ippi report

8/8/2019 Ippi Report..

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I-B. Cranes

Cranes are used to move materials over variable paths within a restricted area. Themajor types of cranes are:

1. Jib crane 2. Bridge crane 3. Gantry crane 4. Stacker crane

G eneral characteristics of cranes:

y Us ed to move load s over variable (horizontal and vertical) path s within are s tricted area

y Us ed when there i s insuff icient (or intermittent) f low vol u me su ch that the us eo f a conveyor cannot be j us tif ied

y P rovide more f lexibility in movement than conveyor s y P rovide le ss f lexibility in movement than ind us trial tr u cks y Load s handled are more varied with re s pect to their s hape and weight than

tho s e handled by a conveyory M o s t crane s u tilize hoi s t s f or vertical movement, altho u gh manip u lator s can

be us ed i f preci s e po s itioning o f the load i s req u ired


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Tower Crane

A crane with the boom on a tower, used for hoisting materials during high-riseconstruction.


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crane

A crane is a lifting machine, generally equipped with a winder (also called a wire rope drum), wireropes or chains and sheaves , that can be used both to lift and lower materials and to move them horizontally. It uses one or

more simple machines to create mechanical advantage and thus move loads beyond the normal capability of a human.Cranes are commonly employed in the transport industry for the loading and unloading of freight, in the construction industry

for the movement of materials and in the manufacturing industry for the assembling of heavy equipment .


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1. Jib Crane

O perates like an arm in a work area, where it can function as a manipulator for positioning tasks

A hoist is attached to the arm for lifting

Arm mounted on the wall or attached to a floor mounted support

Arm can rotate 360

The hoist can move along the arm


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2 . Bridge Crane

B ridge mounted on tracks that are located on opposite walls of the facility

Enables three-dimensional handling

Top riding (heavier loads) or underhung (more versatile) versions of the crane

Underhung crane can transfer loads and interface with other MHS (e.g., monorail

systems)


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3 . Gantry Crane

Single leg, double leg, and mobile types of gantry cranes

Similar to a bridge crane except that it is floor supported at one or both ends instead of overhead (wall) supported

Used to span a smaller portion of the work area as compared to a bridge crane

The supports can be fixed in position or they can travel on runways

Can be used outdoors when "floor" supported at both ends


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4 . Stacker Crane

Similar to a bridge crane except that, instead of a hoist, it uses a mast with forks or a platform to handle unit loads

Considered "fork trucks on a rail"

Used for storing and retrieving unit loads in storage racks, especially in high-riseapplications in which the racks are more than 50 feet high

Can be controlled remotely or by an operator in a cab on the mast

Can be rack supported

I-C. Industrial Trucks

I ndustrial trucks are used to move materials over variable paths, with no restrictionson the area covered by the movement. The major types of industrial trucks are:


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1. Hand tr u ck a. Two-wheeled hand tr u ck b. Dolly c. Floor hand tr u ck

2. P allet jack

a. M an u al pallet jack b. P owered pallet jack

3. Walkie s tacker

a. M an u al walkie s tacker b. P owered walkie s tacker

4. P allet tr u ck 5. P lat f orm tr u ck

a. Walkie plat f orm tr u ck

b. Rider platf orm tr

uck 6. Cou nterbalanced li f t tr u ck

a. Sit-down co u nterbalanced li f ttr u ck

b. Stand- u p co u nterbalanced li f ttr u ck

7. Narrow-ai s le s traddle tr u ck 8. Narrow-ai s le reach tr u ck 9. Tu rret tr u ck

a. Operator-down t u rret tr u ck b. Operator- u p t u rret tr u ck

10. Order picker 11. Sideloader 12. Tractor-trailer 13. P er s onnel and b u rden carrier 14. Au tomatic g u ided vehicle (AGV)

a. Tow AGV b. U nit load AGV c. Ass embly AGV d. Light load AGV e. Fork AGV

I ndustrial trucks:

y Us ed to move material s over variable (horizontal) path s with no re s triction s on the area covered (i.e., u nre s tricted area)

