IE 447 COMPUTER INTEGRATED MANUFACTURING

IE 447 - CIM Lecture Notes - Chapter 9 MHS 1

IE 447 IE 447 COMPUTER INTEGRATED COMPUTER INTEGRATED

MANUFACTURINGMANUFACTURING

CHAPTER 9CHAPTER 9

Material Handling Material Handling SystemSystem


Material HandlingMaterial Handling is the movement, is the movement, storage, control and protection of storage, control and protection of materials, goods and products materials, goods and products throughout the process of throughout the process of manufacturing, distribution, manufacturing, distribution, consumption and disposal.consumption and disposal.

2IE 447 - CIM Lecture Notes - Chapter 9

MHS


The Material Handling System (MHS) The Material Handling System (MHS) is a fundamental part of a Flexible is a fundamental part of a Flexible Manufacturing system since it Manufacturing system since it interconnects the different interconnects the different processes supplying and taking out processes supplying and taking out raw material, work-pieces, sub-raw material, work-pieces, sub-products, parts and final products. products, parts and final products.


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Components:Components: RobotsRobots ConveyorsConveyors Automated Guided Vehicles(AGVs)Automated Guided Vehicles(AGVs) Automated Storage/Retrieve System Automated Storage/Retrieve System


MHS


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Robots in Robots in ManufacturingManufacturing

Industrial robot is aIndustrial robot is a ProgrammableProgrammable Multi-functionalMulti-functional Designed to move materials, parts, Designed to move materials, parts,

tools or special devicestools or special devices Through programmed motionsThrough programmed motions To perform many different tasksTo perform many different tasks


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Robots in ManufacturingRobots in Manufacturing First industrial robot was developed in the First industrial robot was developed in the

1950s1950s Further advancements enable to utilize robots Further advancements enable to utilize robots

inin Variety of typesVariety of types StyleStyle SizeSize

Their functionalities may include but not Their functionalities may include but not restricted torestricted to WeldingWelding DrillingDrilling PaintingPainting Military applicationsMilitary applications AssemblyAssembly Explosive material removalExplosive material removal Pick-and-placePick-and-place Material handlingMaterial handling


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A typical robot consists of many A typical robot consists of many different part connected to each otherdifferent part connected to each other

Most robots resembles a human armMost robots resembles a human arm Its motions are controlled by a Its motions are controlled by a

computer programcomputer program Depends on the type of robot, Depends on the type of robot,

movement capabilities of them are movement capabilities of them are measured by the term degrees of measured by the term degrees of freedomfreedom


MHS


Robots with different degrees of Robots with different degrees of freedomsfreedoms2-3 dof

Robots used in surgery


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Robots in ManufacturingRobots in Manufacturing How do robots work:How do robots work: there are 3 power sources there are 3 power sources

Hydraulic Hydraulic drivedrive

Joints are actuated by hydraulic driversJoints are actuated by hydraulic drivers

The major disadvantages are:The major disadvantages are: Floor is used by the installation of hydraulic systemFloor is used by the installation of hydraulic system Leaks may seen often and cause messy floorLeaks may seen often and cause messy floor

AdvantagesAdvantages Due to the speed and power, they are used in large Due to the speed and power, they are used in large industrial robotsindustrial robots Also desired to use in the environments where electric-Also desired to use in the environments where electric-driven robots might cause fire etc.driven robots might cause fire etc.

Electric Electric DriveDrive

Comparison to Hydraulic systems, less power and slower Comparison to Hydraulic systems, less power and slower speedspeed

Most common robot types in the industryMost common robot types in the industry

There are two distinct group: Stepper motors and Direct There are two distinct group: Stepper motors and Direct current (DC) servo-motor drivencurrent (DC) servo-motor driven

PneumatiPneumatic Drivec Drive

Usually installed to small robotsUsually installed to small robots

Tends to have less degrees of freedomTends to have less degrees of freedom

Operations are simple and less cycle timesOperations are simple and less cycle times

Less expensive, Since most of the robot parts are Less expensive, Since most of the robot parts are commercially available, small institution can build commercially available, small institution can build their own robotstheir own robots


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How do we know the location of robot How do we know the location of robot arms?arms? Sensors are usedSensors are used to monitor the motion of to monitor the motion of

robotsrobots Motion of robots is sustained by the power Motion of robots is sustained by the power

based on the given input (computer algorithm)based on the given input (computer algorithm) Once the order is given, it is important to know Once the order is given, it is important to know

the location of robot’s arm/partsthe location of robot’s arm/parts Its movements should be controlled during the Its movements should be controlled during the

entire motionentire motion Robot should also be capable of sensing their Robot should also be capable of sensing their

environmentsenvironments Sensors provides feedback to the controller and Sensors provides feedback to the controller and

give flexibility to robotsgive flexibility to robots


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Robots in Robots in ManufacturingManufacturingType of sensors being used in roboticsType of sensors being used in robotics

