Transfer lines and Transfer lines and similar automated similar automated

manufacturing manufacturing systemssystems

Transfer Transfer lineslines

Introduction Introduction (transfer lines = ?) (transfer lines = ?)

The The industries needindustries need considered for considered for high productionhigh production of parts of parts that that require require multiple processingmultiple processing operation ,operation ,which is done at which is done at physically physically integrated workstationintegrated workstation through through mechanized transport system. which mechanized transport system. which forms automated forms automated production linesproduction lines (due to this case (due to this case transfer linetransfer line or or transfer machine is used).transfer machine is used).

Conditions for applyingConditions for applying Usually automated Usually automated

production lines production lines requires requires heavy heavy initial capitalinitial capital investment hence investment hence require appropriate require appropriate conditions.conditions.

Those are..Those are..

1.High production 1.High production demand. (demand. (for lowering for lowering production timeproduction time))

2.Stable production 2.Stable production design. (design. (due to damage-due to damage-less transfer of materialless transfer of material))

3.Long product life. (3.Long product life. (due due to max accuracy of to max accuracy of transfertransfer))

4.Multiple operation4.Multiple operation

If conditions satisfy then benefits If conditions satisfy then benefits are…are…

1.1. Low labor content. (Low labor content. (in workpiece transfer in workpiece transfer they have no rolethey have no role))

2.2. Low product cost. (Low product cost. (due to elimination of due to elimination of labor worklabor work))

3.3. Higher production rates. (Higher production rates. (transfer lines are transfer lines are faster than “human material transfer”faster than “human material transfer”))

4.4. Production lead time. (Production lead time. (time before starting time before starting the productionthe production))

5.5. Factory floor space is minimized. Factory floor space is minimized. ((optimizationoptimization))

FundamentalsFundamentals An automated production line An automated production line

consists of multiple workstation that consists of multiple workstation that are linked together by a work are linked together by a work handling system that transfers parts handling system that transfers parts ((part handlingpart handling) from one workstation ) from one workstation to the next workstation.to the next workstation.

Part handlingPart handling Depending on the work part geometry a Depending on the work part geometry a

transfer line may be utilize pallet (transfer line may be utilize pallet (single single head carrying multiple holdingshead carrying multiple holdings) fixture ) fixture for part handling.for part handling.

It is designed forIt is designed for1.1. Fixture size of the part at precise Fixture size of the part at precise

locations.locations.2.2. Need of Accurate clamping. Need of Accurate clamping. The palletized transfer line is sometimes The palletized transfer line is sometimes

used to introduce in a transfer line that used to introduce in a transfer line that uses pallet fixtures.uses pallet fixtures.

System configurationSystem configuration(working system arrangement)(working system arrangement)

System configuration actually is the System configuration actually is the Work flowWork flow which can be take place in which can be take place in many different form.many different form.

1.1. In-lineIn-line = sequence of operation in = sequence of operation in straight line arrangement.straight line arrangement.

2.2. Segmented in-lineSegmented in-line = two or more = two or more straight line arrangement .straight line arrangement .

3.3. RotaryRotary = work parts are fixed around = work parts are fixed around the periphery of circular work table.the periphery of circular work table.

Pictorial view of system Pictorial view of system configurationconfiguration

In-lineIn-linesequence of operation in straight line

arrangement.

Pictorial view of system Pictorial view of system configuration…..configuration…..

Segmented in-lineSegmented in-linetwo or more straight line

arrangement.

Pictorial view of system Pictorial view of system configuration…..configuration…..

RotaryRotarywork parts are fixed

around the periphery of circular work

table.

Work part transfer mechanismWork part transfer mechanism

The work parts transfer mechanism is The work parts transfer mechanism is actually actually physical means through the physical means through the workpart gets travel during the operationsworkpart gets travel during the operations. . The respected workpart transfer mechanism The respected workpart transfer mechanism can be synchronous or asynchronous.can be synchronous or asynchronous.

1.1. Synchronous mech.Synchronous mech. = Traditional means of = Traditional means of moving parts in a transfer lines speed of moving parts in a transfer lines speed of transfer remain constant & transfer remain constant & synchronization synchronization as per the speed of operations.as per the speed of operations.

2.2. Asynchronous mech.Asynchronous mech. = transfer speed = transfer speed varies.varies.

Advantage of Asynchronous Advantage of Asynchronous mechanismmechanism

1.1. Greater flexibility. (Greater flexibility. (due to variable due to variable speedspeed))

2.2. Fewer pallet fixture required. Fewer pallet fixture required. ((because it is not much process because it is not much process dependentdependent))

3.3. Easier to rearrange or expand the Easier to rearrange or expand the production system. (production system. (due to flexibilitydue to flexibility))

Division of workpart transferDivision of workpart transfer

There are two main category of There are two main category of workpart transfer.workpart transfer.