y P rovide vertical movement i f the tr u ck ha s lif ting capabilitie s y Us ed when there i s insuff icient (or intermittent) f low vol u me su ch that the us e

o f a conveyor cannot be j us tif iedy P rovide more f lexibility in movement than conveyor s and crane s y Not licen s ed to travel on p u blic road s " commercial tr u cks" are licen s ed to

travel on p u blic road s

Characteristics:y Pallet/Non-Pallet : Doe s the tr u ck have f ork s f or handling pallet s , or doe s the

tr u ck have a f lat su rf ace on which to place load s . Non- P allet => ( usu ally) othermean s req u ired to load tr u ck.


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y M anual/Powered: Doe s the tr u ck have man u al or powered vertical (li f ting)and/or horizontal (travel) movement capabilitie s . M an u al => walk => operatorprovide s the f orce needed f or li f ting load s and/or p us hing the vehicle.P owered => on-board power s ou rce (e.g., batterie s ) us ed f or li f ting and/or

travel.y W alk/Ride : For non-a u tomated tr u cks , can the operator ride on the tr u ck (in

either a s tanding or s itting po s ition) or i s the operator req u ired to walk withthe tr u ck d u ring travel. Walk => man u al or powered travel po ss ible =>powered travel s peed limited to a normal walking pace. Ride => powered =>travel s peed can be f as ter than a walking pace.

y S tack/No S tack : Can the tr u ck be us ed to li f t load s f or s tacking p u rpo s e s . Stack=> can al s o be us ed a s no s tack => more expen s ive to add s tacking capability.

No Stack may li f t a load a f ew inche s to clear the f loor f or su bs eq u ent travel(e.g., pallet jack), b u t the load s cannot be s tacked on top o f each other or ons helve s .

y Narrow Aisle : Is the li f t tr u ck de s igned to have a s mall t u rning radi us or doe s itnot have to t u rn at all in an ai s le when loading/ u nloading. Narrow Ai s le =>greater co s t and ( usu ally) s tanding operator => le ss ais le s pace req u ired.Cou nterbalance and/or s traddle us ed f or load su pport. Small t u rning radi us =>load su pport via s traddle or reaching capabilitie s . No t u rning req u ired => even

narrower aisle => only one-

side loading (

sideloader

s) or the capability torotate the load (t u rret tr u ck).

y Automated : Is the tr u ck a u tomated s o that it can tran s port load s witho u treq u iring an operator. Non-A u tomated => direct labor co s t o f operator i s byf ar the large s t co s t to operate a non-a u tomated tr u ck. Semi-A u tomated =>operator us ed to control loading/ u nloading, b u t a u tomated tran s port control(e.g., the S/R machine o f a M an-on-board AS/RS). A u tomated => A u tomatedGu ided Vehicle (AGV) => no direct labor co s t, b u t higher eq u ipment co s t s .

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1. Hand Truck

N on-pallet + manual + no stack

1(a) Two-Wheeled Hand Truck

Load tilted during travel

1(b) Dolly

Three or more wheeled hand truck with a flat platform in which, since it has nohandles, the load is used for pushing

2 . Pallet Jack

P allet + walk + no stack

Front wheels are mounted inside the end of the forks and extend to the floor as the pallet is only lifted enough to clear the floor for subsequent travel


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P allet restrictions: reversible pallets cannot be used, double-faced nonreversible pallets cannot have deckboards where the front wheels extend to the floor, and enablesonly two-way entry into a four-way notched-stringer pallet because the forks cannot

be inserted into the notches

2 (a) Manual Pallet Jack

Pallet + walk + no stack + manual

Manual lifting and/or travel

2 (b) Powered Pallet Jack

P allet + walk + no stack + powered

P owered lifting and/or travel


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3 . Walkie Stacker

P allet + walk + stack

3 (a) Manual Walkie Stacker

P allet + walk + stack + manual

Manual lifting and/or travel (and straddle load support)

