DETROIT TYPE

AUTOMATION
 Detroit Automation
• What is Detroit automation and how does it relate to the whole broad subject? As a
word, and to some extent as a concept, automation itself had its origin in Detroit. It
began at the Ford Motor Company late in 1946 when Del S. Harder, then Vice-President
of Manufacturing, was reviewing plans for a new plant and said words to this effect:
"Let's see some more mechanical handling between these transfer machines. Give us
some more of that automatic business. . . . Some more of that-that 'automation.‘
• Thus, in the past decade, the meaning has been stretched to cover many other things
than the linking of automatic machines into automatic lines. As a result, the term
"Detroit automation" has come to be the popular term applied to the original
application. It should be added that, within the metal- working industries, these basic
applications are still usually called just "automation," and the addition of the adjective
is rarely encountered.
 Automated Flow Lines
• An automated flow line consists of several machines or
workstations which are linked together by work handling devices
that transfer parts between the stations. The transfer of work parts
occurs automatically and the workstations carry out their
specialized functions automatically. A raw work part enters one end
of the line and the processing steps are performed sequentially as
the part moves from one station to the next. It is possible to
incorporate buffer storage zones into the flow line, either at a single
location or between every workstation. It is also possible to include
inspection stations in the line to automatically perform
intermediate checks on the quality of the work parts.
• Manual stations might also be located along the flow line to perform
certain operations which are difficult or uneconomical to automate.
Automated flow lines are generally the most appropriate means of
production in cases of relatively stable product life ; high product
demand, which requires high rates of production; and where the
alternative method of manufacture would involve a large labor
content. The objectives of the use of flow line automation are,
therefore :
o To reduce labor costs
o To increase production rates
o To reduce work-in-process
o To minimize distances moved between operations
o To achieve specialization of operations
o To achieve integration of operations
 TYPES OF AUTOMATED FLOW LINES
a)Inline
• The in-line configuration consists of a sequence of workstations in a more-or-less
straight-line arrangement. The flow of work can take a few 90° turns, either for work
piece reorientation, factory layout limitations, or other reasons, and still qualify as a
straight-line configuration. A common pattern of work flow, for example, is a
rectangular shape, which would allow the same operator to load the starting
workpieces and unload the finished workpieces. An example of an in-line transfer
machine used for metal-cutting operations is illustrated in Figure 4.2.
 TYPES OF AUTOMATED FLOW LINES
b)Rotary
• In the rotary configuration, the work parts are indexed around a circular table or dial.
The work stations are stationary and usually located around the outside periphery of
the dial. The parts ride on the rotating table and are registered or positioned, in turn,
at each station for its processing or assembly operation. This type of equipment is
often referred to as an indexing machine or dial index machine and the configuration
is shown in Figure 4.3.
 Selection
• The choice between the two types depends on the application. The rotary type is
commonly limited to smaller workpieces and to fewer stations. There is generally not
as much flexibility in the design of the rotary configuration. For example, the dial-
type design does not lend itself to providing for buffer storage capacity. On the other
hand, the rotary configuration usually involves a lower-cost piece of equipment and
typically requires less factory floor space.
• The in-line design is preferable for larger workpieces and can accommodate a larger
number of workstations. The number of stations on the dial index machine is more
limited due to the size of the dial. In-line machines can be fabricated with a built-in
storage capability to smooth out the effect of work stoppages at individual stations
and other irregularities.
 Methods of workpart transport
• The transfer mechanism of the automated flow line must not only move the partially completed
work parts or assemblies between adjacent stations, it must also orient and locate the parts in the
correct position for processing at each station. The general methods of transporting work pieces on
flow lines can be classified into the following three categories :
– Continuous transfer
– Intermittent or synchronous transfer
– Asynchronous or power-and-free transfer
• These three categories are distinguished by the type of motion that is imparted to the work piece
by the transfer mechanism. The most appropriate type of transport system for a given application
depends on such factors as :
– The types of operation to be performed
– The number of stations on the line
– The weight and size of the work parts
– Whether manual stations are included on the line
– Production rate requirements
– Balancing the various process times on the line
 a)Continuous transfer
• With the continuous method of transfer, the work parts are moved continuously at
constant speed. This requires the work heads to move during processing in order to
maintain continuous registration with the work part. For some types of operations, this
movement of the work heads during processing is not feasible. It would be difficult, for
example, to use this type of system on a machining transfer line because of inertia
problems due to the size and weight of the work heads. In other cases, continuous
transfer would be very practical. Examples of its use are in beverage bottling operations,
packaging, manual assembly operations where the human operator can move with ‘the
moving flow line, and relatively simple automatic assembly tasks. In some bottling
operations, for instance, the bottles are transported around a continuously rotating drum.
Beverage is discharged into the moving bottles by spouts located at the drum’s periphery.
The advantage of this application is that the liquid beverage is kept moving at a steady
speed and hence there are no inertia problems.Continuous transfer systems are relatively
easy to design and fabricate and can achieve a high rate of production
 b)Intermittent transfer
• As the name suggests, in this method the workpieces are
transported with an intermittent or discontinuous motion. The
workstations are fixed in position and the parts are moved
between stations and then registered at the proper locations
for processing. All work parts are transported at the same time
and, for this reason, the term “synchronous transfer system” is
also used to describe this method of work part transport.
Examples of applications of the intermittent transfer of work
parts can be found in machining operations, press working
operations or progressive dies, and mechanized assembly.
 c)Asynchronous transfer
• This system of transfer, also referred to as a “power-and-free system,” allows each work part
to move to the next station when processing at the current station has been completed. Each
part moves independently of other parts. Hence, some parts are being processed on the line
at the same time that others are being transported between stations. Asynchronous transfer
systems offer the opportunity for greater flexibility than do the other two systems, and this
flexibility can be a great advantage in certain circumstances. In-process storage of work parts
can be incorporated into the asynchronous systems with relative ease. Power-and-free
systems can also compensate for line balancing problems where there are significant
differences in process times between stations. Parallel stations or several series stations can
be used for the longer operations, and single stations can be used for the shorter operations.
Therefore, the average production rates can be approximately equalized. Asynchronous lines
are often used where there are one or more manually operated stations and cycle-time
variations would be a problem on either the continuous or synchronous transport systems.
Larger work parts can be handled on the asynchronous systems. A disadvantage of the
power-and-free systems is that the cycle rates are generally slower than for the other types.
 Pallet fixtures
• The transfer system is sometimes designed to
accommodate some sort of pallet fixture. Work parts
are attached to the pallet fixtures and the pallets are
transferred between stations, carrying the part
through its sequence of operations. The pallet fixture
is designed so that it can be conveniently moved,
located, and clamped in position at successive
stations. 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.
 Transfer Mechanisms
• There are various types of transfer mechanisms used to move
parts between stations. These mechanisms can be grouped
into two types: those used to provide linear travel for in-line
machines, and those used to provide rotary motion for dial
indexing machines.

