Automated

Production Lines
Chap # 18

Automated Production Lines

An automated production line consists of multiple workstations
that are linked together by a work handling system that transfers
parts from one station to the next, as shown in the following
Figure.

A raw work part enters one end of the line, and the processing
steps are performed sequentially as the part progresses

forward.

Automated Production Lines

The line may include inspection stations to perform intermediate
quality checks.
Manual stations may also be located along the line to perform
certain operations that are difficult or uneconomical to
automate.
Multiple parts are processed simultaneously on the line, one
part at each workstation.
In the simplest form of production line, the number of parts on
the line at any moment is equal to the number of workstations.
In more complicated lines, provision is made for temporary
parts storage between stations, in which case there is on
average more than one part per station.

Where to use Automated Production

lines
Automated production lines require a significant capital investment.
They are examples of fixed automation, and it is generally difficult
to alter the sequence and content of the processing operations
once the line is built. Their application is therefore appropriate only
under the following conditions:

High product demand

Stable product design
Long product life
Multiple operations

Benefits of Automated Production

lines
Automated production lines provide the following benefits:
Low direct labor content
Low product cost because cost of fixed equipment is spread
over many units.
High production rates.
Production lead time and work-in-process are minimized.
Factory floor space is minimized.

Transfer Lines
Transfer lines are the type of automated production lines where
machining is a common process performed on the workstations.
Other applications of automated production lines include:

Robot spot welding

Sheet metal press working
Automated assembly lines
Electroplating of metals.

Work holding device

Depending on work-part geometry, a transfer line may utilize pallet
fixtures for part handling. A pallet fixture is a work holding device
that is designed to:
fixture the part in a precise location relative to its base and
be moved, located, and accurately clamped in position at
successive workstations by the transfer system.
With the parts accurately located on the pallet fixture, and the
pallet accurately registered at a given workstation, the part is
therefore itself accurately positioned relative to the processing
operation performed at the station.
The term palletized transfer line is sometimes used to identify a
transfer line that uses pallet fixtures or similar work holding
devices.

System Configurations
The work flow can take following different forms:
1. In-line
2. Segmented in-line
3. Rotary

In-line: The in-line configuration consists of a sequence of

stations in a straight line arrangement.

In-line configuration
The in-line configuration consists of a sequence of stations in a
straight line arrangement.
This configuration is common for machining big work-pieces,
such as automotive engine blocks, engine heads, and
transmission cases.
Because these parts require a large number of operations, a
production line with many stations is needed.
The in-line configuration can accommodate a large number of
stations.

Segmented in-line configuration

The segmented in-line configuration consists of two or more
straight-line transfer sections, where the segments are usually
perpendicular to each other.

L-shaped

U-shaped

Rectangular
shaped

Segmented in-line configuration

There are a number of reasons for designing a production line in
these configurations rather than in a pure straight line
1. Available floor space may limit the length of the line
2. It allows reorientation of the work-piece to present different
surfaces for machining, and
3. The rectangular layout provides for return of work holding
fixtures to the front of the tine for reuse.

Rotary configuration
In the rotary configuration, the work-parts are attached to fixtures
around the periphery of a circular worktable, and the table is
indexed (rotated in fixed angular amounts) to present the parts to
workstations for processing.

Rotary configuration
The worktable is often referred to as a dial, and the equipment
is called a dial indexing machine, or simply, indexing
machine.
Compared with the in-line and segmented in-line configurations,
rotary indexing systems are commonly limited to smaller workparts and fewer workstations; and they cannot readily
accommodate buffer storage capacity.
On the positive side, the rotary system usually involves a less
expensive piece of equipment and typically requires less floor
space

Work Transfer Mechanisms

The work part transfer system moves parts between stations on
the production line. Transfer mechanisms used on automated
production lines are usually either synchronous or asynchronous.
There are two categories of work part transfer mechanisms:
1. Linear transport systems for in-line systems and
2. Rotary indexing mechanisms for dial indexing machines.

Linear transport systems

For linear motion of work-part in automated production systems
the material transport systems include; powered roller conveyors,
belt conveyors, chain-driven conveyors, and cart-on-track
conveyors.