3 (b) Powered Walkie Stacker

P allet + walk + stack + powered


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P owered lifting and/or travel (and either counterbalance or straddle load support)

5. Platform Truck

N on-pallet + powered + no stack

P latform used to provide support for nonpalletized loads

Used for skid handling; platform can lift skid several inches to allow it to clear thefloor

G reater lifting capacity compared to fork trucks because the platform provides agreater lifting surface to support a load

5 (a) Walkie Platform Truck

N on-pallet + powered + no stack + walk

O perator walks next to truck


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Floor hand truck is sometimes referred to as a "(manual) platform truck"

6 (a) Sit-Down Counterbalanced Lift Truck

O perator sits down

12-13 ft. minimum aisle width requirement

6 (b) Stand-Up Counterbalanced Lift Truck

O perator stands up, giving vehicle narrow-aisle capability



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Faster loading/unloading time compared to N A straddle and reach trucks

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7 . Narrow-Aisle (NA) Straddle Truck

Similar to stand-up C B lift truck, except outrigger armsstraddle a load and are used to support the load instead of thecounterbalance of the truck


Less expensive than stand-up C B lift truck and N A reach truck

Since the load is straddled during stacking, clearance betweenloads must be provided for the outrigger arms

Arm clearance typically provided through the use of load-on- beam rack storage or single-wing pallets for load-on-floor storage

8 . Narrow-Aisle (NA) Reach Truck

Similar to both stand-up C B lift truck and N A straddletruck


Load rests on the outrigger arms during transport, but a pantograph (scissors) mechanism is used for reaching,thereby eliminating the need to straddle the load duringstacking

Reaching capability enables the use of shorter outrigger arms (arms > 1/2 load depth) as compared to N A straddle

truck (arms = load depth)


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Counterbalance of the truck used to support the load when it extends beyond theoutrigger arms

Although the N A reach truck requires slightly wider aisles than a N A straddle truck since its outrigger arms do not enter a rack during storage, it does not require armclearance between loads (arm clearance is still required when the truck must enter astorage lane when block stacking or drive-in or -through racks are used)

Extended reaching mechanisms are available to enable double-deep storage

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9 . Turret Truck

G reater stacking height compared to other narrow-aisle trucks (40 ft. vs. 25 ft.), butgreater investment cost

Forks rotate to allow for side loading and, since truck itself does not rotate duringstacking, the body of the truck can be longer to increase its counterbalance capabilityand to allow the operator to sit

Can function like a sideloader for transporting greater-than-pallet-size load

9 (a) Operator-Down Turret Truck

O perator not lifted with the load



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Termed a swingmast truck (picture shown) when, instead of just the forks, the entiremast rotates (thus can store on only one side of a aisle while in aisle)

9 (b) Operator-Up Turret Truck

O perator lifted with the load to allow precise stackingand picking


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10. Order Picker

Similar to N A straddle truck, except operator liftedwith the load to allow for less-than-unit-load picking

Typically has forks to allow the truck to be used for pallet stacking and to support a pallet during less-than-pallet-load picking

"B elly switch" used for operator safety during picking

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11. Sideloader

Forks mounted perpendicular to direction of travelto allow for side loading and straddle load support


Can be used to handle greater-than-pallet-sizeloads (e.g., bar stock)

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1 2 . Tractor-Trailer

N on-load-carrying tractor used to pull a train of trailers (i.e., dollies or floor handtrucks)

Extends the transporting capacity of floor hand trucks

Typically used at airports for baggage handling

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1 3 . Personnel and Burden Carrier

N on-load-carrying vehicle used to transport personnel within a facility (e.g., golf cart, bicycle, etc.)

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1 4 . Automatic Guided Vehicle (AGV)

AGV s do not require an operator

G ood for high labor cost, hazardous, or environmentally sensitive conditions (e.g.,clean-room)

Also termed "automated" guided vehicle


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AGV s good for low-to-medium volume medium-to-long distance random materialflow operations (e.g., transport between work cells in a flexible manufacturing system(FMS) environment)

Two means of guidance can be used for A GV systems:

F ixed path: P hysical guidepath (e.g., wire, tape, paint) on the floor used for guidance

F ree-ranging: N o physical guidepath, thus easier to change vehicle path (in software), but absolute position estimates (from, e.g., lasers) are needed to correct dead-reckoning error.

