UNIT V IMPLEMENTATION AND

ROBOT ECONOMICS
INTRODUCTION
TO RGV AND
AGVS
 RGV (Rail Guided Vehicle)
RGV system constitutes of transportation rail, vehicles and controller. RGV
rail can be installed linear or circular.

RGV is controlled by distribution control system and can be expanded easily

as the system parameter changes. This characteristic cannot be obtained in
normal conveyor system.

Features

· Independent operation of vehicle by individual controller on each

vehicle
· Low noise & vibration
· Modular design of drive unit to enable less parts and easy maintenance
· Relatively accurate positioning by an encoder
· Distribution control system
 Automated guided vehicles (AGV)
AGV is a transport trolley equipped with electromagnetic, optical or other
automatic guidance devices, capable of driving along a prescribed
guidance path, and having safety protection and various transfer functions.

Features and applicable scenarios of AGV

The AGV (IGV) system is widely used in three-dimensional storage systems and
flexible production lines. It is also the best choice for many manufacturing enterprises
to improve production efficiency and reduce production costs.

Because AGV is a trackless driving, it has a wide range of applications, a variety of

structural forms and control methods, so there are many types of AGV.
 Automated guided vehicles (AGV)
Advantages of AGV
- High working efficiency
- Save management effort
- Good flexibility and system expandability
- High reliability
AUTOMATED GUIDED
VEHICLES
 A material-handling system can be simply defined as an integrated

system involving such activities as handling, and controlling of

materials. Materials include all kinds of raw material, work-in-
progress, sub-assemblies, and finished assemblies. The main motto
of an effective material-handling system is to ensure that the
material in the right amount is safely delivered to the desired
destination at the right time and at minimum cost.
AUTOMATED GUIDED
VEHICLES
 AGVs commonly known as driverless vehicles, are turning out to be an

important part of the automated manufacturing system.

 With the shift from mass production to mid-volume and mid-variety, flexible

manufacturing systems, are increasingly in use.

 They require not only machine flexibility but also material handling, storage,

and retrieval flexibility.

 It is a battery-powered driverless vehicle with programming capabilities for

destination, path selection, and positioning

AUTOMATED GUIDED
VEHICLES
 The AGVs belongs to a class of highly flexible, intelligent, and versatile

material-handling systems used to transport materials from various loading

locations to various unloading locations throughout the facility.

 The capability related to collision avoidance is nicely inbuilt in AGVS.

 They are becoming an integral part of flexible manufacturing system

installations.
AUTOMATED GUIDED
VEHICLES
 Now-a-days, AGVS are versatile in nature and possess flexible material-handling

system.

 They use modern microprocessor technology to guide a vehicle along a prescribed

path and makes correction if the vehicle strays from the path.

 A system controller receives instructions directly from the host computer,

communicates with other vehicles, and issues appropriate commands to each

vehicle.

 To avoid collision, communication is necessary among the AGVs. To facilitate the

communication, they are connected through a wire in the floor or by radio.

COMPONENTS OF AGVS
 The Vehicle : It is used to move the material within the system without a

human operator.

 The Guide Path : It guides the vehicle to move along the path.

 The Control Unit: It monitors and directs system operations including

feedback on moves, inventory, and vehicles.

 The Computer Interface : It is connected with other computers and systems

such as mainframe host computer, the Automated Storage and Retrieval

System (AS/RS), and the Flexible Manufacturing System.
DIFFERENT TYPES OF AGVS
 The vehicle types include :

1. AGVS towing vehicles

2. AGVS unit load transporters

3. AGVS pallet trucks

4. AGVS forklift trucks

5. AGVS light-load transporters

6. AGVS assembly line vehicles

AGVS TOWING VEHICLES
 First type of AGV introduced.

 Towing vehicle is called an automated guided tractor

 Flatbed trailers, pallet trucks, custom trailers can be used.

 Generally, used for large volumes (>1000 lb) and long moving distances

(>1000 feet).

Video 1
AGVS UNIT LOAD TRANSPORTERS

Video 2
AGVS PALLET TRUCKS
Normal operations carried out in pallet trucks are :

 (i) loads are pulled off onto a spur,

 (ii) lowering of the pallet forks to the floor,

 (iii) pulling out from the pallet, and

 (iv) finally automatically returns empty to the loading area.

Video 3
AGVS FORKLIFT TRUCKS
 An AGVS forklift truck has the capability to pick up and drop off palletized

loads both at floor level and on stands, and the pickup height can be different
from the drop-off height.