Powered Roller Conveyors

DynaCon Powered Roller Conveyor -.mp4

Powered Roller Conveyors

Chain Driven Conveyors

Chain Driven Conveyors

Chain Conveyor.mp4

Belt Conveyors

Belt Conveyor.mp4

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Cart-on-Track

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Cart-on-Track

Cart-on-Track

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Cart-on-Track

Cart-on-Track

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Rotary Indexing Mechanism

Several mechanisms are available to provide the rotational
indexing motion required in a dial indexing machine. Two
representative types are: Geneva mechanism and cam drive.

Geneva mechanism:
It uses a continuously rotating driver to index the table through
a partial rotation.
If the driven member has six slots for a six station dial indexing table,
each turn of the driver results in 1/6 rotation of the worktable, or 60.

Rotary Indexing Mechanism

Geneva Mechanism.mp4

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Storage Buffers
Automated production lines can be designed with storage
buffers.
A storage buffer in a production line is a location where parts
can be collected and temporarily stored before proceeding to
subsequent (downstream) workstations.
A key parameter of a storage buffer is its storage capacity, that
is the number of work-parts it is capable of holding.
Storage buffers may be located between every pair of adjacent
stations or between line stages containing multiple stations.

Storage Buffers
There are a number of reasons why storage buffers are used on
automated production lines. The reasons include:
1. To reduce the effect of station breakdowns.
2. To provide a bank of parts to supply the line.
3. To provide a place to put the output of the line.
4. To allow for curing time or other required delay.
5. To smooth cycle time variations.

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Control of the Production Line

Controlling an automated production tine is complex because of the
number of sequential and simultaneous activities that must be
accomplished during operation of the line.
There are two important decisions about the controlling of
automated production lines:
1. The basic control functions that are accomplished to run the line.
2. The characteristics of controllers used on automated line.

Basic Control Functions

Three basic control functions can be distinguished in the operation of
an automatic transfer machine. One is an operational requirement,
the second is a safety requirement, and the third is for quality control.

Sequence Control:
1. The purpose of this function is to coordinate the sequence of actions of
the transfer system and associated workstations.
2. For example, the parts must be released from their current workstations,
transported, located, and clamped into position at their respective next
stations; then the work-heads must be actuated to begin their feed
cycles; and so on. Sequence control is basic to the operation of an
automated production line.

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Basic Control Functions

Safety Monitoring:
1. This function ensures that the production line does not operate in an
unsafe condition. Safety applies to both the human workers in the area
as well as the equipment itself.
2. Additional sensors must be incorporated into the line beyond those
required for sequence control to complete the safety feedback loop and
avoid hazardous operation.
3. Interlocks must be installed to prevent the equipment from operating
when workers are performing maintenance or other duties on the line.
4. In the case of machining transfer lines, cutting tools must be monitored
for breakage and/or excessive wear to prevent feeding a defective cutter
into the work.

Basic Control Functions

Quality Control:
In this control function certain quality attributes of the work-parts are
monitored. The purpose is to detect and possibly reject defective work units
produced on the line

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Auxiliary Control Functions

When a defect is encountered during quality control inspection, there are
two questions about possible actions:
1. Stop the line immediately and remove the defective part, but it results in
production time lost.
2. To continue to operate, but to lock out the affected work unit from further
processing as it proceeds through the sequence of stations. This keeps
the line producing but requires a more sophisticated level of control over
the equipment.
The same question of whether to interrupt or continue operation of the line
arises when
1. a workstation feed mechanism jams,
2. a life-threatening safety violation occurs,
3. a minor safety problem occurs, such as detection of worn cutter that will
last only a few more cycles.

Auxiliary Control Functions

To address the two alternative possible actions, the following auxiliary
functions are imbedded within the three basic functions.
Instantaneous control

1. This control mode stops the line immediately when a defect or

malfunction is detected. This reaction to a problem is the simplest, most
reliable, and easiest to implement.
2. Diagnostic features can be added to aid in identifying the location and
cause of the problem so that repairs can be made in the minimum
possible time.
3. Instantaneous control is appropriate for serious safety problems and for
malfunctions in sequence control that repeat every cycle.

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