14(a) Tow AGV

Used to pull a train of trailers

Automated version of a tractor trailer

Trailers usually loaded manually (early type of A GV , not much used today)


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14(b) Unit Load AGV

Have decks that can be loaded manually or automatically

Deck can include conveyor or lift/lower mechanism for automatic loading

Typically 4 by 4 feet and can carry 12,000 lb. loads

Typically less than 10 vehicles in A GV system

14(c) Assembly AGV

Used as assembly platforms (e.g., car chassis, engines, appliances)

G reatest development activity during the 1980s (alternative to AEMs)

Typically 50100 vehicles in A GV system


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14(d) Light Load AGV

Used for small loads (< 500 lbs), e.g., components, tools

Typically used in electronics assembly and office environments (as mail and snack carriers)

14(e) Fork AGV


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Counterbalanced, narrow-aisle straddle, and sideloading versions available

Typically have sensors on forks (e.g., infrared sensors) for pallet interfacing.

Conveyors

Conveyor s ys tem s allow q u ick and e ff icient tran s portation f or a wide variety o f material s . M any kind s of conveying s ys tem s are available, and are us ed accordingto the vario us need s o f diff erent ind us trie s .

Conveyor s are able to s a f ely tran s port material s f rom one level to another, which when done byhu man

labo u r wo u ld be s tren u ous and expen s ive.

They can be in s talled almo s t anywhere, and are m u ch s a f er than us ing a f orkli f t or other machineto move

material s .

They can move load s of all s hape s , s ize s and weight s . Als o, many have advanced s a f ety f eat u re s that help

prevent accident s .

There are a variety o f option s available f or r u nning conveying s ys tem s , inclu ding the hydra u lic,mechanical

and fu lly au tomated s ys tem s , which are eq u ipped to f it individ u al need s .


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Many factors are important in the accurate selection of a conveyor system. It is important to know how the

conveyor system will be used beforehand.

Type o f prod u ct being handled : u nit load or b u lk load

Location o f the conveyor : overhead, on- f loor, or in- f loor.

Whether or not load s can acc u m u late on the conveyor

T o help ensure you select the right conveyor system for your needs refer to our extensive list of conveyors below,

or contact one of our conveyor specialists.

Types of Conveyors

1. Chute Conveyor

Unit/Bulk, On-Floor, AccumulateI nexpensive

Used to link two handling devices

Used to provide accumulation in shipping areas

Used to convey items between floors

Diff icu lt to control po s ition o f the item s


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2 . Wheel Conveyor

Unit, O n-Floor, Accumulate

Uses a series of skatewheels mounted on a shaft (or axle), where spacing of the wheels is dependent on the

load being transported

Slope for gravity movement depends on load weight

More economical than the roller conveyor

For light-duty applications

Flexible, expandable versions available

3 . Roller Conveyor Unit, O n-Floor, Accumulate

May be powered (or live) or nonpowered (or gravity)

Materials must have a rigid riding surface

Minimum of three rollers must support smallest loads at all times

Tapered rollers on curves used to maintain load orientation

(a) Gravity Roller Conveyor Alternative to wheel conveyor

For heavy-duty applications

Slope for gravity movement depends on load weight

For accumulating loads (b) Live ( P owered) Roller Conveyor

B elt or chain driven

Force-sensitive transmission can be used to disengage rollers for accumulation

For accumulating loads and merging/sorting operations

P rovides limited incline movement capabilities


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4 . Chain Conveyor Unit, I n-/O n-Floor, N o Accumulate

Uses one or more endless chains on which loads are carried directly

P arallel chain configuration used to transport palletsV ertical chain conveyor used for continuous high-frequency vertical

transfers(cf. vertical conveyor used for low-frequency intermittent transfers)

