and office environments.
In a manufacturing facility, the machines
involved in the production process
would be arranged so the goods being produced move
smoothly and seamlessly from one stage to the
next. This would only be possible if the machines are grouped in work
cells that facilitate the logical
progression of the goods being produced—from raw
materials at one end to finished product
at the other.
Cellular manufacturing is a manufacturing process
which is a subsection of just-in-time manufacturing and lean manufacturing encompassing group technology.
Cellular manufacturing
involves the use of multiple cells in an assembly
line fashion. A cell is created by
consolidating the processes required to create a specific output, such as a
part or a set of instructions. These
cells allow for the reduction of extraneous steps in the process of creating
the specific output,
facilitate quick identification of problems, and encourage communication of employees within
the cell in order
to resolve issues that arise quickly.
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Figure 1.1 Work cell layout in different industries.
B.1.2 Description of the functions carried out by the
selected Robot work cell arrangement with block diagram:
Computer numerically controlled (CNC) punching is a
sheet metal manufacturing process that is
carried out by CNC punch presses. These machines can be either a single head
and tool rail (Trumpf) design or multi-tool turret design. The CNC punching
machine is basically
programmed to move a sheet of metal in an x and y direction so as to
accurately position the sheet under the machine’s punching ram ready
to punch a hole or form.
The
manufacturing engineer at Acme asked the operator to comment on the various
steps in the process while he
recorded a video with his phone. Since it’s a continuous process, he had to decide what to define as the starting
point in the cycle. He chose the state of the system when a finished part is present in the CNC machine’s vise. So
the first step is to open the machine’s door to remove
the finished part.
Figure 1.2: Process
flow diagram in manual cell layout.
Block diagram
or Manual task map of working cell –
Previous cell operator – He is unloading the product and he will
pass through the operator. Operator – He will load the part into the CNC machine and after process he will unloading the product then give it to the next cell operator.
Next cell
operator – they will load the part for further
operations.
Process -
1.
Open door- the operator
opens the door in automatically.
2.
Clean part and vice with air- when the part insert they will
must be clean the product.
3.
Pick the part- After the operation operator
must unload the part and put
into the trey.
4.
Pick the raw material
– Once complete operation he will take new part into the cnc machine
.
5. Close the door – Once material into the cnc machine
he must close the door before start the operation.
Figure 1.2: Manual cell layout for the considered process.
.
B.1.3
Suggestion of an alternate
layout for the Robot work cell with justification
Manual work is time consumption, less KPI’S and
considering the safety issues of operator automation
can be brought up in this field. Robotic implementation can be applied for the standardized cell structure for the mention
operation. Non value added process
can be eliminated and increase
the efficiency.
Alternative
concept - The chosen operation is to position the
parts on a table and use a camera to
locate them. This method seemed to be more flexible than the alternatives,
since the vision system can locate
different parts automatically, whereas a hardware-only solution would require manually
changing the physical setup to handle different
parts.
Although they had a hunch this concept would work, they
felt they needed more technical work to determine whether
this was the right solution.
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Figure 1.3: Process flow diagram for proposed robotic
cell layout.
Working of the proposed
Robotic cell layout –
A typical robotic
arm is made up of seven metal segments, joined
by six joints. The computer
controls the robot by rotating
individual step motors connected to each joint(some
larger arms use hydraulics or pneumatics). Your arm's job is
to move your hand from place to place.
Process -
1.
Open door- the door will opens in
while vise once the operation over door will open in automatically.
2.
Clean part and vice with air- Robot will pick
the part using there grippers
and clean the surface of the machine
as well as product.
3.
Pick the part- Once the unloading
the part it will prepare
the anther part to further
operations.
4.
Pick the raw material – Once complete operation
it will take new part into the cnc machine .
5.
Close the door – Once material into
the cnc machine the door will close automatically before start the operation.
Figure 1.4: Robotic task map.
B.2.1 Discuss the role of material handling systems in the manufacturing industry:
For the large companies, warehouse is the hub of their operations. Material handling is an integral part of the manufacturing
industry. The protection, movement, control of materials, and end products throughout the process of manufacturing, disposal,distribution,warehousing, and storage comes
under material handling.
Material handling helps many other processes in the
industry. This includes product planning, flow and process management, resource allocation, forecasting, customer delivery, control
and management of
inventories, and after-sales services and support. Proper planning of material handling results in shortening the
delivery time, lower overall costs of manufacturing, improve customer service and reduce inventory.
Distribution and transportation are other significant areas where changes affect.
B.2.2
Describe the adopted material
handling system for the selected
application in the manufacturing industry with a block diagram
Material handling case study -Material Handling
System for JIT Automotive Production Line
Situation –The GFR system for an automotive component which is Air Cleaner
that emphasized on manpower
productivity and occupied space in the production area. The study explores the design and concepts of the GFR system for an automotive component
which is Air Cleaner that emphasized
on manpower productivity and occupied space in the production area. Gravity Flow Rack system (GFR) is a
storage rack with metal shelves, equipped with
rollers or wheels to move goods from the one end to another by using the
force of gravity. The GFR was
designed to be inclined along the length of the rack. This system is introduced
in the assembly line as a temporary
storage in order to place the components or parts as close as possible to the operators’ Point of Use
(POU) to make it easy for the operator to pick up parts or components for the assembly
processes.
Assessment:
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The size of the trolley is 1340 mm length, 380 mm width and 1770 mm height. Due to its size, it requires more space in the assembly line. The bulk size of the trolley requires
a large space in the assembly area. During replenishment by material handler,
short stoppages were frequently
occurred as the operator was asked to help the material handler to rearrange
the trolley at the line. Since the
trolley is bulk in size, the operator required to take the part at a certain position. In this situation, the
operator has higher chances to get back pain due to non- ergonomic design of the trolley. Once the inventory runs out,
the material handler has to walk further
to the store room to replenish the inventory of the trolley. Due to this, the
walking distance of the material
handler has increased. Minor stoppages and long walking distance are the wastes that must be eliminated in
order to adhere to the philosophy of the TPS. These wastes may reduce production output and productivity as well.
Solution:
Based on the dimensions of the Air Cleaner, the standard
poly-boxes have been designed by using
CATIA. The size of the poly-boxes is 515 mm length, 399 mm width and 460 mm
height with the weight of 1.2 kg. The
estimation weight for the overall poly-boxes including the 10 pieces of air cleaner is 3.7 kg. This new poly-boxes have 10 partitions where each of them is for
1 piece of air cleaner. Therefore, each poly-box can store 10 pieces of air
cleaner at one time. These poly-boxes
are designed to maintain proper part presentation and orientation. Therefore, it can be integrated with a
partition to increase protection by preventing contact between parts which can cause damage on the part’s surface.
These poly-boxes are made up from polyethylene corrugated plastic material.
The advantages of using polyethylene corrugated plastic are it is easy, cheap and cost-effectively
customized and can achieve perfect fit
for unconventionally shaped components or products. Moreover, it is lighter by
50% than a conventional container
made from metal or wood. In addition, this material is fully recyclable and can be found in recycled materials.
However, limitations of this material
are that it is not
durable and not suitable for products that are too heavy. To solve the limitation, it is suggested that the poly-boxes should be
injected so as to last longer though the price of poly- boxes from plastic
injection may be costly
but it is able to withstand a longer period
of time.
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