1. 1. Position Position SensorsSensors

Monitors the location of jointsMonitors the location of joints

Coordinate information is feedback to controllerCoordinate information is feedback to controller

This communication gives the system the capability of location This communication gives the system the capability of location the end-effectors, which is the part usually performs the tasks.the end-effectors, which is the part usually performs the tasks.

2. Range 2. Range sensorssensors

Measures the distance between a point in the robot and interest Measures the distance between a point in the robot and interest point that surrounds the robotspoint that surrounds the robots

The task is usually performed by television cameras or sonar The task is usually performed by television cameras or sonar transmitter and receiverstransmitter and receivers

If the sonar or camera misses a point, undesired coincidences If the sonar or camera misses a point, undesired coincidences may occurmay occur

3. 3. Velocity Velocity sensorssensors

Estimates the speed using a moving manipulatorEstimates the speed using a moving manipulator

Due the the effects caused by, mechanical force, gravity, weight Due the the effects caused by, mechanical force, gravity, weight of load etc, desired speed and required force to reach the speed of load etc, desired speed and required force to reach the speed should be computed continuouslyshould be computed continuously

4. 4. Proximity Proximity sensorssensors

Sense and indication of presence of another object within Sense and indication of presence of another object within specified distancesspecified distances

Prevents accidents and locate the existence of work-piecePrevents accidents and locate the existence of work-piece


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Robot movements:Robot movements: Robots are feasible when they are Robots are feasible when they are fastfast

but also the but also the stability is highstability is high The trade-off between speed and stability The trade-off between speed and stability

is sustained by a powerful control systemis sustained by a powerful control system Robotics and Control are two joint Robotics and Control are two joint

disciplinesdisciplines


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Robotic movements and jointsRobotic movements and joints Robots required to performRobots required to perform

1.1. Rotational movementsRotational movements

2.2. Radial movementsRadial movements

3.3. Vertical movementsVertical movements Type of jointsType of joints

1.1. Rotational jointsRotational joints

2.2. Twisting jointsTwisting joints

3.3. Revolving jointsRevolving joints

4.4. Linear jointsLinear joints


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Analysis of robot motions:Analysis of robot motions:

Forward and Backward Kinematics conceptsForward and Backward Kinematics concepts Forward Kinematics:Forward Kinematics: Transformation of Transformation of

coordinate of the end-effectors point from the coordinate of the end-effectors point from the joint space to the world spacejoint space to the world space

Position of end-effectors is computed based on Position of end-effectors is computed based on the joints locationsthe joints locations

Backward Kinematics:Backward Kinematics: Transformation of Transformation of coordinates from world space to joint spacecoordinates from world space to joint space

In this concept the position of end-effectors is In this concept the position of end-effectors is known in world coordinate systemknown in world coordinate system

Required motion is computed based on this Required motion is computed based on this informationinformation


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Robot ConfigurationsRobot Configurations

LL Robot: Base is static, arms are linear joints

RRR Robot: Base is static, arms are rotational

joints

TL Robot: Base is rotational and the arm is

linear joint

(x1, y1) (x2, y2)

(x, y)

L2

L1

L3

(x, y)

(x, y)


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Essentials of robot programmingEssentials of robot programming RequiresRequires

The path robot should followThe path robot should follow The points it should reachThe points it should reach Details about how to interpret the Details about how to interpret the

sensor datasensor data How and when the end-effectors should How and when the end-effectors should

be activatedbe activated How to move parts between given How to move parts between given

locationslocations


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Essentials of robot programmingEssentials of robot programming Programming techniquesProgramming techniques

Teach-by showing:Teach-by showing: Robot can repeat the motion already been Robot can repeat the motion already been

done by the programmerdone by the programmer Textual language programmingTextual language programming

A computer programming is written using A computer programming is written using logical statementslogical statements

Some of the languages are:Some of the languages are: Wave, VAL, AML, RAIL, MCL, TL-10, Wave, VAL, AML, RAIL, MCL, TL-10,

IRL, PLAW, SINGLA and IRL, PLAW, SINGLA and ACLACL


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Robots of IE CIM LABRobots of IE CIM LAB


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SCORA ER14

A four-axis, table-top mounted SCARA robot, the SCORA-ER 14 is designed for work in industrial training facilities. This rugged and reliable robot performs light-payload assembly, handling and packaging applications with impressive speed and accuracy.

