EXPERIMENT NO: 1
Aim: - To study automated flow line (AFL) & transfer line mechanism.
1. Introduction
1.1 Automated flow line (AFL)
• An automated flow line consists of multiple workstations that are linked together by a
work handling system that transfers parts from one station to the next.
• A raw work part enters one end of the line, and the processing steps are performed
sequentially as the part progresses forward.
• The line may include inspection stations to perform intermediate quality check.
• Manual stations may also be located along the line to perform certain operations that are
difficult or uneconomical to automate.
• Each station performs a different operation, so that the sum total of all the operations is
required to complete one unit of work.
• The slowest workstation on the line sets the pace of the line.
1.2 Automation Strategies
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing (CIM)
Department of Mechanical Engg.,
R C O E M , Nagpur
2. Work Transfer Methods
2.1 The work part transfer system moves parts between stations on the production line.
Transfer mechanisms used on automated flow lines are classified into three categories
1. Continuous transfer: - In continuous method of work transfer, the work part moves
continuously with constant speed. This method is applied in those cases where work
head moves during processing in order to maintain continuous registration with work-
part. Ex. Beverage bottling plant.
2. Synchronous Transfer: - In this method the work pieces are transported with an
intermittent motion. The work stations are fixed in position and the parts are moved
between the stations at the same time and then registered at proper location for
processing. Ex. Press working operation.
3. Asynchronous transfer: - This method of transfer is also called as ‘power and free
system’. In this method, work part move to next station when processing at the
current station is completed. Each part moves independently of the other parts.
Hence, some parts are being processed on the line at same time that other are being
transported between stations.
4. Pallet Fixture: - The transfer system is sometimes designed to accommodate some
sort of pallet fixture. Work parts are attached to the fixture and the pallet is
transferred between the stations, carrying the part through its sequence of operation.
The pallet fixture is designed so that it can be conveniently moved, located and
clamped in apposition at successive station. Since the part is accurately located in the
fixture, it is therefore correctly positioned for each operation. In addition to the
obvious advantage of convenient transfer and location of work parts, another
advantage of pallet fixtures is that they can be designed to be used for a variety of
similar parts.
Department of Mechanical Engg.,
R C O E M , Nagpur
2.2 Work transfer mechanism is grouped into two types:-
1. Linear transfer mechanism
2. Rotary transfer mechanism
1. Linear transfer mechanism:-These transfer mechanism are used to provide linear travel
for in-line machine. Some Linear transfer mechanisms areexplained below.
a. Walking beam mechanism:- In the walking beam mechanism, the parts are
synchronously lifted up from their respective stations by a transfer beam and moved
one position ahead to the next station.
Figure 1: Operation of walking beam transfer system
The transfer beam then lowers the parts into nests that position them for processing
at their stations. The beam then retracts to make ready for the next transfer cycle.
b. Belt conveyor system: -Belt conveyors consist of a continuous loop. Half its length
is used for delivering materials, and the other half is the return run. The belt is made
of reinforced elastomer (rubber), so that it possesses high flexibility but low
extensibility. At one end of the conveyor is a drive roll that powers the belt. The
flexible belt is supported by a frame that has rollers or support sliders along its
forward loop. Belt conveyors are available in two common forms: (1) flat belts for
pallets, individual parts. Or even certain types of bulk materials; and (2) troughed
belts for bulk materials. Materials placed on the belt surface travel along the moving
pathway.
Department of Mechanical Engg.,
R C O E M , Nagpur
Figure2: Flat Belt Conveyor
2. Rotary transfer mechanism: -These transfer mechanism provides controlled rotary
motion to the work part. Several mechanisms are available to provide the rotational
indexing motion required in a dial indexing machine. Two representative types
explained here: Geneva mechanism and cam drive.
a. Geneva Mechanism: - The Geneva mechanism 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 work
table or 60°.The driver only causes motion of the table through a portion of its own
rotation.. In general.
θ=360/ns
Where, θ= angle of rotation of worktable during indexing
ns= number of slots in the Geneva.
The angle of driver rotation during indexing = 2θ, and the angle of driver rotation
during which the work table experiences dwell time is (360-2θ)Geneva mechanisms
usually have four, five, six, or eight slots, which establishes the maximum number of
workstation positions that can be placed around the periphery of the table, Given the
rotational speed of the driver. We can determine total cycle time as:
T c= 1/N
WhereTc= cycle time (min)
Department of Mechanical Engg.,
R C O E M , Nagpur
N = rotational speed of driver (rev/min).
The total cycle time, the dwell time, or available operation time per cycle, is given by
Ts= (180 +θ)/360*N
Where,Ts= available service or processing time.
Similarly, the indexing time is given by
Ti= (180- θ)/360*N
Figure 3: Geneva mechanism
b. Cam mechanism: -Various forms of cam drive mechanisms, one of which is
illustrated in Figure 4, are used to provide an accurate and reliable method of
indexing a rotary dial table. They are in widespread use in industry despite the fact
that the cost is relatively high. The advantage of the cam is that, it can be designed
top provide a variety of velocity and dwell characteristics.
Figure 4: Cam mechanism
Department of Mechanical Engg.,
R C O E M , Nagpur
2.3 Difference between the linear transfer mechanism & rotary transfer mechanism
Sr. Linear transfer mechanism Rotary transfer mechanism
No.
This mechanism provides linear This mechanism provides rotary travel to
1
travel to the job. the job.
This mechanism is used for in line This mechanism is used for dial indexing
2
machine. machine.
This mechanism is preferable for This mechanism is limited to smaller size
3
larger size of workpieces. of workpieces.
The automated flow line in which The automated flow line in which linear
4
linear transfer mechanism is used transfer mechanism is used can
can accommodate more number of accommodate less number of workstation.
workstation.
There is generally more flexibility in There is generally not as much flexibility in
5
the design of linear transfer the design of rotary transfer mechanism.
mechanism.
In this type of mechanism it is very In this type of mechanism it is very
6
easy to provide buffer storage difficult to provide buffer storage facility.
facility.
Examples of linear transfer Examples of rotary transfer mechanism are
7
mechanism are 1. Rack and pinion mechanism
1. Walking beam mechanism 2. Ratchet and pawl mechanism
2. Powered roller conveyor system 3.Geneva mechanism
3. Chain drive conveyor system
Department of Mechanical Engg.,
R C O E M , Nagpur
❖ Conclusions:
▪ From the study of this experiment we have listed out following advantages of AFL
1. AFL reduces work in progress.
2. AFL minimizes distance moved between operations.
3. AFL helps to achieve specialization of operation.
4. AFL helps to achieve the integration of operation.
▪ The meaning & significance of automated flow lines in order to achieve high level
automation in industries has been understood. The importance and application of
principles of ‘Automation Strategies’ in the design of automated flow lines are
studied.
▪ The different types of work transfer methods used in the development of automated
flow line are studied in detail.
▪ The difference between the rotary transfer mechanism & linear transfer mechanism
with reference to various aspects are learned.
✓ In addition to the conclusion [Hand written] given above
✓ Complete and continue the conclusion section using Additional five points from
student end as individual.
✓
Department of Mechanical Engg.,
R C O E M , Nagpur
Department of Mechanical Engg.,
R C O E M , Nagpur