 They are capable of picking up and dropping off a palletized load

automatically. AGVS forklift trucks are one of the most expensive AGVS
types. Therefore, they are used in the case of full automation.

 the advantage of greater flexibility in integrating with other subsystems with

various loading and unloading heights throughout the material handling

Video 4
system.
AGVS LIGHT-LOAD TRANSPORTERS

 They are applied in handling small, light parts over a moderate distance and

distribute the parts between storage and number of work stations.

Video 5
AGVS ASSEMBLY LINE VEHICLES
 As the vehicle moves from one station to the next, succeeding assembly

operations are performed. After the loading of part onto the vehicle, the
vehicle moves to an assembly area and stops for assembly.

 As the assembly process is completed, the operator releases the vehicle that

proceeds to the next part’s staging area for new parts. After that the vehicle
moves forward to the next assembly station. The process is repeated until the
final unloading station is reached.

Video 6
AGVS ASSEMBLY LINE VEHICLES
Main advantage
The AGVS assembly line is its lower expense and ease of installation
compared with “hard” assembly lines. The line can be easily reconfigured by
altering the guide path and by reprogramming. Variable speeds and dwell
intervals can be easily programmed into the system.

However, an extensive planning and complex computer control is needed in the

case of overall integration.
Video 6
AGVS ASSEMBLY LINE VEHICLES

Some of the guiding factors determining the functioning of the

AGVS are :
 (i) Guidance Systems
 (ii) Routing
 (iii) AGVS Control Systems
 (iv) Load Transfers
 (v) Interfacing with other subsystems

Video 6
ROUTING OF THE AGVS

 AGVS routing means determining how the vehicle conforms the path and

takes a shortest path between the two points.

 The commonly used methods are :

1.frequency selection method

2.path switch selection method

AGVS CONTROL SYSTEMS

 Three types of AGVS control systems are available.

(i) Computer-controlled system

(ii) Remote dispatch control system

(iii) Manual control system

FLOW PATH DESIGN

 The flow path design is one of the most important processes in the AGVS

design. Some of the important decisions involved in flow path design are:

(i) Type of guide path layout.

(ii) Flow path within the layout.

(iii) The number and locations of load transfer points.

(iv) Load transfer function station storage space.

GUIDANCE SYSTEMS FOR
AGVS
 The main purpose of a guidance system is to keep the vehicle in the predestinated

path. The main advantage of AGVS guidance system is that the guide path can be
changed easily at low cost compared to the high cost of modifying fixed-path
equipment such as conveyors, chains, and tow lines. Many guidance systems are
available and their selection will depend on need, application, and environmental
constraints. Some of the familiar guidance systems are wire-guided guidance system,
optical guidance system, inertial guidance system, infrared guidance system, laser
guidance system, and teaching-type guidance system.
REQUIRED NUMBER OF AGVS

 Estimation of the number of AGVs required in the system is an important

element of the system design. Here, we provide a simple mathematical

analysis for the determination of the number of vehicles.
Dd = Total average loaded travel distance.

Dc = Total average empty travel distance.

Ndr = Number of deliveries required per hour.

Tf = Traffic factor that accounts for blocking of vehicles and waiting of vehicles
in line and at intersection. If there is no congestion, the traffic factor is 1. However,
when more vehicles are involved, the traffic factor value will certainly be less than
1. Normally, Tf lies between 0.85 and 1.

v = Vehicle speed.

Th = Loading and unloading time.

The total time per delivery per vehicle (Tdv) is given by the sum of loaded
travel time, loading and unloading time, and empty travel time as follows :

Number of deliveries per vehicle per hour

Number of automated guided vehicles = Ndr / Nd

Implementation Of Robots In Industries

Step 1: Get company-wide support.

Step 2: Get consensus on the definition of success.

Step 3: Get consensus on the definition of failure.

Step 4: Prepare the budget.

Step 5: Gather information.

Safety Considerations for Robot Operations

 Remove all obstructions from the robot work area.

 Check for signs of damage to the robot.

 Remove loose fitting clothing (ties, scarves, sleeves, etc).

 Tie up long hair.

 Remove the tech pendant from the robot work area.

 Locate the emergency stop pushbutton.

 ECONOMIC ANALYSIS OF ROBOTS
• The economy is an important issue while setting up a new automated firm. An
economic analysis of the proposed engineering project must be done. On the
basis of this analysis, the management usually decides the feasibility of the
project.
• To perform the economic analysis of the proposed robot project, we require
certain basic information about the project. This information includes the
following:
1. Type of robot installation.
2. Cost of robot installation.
3. Production cycle time.
4. Savings and benefits resulting from the project.