• Handling and packaging operations with palletizing and storage devices• Assembly operations with automatic screw driving and gluing devices• Quality control operations with machine vision and high-precision measurementdevices


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SCORBOT ER9

The SCORBOT-ER 9 is a five-axis vertically articulated robot designed for work inindustrial training facilities.With a multi-tasking controller that provides real-time control and synchronization of up to 12 axes, 16 inputs and 16 outputs, the SCORBOT-ER 9 supports both stand-alone applications as well as sophisticated automated work cells.


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Steps in Robot Steps in Robot ProgrammingProgramming

Programming of an Industrial TaskProgramming of an Industrial Task

1. Teach Pendant 1. Teach Pendant OperationOperation

move the robot arm inmove the robot arm in JointsJoints CartesianCartesian Tool coordinatesTool coordinates

Control robot grippers Control robot grippers and the speed of motionand the speed of motion

Record positions to the Record positions to the robot controller’s robot controller’s memorymemory

Move robot arm to Move robot arm to recorded positionsrecorded positions

1AXIS 1 X

2AXIS 2 Y

3AXIS 3 Z

4AXIS 4

5AXIS 5

6AXIS 6

7AXIS 7

8AXIS 8

9AXIS 9

0SELEC T

AXIS

S IN G LE STE P

SPLIN E

M O VE C

IN SERT

D ELETE

R EC O R DPO SITIO N

ABO RTSPEED (% )

S P EE D L(% )

M O VE

M O VE L

EN TER

EXEC UTE

O PEN

C LO SE

CO N TR O LO N/O FF

R U N

C LR

G RO U PSELEC T

AU TO M ODE


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2. Writing robot programs2. Writing robot programs Use ACL (Automatic Control Language) to edit Use ACL (Automatic Control Language) to edit

robot programs.robot programs. Commonly used robot program statements.Commonly used robot program statements.

MOVE:MOVE:

MOVED: MOVED:

OPEN:OPEN:

CLOSE:CLOSE:

SPEED:SPEED:


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3. Executing Robot Programs3. Executing Robot Programs Use ATS DIRECT Mode;Use ATS DIRECT Mode;

Statements to execute;Statements to execute;

RUN RUN prgname prgname : To execute the program : To execute the program prgnameprgname

ABORT: To abort the current running robot ABORT: To abort the current running robot program.program.

Conveyors In CIMConveyors In CIM

Belt ConveyorsBelt Conveyors Roller ConveyorsRoller Conveyors Crane ConveyorsCrane Conveyors Screw ConveyorsScrew Conveyors ……


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Conveyors In CIMConveyors In CIM

The package conveyor business has been in The package conveyor business has been in existence for almost one hundred years.existence for almost one hundred years.

Material handling engineering, in an over-Material handling engineering, in an over-simplified, basically, consists of simplified, basically, consists of determining "how a product should be determining "how a product should be moved from one place to another, within moved from one place to another, within the shortest allowable period of time, for the shortest allowable period of time, for the least cost and with the least amount of the least cost and with the least amount of manual effort".manual effort".


MHS

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Material Material Handling Handling Systems Systems Automatic Guided Vehicle Automatic Guided Vehicle

SystemsSystemsAGVSAGVS

IE 447 - CIM Lecture Notes - Chapter 9 MHS

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Understanding Understanding AGVSAGVS

History of AGVSHistory of AGVS


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History of AGVSHistory of AGVS1953 First AGV1953 First AGV

The first AGV system The first AGV system was built and was built and introduced in 1953introduced in 1953( A( A modified modified towing towing tractortractor that was used that was used to pull a trailer and to pull a trailer and follow an overhead follow an overhead wire in a grocery wire in a grocery warehousewarehouse))


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History of AGVSHistory of AGVS1973 Volvo Assembly 1973 Volvo Assembly

PlantPlant In 1973, Volvo in In 1973, Volvo in

Kalmar, Sweden set Kalmar, Sweden set out to develop non-out to develop non-synchronous synchronous assembly assembly equipment as an equipment as an alternative to the alternative to the conventional conventional conveyor assembly conveyor assembly line. The result line. The result was was 280280 computer-computer-controlled controlled assembly AGVsassembly AGVs..


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History of AGVSHistory of AGVS1970s First Unit Load1970s First Unit Load

IIntroduction of a ntroduction of a unit load vehicleunit load vehicle

They have the ability to serve several functions;

a work platform,

a transportation device, and

a link in the control and information system

They transport material in warehouses, factories, mills, hospitals, and other industrial and commercial settings.