Linear Rotary
Linear Transfer Mechanism

Walking Beam Systems

Powered Roller Conveyor

Systems

Chain Drive Conveyor

Systems
 a)Walking beam systems
• With the walking beam transfer
mechanism, the work parts are
lifted up from their workstation
locations by a transfer bar and
moved one position ahead. to the
next station. The transfer bar
then lowers the parts into nests
which position them more
accurately for processing.
• https://www.youtube.com/
watch?v=8OJ82qKhYcg
 b)Powered Roller Conveyor systems
• This type of system is used in general stock
handling systems as well as in automated
flow lines. The conveyor can be used to
move pans or pallets possessing flat riding
surfaces The rollers can be powered by
either of two mechanisms. The first is a
belt drive, in which a flat moving belt
beneath the rollers provides the rotation of
the rollers by friction. A chain drive is the
second common mechanism used to power
the rollers. Powered roller conveyors are
versatile transfer systems because they
can be used to divert work pallets into
workstations or alternate tracks.
 c)Chain drive conveyor systems
• Either a chain or a flexible steel belt is used to
transport the work carriers. The chain is driven
by pulleys in either an “over-and-under”
configuration, in which the pulleys turn about a
horizontal axis, or an “around-the-corner”
configuration, in which the pulleys rotate about
a vertical axis.
• This general type of transfer system can be used
for continuous, intermittent, or non
synchronous movement of work parts. In the
non synchronous motion, the work parts are
pulled by friction or ride on an oil film along a
track with the chain or belt providing the
movement. It is necessary to provide some sort
of final location for the work parts when they
arrive at their respective stations.
Rotary Transfer Mechanism

Rack and Pinion

Geneva Mechanism

Ratchet and Pawl

Cam Mechanism
 a)Rack and Pinnion
• This mechanism is simple but is
not considered especially suited
to the high-speed operation
often associated with indexing
machines. The device is pictured
in Figure 4.6 and uses a piston to
drive the rack, which causes the
pinion gear and attached
indexing table to rotate. A clutch
or other device is used to provide
rotation in the desired direction.
 b)Ratchet and Pawl
• This drive mechanism is shown
in Figure 4.7. Its operation is
simple but somewhat
unreliable, owing to wear and
sticking of several of the
components.
 c)Geneva Mechanism
• The two previous mechanisms convert a linear
motion into a rotational motion. The Geneva
mechanism uses a continuously rotating driver
to index the table, as pictured in Figure 4.8. If
the driven member has six slots for a six-station
dial indexing machine, each turn of the driver
will cause the table to advance one-sixth of a
turn. The driver only causes movement of the
table through a portion of its rotation. For a six-
slotted driven member, 120° of a complete
rotation of the driver is used to index the table.
The other 240° is dwell. For a four-slotted driven
member, the ratio would be 90° for index and
270° for dwell. The usual number of indexings
per revolution of the table is four, five, six, and
eight.
 d)Cam Mechanism
• Various forms of cam mechanism,
an example of which is illustrated
in Figure 4.9, provide probably the
most accurate and reliable
method of indexing the dial. They
are in widespread use in industry
despite the fact that the cost is
relatively high compared to
alternative mechanisms. The cam
can be designed to give a variety of
velocity and dwell characteristics.
 Buffer storage
• When a breakdown occurs on an automated flow line, the purpose of the buffer storage zone is to allow
a portion of the line to continue operating while the remaining portion is stopped and under repair. For
example, assume that a 20-station line is divided into two sections and connected by a parts storage
zone which automatically collects parts from the first section and feeds them to the second section. If a
station jam were to cause the first section of the line to stop, the second section could continue to
operate as long as the supply of parts in the buffer zone lasts. Similarly, if the second section were to
shut down, the first section could continue to operate as long as there is room in the buffer zone to
store parts. Hopefully, the average production rate on the first section would be about equal to that of
the second section. By dividing the line and using the storage area, the average production rate would be
improved over the original 20-station flow line. The second reason for using storage on How lines is to
smooth out the effects of variations in cycle times.