29
 TYPE OF ROBOT INSTALLATION
• There are two basic categories of robot installation:
 New application: Here we have to begin from the scratch. So we are in a need for
new facilities, and the robot installation is the only facility to satisfy that need. In
this case, the best alternative is selected after comparing various alternatives and
the selected alternative should meet the investment criteria of the firm.
 Existing application: Here, the robot is employed as a substitute for the human
labour. In this scenario, the economic justification of the robot installation depends
on how inefficient and costly the manual method is, rather than the absolute merits
of the method.
• In either of these situations, certain basic cost information is needed in order to
perform the economic analysis.

Robot_economic analysis_Sivakumar_C 30
 COST DATA REQUIRED FOR THE ANALYSIS
• The cost data required for the economic analysis involves the following:
 Investment costs
 Operating costs

Investment costs Operating costs

 Robot purchase cost  Direct labour cost
 Engineering cost  Indirect labour cost
 Installation cost  Maintenance cost
 Special tooling cost  Utilities cost
 Miscellaneous cost  Training cost

Robot_economic analysis_Sivakumar_C 31
LIFE CYCLE OF CASH FLOW
Net Annual Cash flow (NACF) = Revenues – Operating cost

Robot_economic analysis_Sivakumar_C 32
 METHODS OF ECONOMIC ANALYSIS
• The methods of economic analysis are listed below:

 Payback (or payback period) Method

 Equivalent Uniform Annual Cost (EUAC) Method

 Rate on Investment (ROI) Method

Robot_economic analysis_Sivakumar_C 33
 PAYBACK PERIOD METHOD

 Assumptions:

 NACF is + ve. [Revenues > Operating Cost]

 All cash flows occur at the end of the year.

Where n = Payback period  All the investments are done at beginning

IC = Investment cost of the year.

NACF = Net Annual Cash Flow

 NACF is calculated at the end of the year.

⚫ Most of the companies require a payback period of not more than two to three years.

Robot_economic analysis_Sivakumar_C 34
Ex1 – the total investment cost is estimated to be Rs. 1,00,000 for a
particular robot project. The total operating costs (labour,
maintenance, and other annual expenses) are expected to be Rs
20,000 per year and the anticipated revenue from the robot
installation are Rs. 65,000 annually. It is expected that the robot
project will have a service life of 5 years. Determine the payback
period that is expected of the investment.

Robot_economic analysis_Sivakumar_C 35
Sol: The net cash flow for the robot project is Rs 65,000
- Rs 20,000 = Rs. 45,000

N = 1,00,000/45,000 = 2.2 years

Disadvantage of payback period method: It ignores

the time value of money

Robot_economic analysis_Sivakumar_C 36
 EUAC METHOD
• The equivalent uniform annual cost (EUAC) is the annual cost of owning an asset over
its entire life. Equivalent uniform annual cost is often used by firms for capital
budgeting decisions. Equivalent uniform annual cost is calculated as:

• This method converts all of the present, future investments and the cash flows into
their equivalent uniform cash flows over the anticipated life of the project. This is
accomplished by using various interest factors associated with engineering economic
calculations.
• When the company is to be started it must select the minimum attractive rate of return
(MARR). This is used to decide whether funding is to be made or not.
• If the sum of EUAC > 0 then the company is attractive. If the sum of EUAC < 0 then
the company is non attractive.

Robot_economic analysis_Sivakumar_C 37
EX2: In Ex 1 , the company uses a 30% MARR as a criterion for selecting its
investment projects. As mentioned in Ex 1 the robot project is expected to
have a 5-year service life and that is what we shall use in determining the
values for any interest factors required in our calculations.
Sol:

• The annual operating cost Rs 20,000 and the annual revenues Rs 65,000
are already expressed as uniform annual cash flows.

• The initial investment cost Rs 1,00,000 must be converted to its

equivalent uniform annual cash value using the capital recovery factor
from appendix (refer book)

Robot_economic analysis_Sivakumar_C 38
• EUAC = 1,00,000 (A/P, 30%, 5) + 65,000-
20,000
• EUAC = -1,00,000(0.41058) + 45,000
• EUAC = +Rs. 3942

• Since the uniform annual cost value in positive

this robot project would be a good investment

Robot_economic analysis_Sivakumar_C 39
 ROI METHOD
• This method determines the rate of returns on the proposed work based on estimated
cost and revenues.
• To calculate ROI, the benefit (or return) of an investment is divided by the cost of the
investment, and the result is expressed as a percentage or a ratio.
• The return on investment formula:

• This rate of return is compared with company’s MARR to determine whether the
investment is justified or not.

Robot_economic analysis_Sivakumar_C 40