5 . Slat Conveyor Unit, I n-/O n-Floor, N o Accumulate

Uses discretely spaced slats connected to a chain

Unit being transported retains its position (like a belt conveyor)

O rientation and placement of the load is controlled

Used for heavy loads or loads that might damage a belt

B ottling and canning plants use flat chain or slat conveyors because of

wet conditions,temperature, and cleanliness requirements

Tilt slat conveyor used for sortation


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6 . Flat Belt Conveyor Unit, O n-Floor, N o Accumulate

For transporting light- and medium-weight loads between operations,departments,

levels, and buildings

When an incline or decline is required

P rovides considerable control over the orientation and placement of theload.

N o smooth accumulation, merging, and sorting on the belt

The belt is roller or slider bed supported; the slider bed is used for smalland irregularly

shaped items

7 . Magnetic Belt Conveyor B ulk, O n-Floor

A steel belt and either a magnetic slider bed or a magnetic pulley is

used

To transport ferrous materials vertically, upside down, and aroundcorners

8 . Troughed Belt Conveyor

B ulk, O n-Floor

Used to transport bulk materials

When loaded, the belt conforms to the shape of the troughed rollers andidlers


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9 . Bucket Conveyor

B ulk, O n-Floor

Used to move bulk materials in a vertical or inclined path

B uckets are attached to a cable, chain, or belt

B uckets are automatically unloaded at the end of the conveyor run

10. Vibrating Conveyor

B ulk, O n-Floor

Consists of a trough, bed, or tube

V ibrates at a relatively high frequency and small amplitude in order toconvey individual

units of products or bulk material

Can be used to convey almost all granular, free-flowing materials

An O scillating Conveyor is similar in construction, but vibrates at alower frequency and

larger amplitude (not as gentle) in order to convey larger objects such ashot castings


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11. Screw Conveyor

B ulk, O n-Floor

Consists of a tube or U-shaped stationary trough through which a shaft-mounted helix

revolves to push loose material forward in a horizontal or inclineddirection

O ne of the most widely used conveyors in the processing industry

1 2 . Pneumatic Conveyor

B ulk/Unit, O verhead

Can be used for both bulk and unit movement of materials

Air pressure is used to convey materials through a system of vertical andhorizontal tubes

Major advantages are that material is completely enclosed and it iseasy to implement turns and vertical moves

(a) Dilute-Phase Pneumatic Conveyor

Moves a mixture of air and solid

P ush (positive pressure) systems push material from one entry point toseveral discharge points

P ull (negative pressure or vacuum) systems move material from severalentry points to one discharge point

P ush-pull systems are combinations with multiple entry and discharge points

(b) Carrier-System Pneumatic Conveyor

Carriers are used to transport items or paperwork (e.g., money fromdrive-in stalls at banks)


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1 3 . Vertical Conveyor

Unit,O

n-Floor, N

o Accumulate

Used for low-frequency intermittent vertical transfers (cf. vertical chainconveyor can be

used for continuous high-frequency vertical transfers

(a) Vertical Lift Conveyor

Carrier used to raise or lower a load to different levels of a facility (e.g.,different floors

and/or mezzanines)

Differs from a freight elevator in that it is not designed or certified tocarry people

Can be manually or automatically loaded and/or controlled and caninterface with

horizontal conveyors

(b) Reciprocating Vertical Conveyor

Utilizes gravity-actuated carrier to lowering loads, where the loadovercomes themagnitude of a counterweight

Can only be used to lower a load

Alternative to a chute conveyor for vertical "drops" when load is fragileand/or space is

limited

Can be manually or automatically loaded and/or controlled and can

interface withhorizontal conveyors


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1 4 . Cart-On-Track Conveyor

Unit, I n-Floor, Accumulate

Used to transport carts along a track

Carts are transported by a rotating tube

Connected to each cart is a drive wheel that rests on the tube and that isused to vary

the speed of the cart (by varying the angle between the drive wheel andthe tube)