1.1. Linear or InlineLinear or Inline transport systems. transport systems.

2.2. Rotary indexingRotary indexing mechanisms. mechanisms.

Line transfer systemLine transfer system

This system use This system use powered rollerpowered roller conveyors, conveyors, beltbelt conveyors, conveyors, chainchain driven conveyors.driven conveyors.

Rotary indexing mechanismsRotary indexing mechanisms

Several mechanisms Several mechanisms are available to are available to provide the rotational provide the rotational indexing motion indexing motion required in a dial required in a dial indexing machine. indexing machine.

E.g. cam drive.. E.g. cam drive..

These are used to These are used to provide an accurate provide an accurate and reliable method of and reliable method of indexing a rotary dial indexing a rotary dial table. table.

Storage bufferStorage buffer

A storage buffer in a production line A storage buffer in a production line is a is a location where parts can be location where parts can be collected and temporarily storedcollected and temporarily stored before proceeding to downstream before proceeding to downstream workstations. Storage buffer can be workstations. Storage buffer can be manually operated or automated.manually operated or automated.

Reasons for using Storage bufferReasons for using Storage buffer1.1. To reduce the effect of station breakdowns.To reduce the effect of station breakdowns.

((one station remain continued if other gets one station remain continued if other gets down for repairdown for repair))

2.2. To provide a bank of parts to supply the line.To provide a bank of parts to supply the line.((here parts can be manually fed to other here parts can be manually fed to other stationstation))

3.3. To provide a place to put the output of the To provide a place to put the output of the line.line.

4.4. To allow for curing time or other required To allow for curing time or other required delaydelay

5.5. To smooth cycle time variations.(To smooth cycle time variations.(manual manual purposepurpose))

Control of the production lineControl of the production line

It’s a It’s a complex controllingcomplex controlling process process because of number of sequential because of number of sequential and simultaneous activities that must and simultaneous activities that must be accomplished during operation of be accomplished during operation of the line.the line.

Control function Control function

Due to this complexity the control on Due to this complexity the control on production lines are divided into three basic production lines are divided into three basic control functions those are..control functions those are..

1.1. Sequence controlSequence control = the function of this control = the function of this control is to coordinate the is to coordinate the sequence of actions sequence of actions of the of the transfer system and associated workstations. transfer system and associated workstations.

2.2. Safety monitoringSafety monitoring = this function ensures that = this function ensures that the the production line does not operate in unsafe production line does not operate in unsafe conditioncondition..

3.3. Quality controlQuality control = in this function, certain = in this function, certain quality attributesquality attributes of the workparts are of the workparts are monitored .monitored .

Application of automated Application of automated production linesproduction lines

They are extensively used in….. They are extensively used in….. Sheet metalSheet metal forming and cutting. forming and cutting. Rolling millRolling mill operations. operations. Spot weldingSpot welding of automobile car of automobile car

bodies.bodies.

Machining systemsMachining systems

Many applications of machining Many applications of machining transfer machines, transfer machines, both in-line and both in-line and rotary configurationsrotary configurations, are found in , are found in the automotive industry. Here is the the automotive industry. Here is the various multiple station machining various multiple station machining systems.systems.

1.1. Transfer linesTransfer lines

2.2. Rotary transfer machines.Rotary transfer machines.

Transfer linesTransfer lines

In this the workstations containing In this the workstations containing machining machining work heads are arranged in work heads are arranged in an in-linean in-line an segmented in-line an segmented in-line configuration and parts are moved configuration and parts are moved between station by transfer between station by transfer mechanisms such as the walking beam mechanisms such as the walking beam system. (system. (in which parts are in which parts are synchronously lifted up from their synchronously lifted up from their respective stations by a transfer beam respective stations by a transfer beam and moved one position ahead to the and moved one position ahead to the next stationnext station).).

Rotary transfer machinesRotary transfer machines

In this a In this a horizontal circular worktablehorizontal circular worktable, , on which fixtures and work pieces are on which fixtures and work pieces are to be processed , stationary to be processed , stationary work head work head are located at the peripheryare located at the periphery the and the and the worktable is given an indexing the worktable is given an indexing arrangement so that at a specific arrangement so that at a specific process process the worktable is rotated the worktable is rotated through a specific angle for machining through a specific angle for machining that piecethat piece which is hold by the which is hold by the workhead.workhead.

FinallyFinally

E.g. If railway lines are supposed to be If railway lines are supposed to be

the the Transfer MechanismsTransfer Mechanisms then the then the railway stations are part of railway stations are part of System System ConfigurationConfiguration and powering means to and powering means to the engine is something like the the engine is something like the Machining SystemMachining System..