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History of AGVSHistory of AGVSSmart Floors and Dumb VehiclesSmart Floors and Dumb Vehicles

In the 1970’s the In the 1970’s the principal guidance principal guidance technology was to technology was to induce an electronic induce an electronic frequency through a frequency through a wire that was buried in wire that was buried in the floor.the floor.

‘‘floor controller’floor controller’

•These first generation navigation schemes were expensive to install.

•All floor cuts needed to follow the exact path of the AGV.


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History of AGVSHistory of AGVSDead Reckoning CapabilityDead Reckoning Capability

As the vehicles became As the vehicles became more intelligent, the more intelligent, the path became less path became less sophisticatedsophisticated

Dead reckoningDead reckoning is a is a term that describes the term that describes the ability of a vehicle ability of a vehicle to to traverse steel expansion traverse steel expansion joints on the factory joints on the factory floor orfloor or to cross a steel to cross a steel grategrate

The biggest advantage was that dead reckoning eliminated the need to make the cut radius turns at intersections. (Installation was greatly simplified).


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History of AGVSHistory of AGVS1980s Non-Wire Guidance1980s Non-Wire Guidance

The introduction of The introduction of llaser aser andand inertia inertia

guidanceguidance..

AAllow for increased system flexibility and llow for increased system flexibility and accuracyaccuracy

NNo need for floor alterations or production o need for floor alterations or production interruptioninterruption


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AGV NAVIGATIONAGV NAVIGATION

The principles which make it possible for an The principles which make it possible for an AGV to navigate its way between any two AGV to navigate its way between any two locations are really quite simple. All navigation locations are really quite simple. All navigation methods use a path. The vehicle is instructed to methods use a path. The vehicle is instructed to FollowFollow a Fixed Path a Fixed Path or or TakeTake an Open Path an Open Path..


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Fixed Path NavigationFixed Path NavigationFollowing a PathFollowing a Path

The paths are well The paths are well marked on the floormarked on the floor

The paths are The paths are continuouscontinuous

The paths are fixed, but The paths are fixed, but can be changedcan be changed


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Fixed Path Navigation: Fixed Path Navigation: Creating a PathCreating a Path

The principle techniques for creating paths are to:The principle techniques for creating paths are to: Apply a narrow Apply a narrow magnetic tapemagnetic tape on the surface of the floor on the surface of the floor Apply a narrow Apply a narrow photo sensitive chemical stripphoto sensitive chemical strip on the on the

surface of the floorsurface of the floor Apply a narrow Apply a narrow photo reflective tapephoto reflective tape on the surface of the on the surface of the

floorfloor Bury a wireBury a wire just below the surface of the floor just below the surface of the floor


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Fixed Path Navigation: Fixed Path Navigation: Buried Wire PathBuried Wire Path

Bury a Bury a current-carrying current-carrying wire just below the wire just below the surface of the floorsurface of the floor


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Fixed Path Navigation: Fixed Path Navigation: Steering Correction CoilsSteering Correction Coils

TThe vehicle steers itself to he vehicle steers itself to FOLLOWFOLLOW the magnetic field the magnetic field surrounding the buried wire.surrounding the buried wire.


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Fixed Path Navigation: Fixed Path Navigation: Path SelectionPath Selection

In this illustration, a In this illustration, a vehicle at “A” has two vehicle at “A” has two choices on how to get to choices on how to get to “B”. A computer either on “B”. A computer either on board the vehicle or at board the vehicle or at some central location some central location selects a path based on selects a path based on established criteria.established criteria.

Criteria: Criteria: TThe shortest distancehe shortest distance TThe path with the least he path with the least

traffic at the present traffic at the present timetime

All of the “PATH All of the “PATH FOLLOWING” methods FOLLOWING” methods permit routing options permit routing options that include guide path that include guide path switching and merging.switching and merging.


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Open Path Navigation: Open Path Navigation: Taking a PathTaking a Path

Unlike “Unlike “path following path following navigationnavigation,” where the ,” where the guide paths are fixed, guide paths are fixed, and more or less and more or less permanent, vehicles permanent, vehicles operating in the “operating in the “Take a Take a PathPath” category are ” category are actually offered more actually offered more variation if not an variation if not an infinite number of ways infinite number of ways to navigate the open to navigate the open space between two space between two points.points.