Carts are independently controlled

Accumulation can be achieved by maintaining the drive wheel parallel tothe tube

1 5 . Tow Conveyor

Unit, I n-Floor, Accumulate

Uses towline to provide power to wheeled carriers such as trucks, dollies,or carts that

move along the floor

Used for fixed-path travel of carriers (each of which has variable pathcapabilities when

disengaged from the towline)

Towline can be located either overhead, flush with the floor, or in thefloor

Selector-pin or pusher-dog arrangements can be used to allow automatic

switching(power or spur lines)

G enerally used when long distance and high frequency moves arerequired


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1 6 . Trolley Conveyor

Unit, O verhead, N o Accumulate

Uses a series of trolleys supported from or within an overhead track

Trolleys are equally spaced in a closed loop path and are suspended froma chain

Carriers are used to carry multiple units of product

Does not provide for accumulation

Commonly used in processing, assembly, packaging, and storageoperations

1 7 . Power-and-Free Conveyor

Unit, O verhead/ O n-Floor, Accumulate

Similar to trolley conveyor due to use of discretely spaced carrierstransported by an

overhead chain; however, the power-and-free conveyor uses two tracks:one powered

and the other nonpowered (or free)

Carriers can be disengaged from the power chain and accumulated or switched onto

spurs

Termed an I nverted P ower-and-Free Conveyor when tracks are locatedon the floor


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1 8 . Monorail

Unit, O verhead, Accumulate

O verhead single track (i.e., mono-rail) or track network on which one or more carriers

ride

Carriers: powered (electrically or pneumatically) or nonpowered

Carrier can range from a simple hook to a hoist to an intelligent-vehicle-like device

Single-carrier, single-track monorail similar to bridge or gantry crane

Multi-carrier, track network monorail similar to both a trolley conveyor,except that the

carriers operate independently and the track need not be in a closed loop,and a fixed-

path automatic guided vehicle (A GV ) system, except that it operatesoverhead

Termed an Automated Electrified Monorail (AEM) system when it hassimilar control

characteristics as an A GV system


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1 9 . Sortation Conveyor

Unit, O n-Floor/ O verhead

Sortation conveyors are used for merging, identifying, inducting, andseparating

products to be conveyed to specific destinations

(a) Sortation Conveyor: Diverter

Stationary or movable arms that deflect, push, or pull a product todesired destination

Since they do not come in contact with the conveyor, they can be usedwith almost any

flat surface conveyor Usually hydraulically or pneumatically operated, but also can be motor

driven

Simple and low cost

(b) Sortation Conveyor: Pop-Up Device

O ne or more rows of powered rollers or wheels or chains that pop upabove surface of

conveyor to lift product and guide it off conveyor at an angle; wheels arelowered when products not required to be diverted

O nly capable of sorting flat-bottomed items

P op-up rollers are generally faster than pop-up wheels

(c) Sortation Conveyor: Sliding Shoe Sorter

Sliding shoe sorter (a.k.a. moving slat sorter) uses series of diverter slats

that slideacross the horizontal surface to engage product and guide it off conveyor

Slats move from side to side as product flows in order to divert the product to either

side


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G entle and gradual handling of products

(d) Sortation Conveyor: Tilting Device

Trays or slats provide combined sorting mechanism and product

transporter

Can accommodate elevation changes

Tilt tray sorters usually designed in continuous loops with a compactlayout and

recirculation of products not sorted the first time

Tilt slat sorters carry products on flat-surface slat conveyor and canhandle wider variety

of products compared to tilt tray

(e) Sortation Conveyor: Cross-Belt Transfer Device

Either continuous loop, where individual carriages are linked together toform an

endless loop, or train style (asynchronous), where a small number of carriers tied

together with potential for several trains running track simultaneously

Each carriage equipped with small belt conveyor, called the cell, that ismounted

perpendicular to direction of travel of loop and discharges product atappropriatedestination

Automatically separates single line of products into multiple in-linedischarge lines

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