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Open Path Navigation: Open Path Navigation: Navigation MethodsNavigation Methods

The three most common open space The three most common open space navigation methods arenavigation methods are:: Laser GuidanceLaser Guidance Inertial GuidanceInertial Guidance Cartesian GuidanceCartesian Guidance

The choice of navigation method for aThe choice of navigation method for a particular particular application is often a simple matter of preferenceapplication is often a simple matter of preference..


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Navigation Methods - Laser Navigation Methods - Laser GuidanceGuidance

RReference points are eference points are strategically located strategically located targetstargets

A beacon on top of the A beacon on top of the vehicle emits a vehicle emits a rotating laser beam rotating laser beam which is reflected back which is reflected back to the vehicle when it to the vehicle when it strikes (sees) a target.strikes (sees) a target.


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Navigation Methods - Inertial Navigation Methods - Inertial GuidanceGuidance

AAn n on board gyroscopeon board gyroscope establishes and maintains a vehicle’s heading establishes and maintains a vehicle’s heading.. Distance traveled is calculated by an Distance traveled is calculated by an on board encoderon board encoder which counts wheel rotations. which counts wheel rotations.


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Navigation Methods – Navigation Methods – Cartesian GuidanceCartesian Guidance

LLocation precision is ocation precision is accomplished by way of a accomplished by way of a fixed grid pattern that fixed grid pattern that covers the entire floor covers the entire floor area.area.

The possible travel paths The possible travel paths in a given, unrestricted in a given, unrestricted operating area for a grid operating area for a grid based system are infinite based system are infinite and most like that and most like that provided by laser provided by laser guidanceguidance


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AGVS DispatchingAGVS Dispatching

Dispatching AGVS is much the same as dispatching Dispatching AGVS is much the same as dispatching taxi taxi cabscabs..

The dispatch function makes sure that all The dispatch function makes sure that all customers get customers get timely services from the vehicle best able to service a timely services from the vehicle best able to service a requestrequest..

RemoteRemote and and local dispatchlocal dispatch are most commonly described as are most commonly described as offboardoffboard and and onboard dispatchersonboard dispatchers respectively. respectively.


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AGVS CommunicationsAGVS Communications

Communications include message Communications include message ccommandsommands such assuch as:: where to go,where to go, when to start,when to start, when to slow downwhen to slow down,, when to stop.when to stop.

FFour types of basic communication mediaour types of basic communication media:: Radio CommunicationRadio Communication Infrared CommunicationInfrared Communication Guide Wire Data CommunicationGuide Wire Data Communication Inductive Loops CommunicationInductive Loops Communication


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AGVS Communications AGVS Communications Radio CommunicationRadio Communication

MMaximum flexibility in aximum flexibility in system controlsystem control

Vehicles can be Vehicles can be programmed “on the programmed “on the fly”fly”

system speed of system speed of response to changing response to changing load movement load movement demands is improveddemands is improved


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AGVS Communications AGVS Communications Infrared CommunicationInfrared Communication

Optical infrared communication Optical infrared communication is is highly reliablehighly reliable but has the but has the disadvantage of not being disadvantage of not being continuouscontinuous; it is point to point. ; it is point to point.

Vehicles may be stopped during Vehicles may be stopped during this data exchange which usually this data exchange which usually occurs at load stations where the occurs at load stations where the fixed and mobile units are fixed and mobile units are aligned and in close proximity. aligned and in close proximity.

Or, the vehicle communicates at fixed points along its guide path as the vehicle travels through a given zone.

Infrared communication is best suited for small systems with few vehicles and load stations.


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Remote DispatchingRemote DispatchingThe DispatcherThe Dispatcher

The remote dispatch function generally resides in a The remote dispatch function generally resides in a

computer (PC),computer (PC), Programmable Controller (PLC),Programmable Controller (PLC), or other microprocessor, known as the Dispatcheror other microprocessor, known as the Dispatcher..

The Dispatcher accepts input from the various system Components (generally transport requests) and directs the AGVS to fulfill the command in the most efficient manner.

Remote dispatch can occur with vehicles at single or various dispatch points.


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AGVS MonitoringAGVS Monitoring

TTypes of monitoringypes of monitoring : : System monitoringSystem monitoring Vehicle monitoringVehicle monitoring

The functions and The functions and reporting capabilities of reporting capabilities of each are important to each are important to the safe operation of the the safe operation of the AGVs.AGVs.


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Material Material Handling Handling SystemsSystems

Automatic Storage Retrieve Automatic Storage Retrieve SystemsSystems

AS/RSAS/RS



MHS

IE 447 COMPUTER INTEGRATED MANUFACTURING

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