ABSTRACT

The aim of the project is to fabricate the Box Shifting Mechanism

which can make easier to move the boxes from one section to another while
processing in the factories. Industries in worldwide use conveyors as a
mechanism to transport boxes from place to place. This mechanism includes
strong belts, pulleys and heavy motors to rotate the pulley to move the
conveyor. As an alternative to this conveyor type, more simple and
comfortable machine using four bar mechanisms can be used. This box
shifting machine helps in transfer of boxes smoothly by use of four bars with
a simple arrangement. The rotary motion of the crank is transferred to the
follower by using connecting rod and is converted to the same rotary motion.

1
 CHAPTER - 1

SCOPE OF THE PROJECT

 To achieve automation

 To reduce the time require for moving boxes

 To reduce human work

 To achieve mass production

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 CHAPTER - 2

INTRODUCTION

A (box shifting machine) is a mobile robot that follows markers or

wires in the floor, or uses vision or lasers. They are most often used in
industrial applications to move materials around a manufacturing facility or
a warehouse. Application of the automatic guided vehicle has broadened
during the late 20th century and they are no longer restricted to industrial
environments.

Automated guided vehicles (box shifting machines) increase

efficiency and reduce costs by helping to automate a manufacturing facility
or warehouse. The first box shifting machine was invented by Berrett
Electronics in 1953. The box shifting machine can tow objects behind them
in trailers to which they can autonomously attach. The trailers can be used to
move raw materials or finished product. The box shifting machine can also
store objects on a bed. The objects can be placed on a set of motorized
rollers (conveyor) and then pushed off by reversing them. Some box shifting
machines use fork lifts to lift objects for storage. box shifting machines are
employed in nearly every industry, including, pulp, paper, metals,
newspaper, and general manufacturing. Transporting materials such as food,
linen or medicine in hospitals is also done.

An box shifting machine can also be called a laser guided vehicle

(LGV) or self-guided vehicle (SGV). In Germany the technology is also
called Fahrerlose Transportsysteme (FTS) and in Sweden förarlösa truckar.
Lower cost versions of box shifting machines are often called Automated

3
Guided Carts (AGCs) and are usually guided by magnetic tape. AGCs are
available in a variety of models and can be used to move products on an
assembly line, transport goods throughout a plant or warehouse, and deliver
loads to and from stretch wrappers and roller conveyors.

The first box shifting machine was brought to market in the 1950s, by
Barrett Electronics of Northbrook, Illinois, and at the time it was simply a
tow truck that followed a wire in the floor instead of a rail. Over the years
the technology has become more sophisticated and today automated vehicles
are mainly Laser navigated e.g. LGV (Laser Guided Vehicle). In an
automated process, LGVs are programmed to communicate (via an offboard
server) with other robots to ensure product is moved smoothly through the
warehouse, whether it is being stored for future use or sent directly to
shipping areas. Today, the box shifting machine plays an important role in
the design of new factories and warehouses, safely moving goods to their
rightful destinations.

In the late 20th century box shifting machines took on new roles as
ports began turning to this technology to move ISO shipping containers. The
Port of Rotterdam employs well over 100 box shifting machines.

box shifting machine applications are seemingly endless as capacities can

range from just a few pounds to millions of tons.

Flexible manufacturing system

To begin to understand box shifting machine it is necessary to

understand the fundamentals of flexible manufacturing systems (FMS). FMS
is a means by which to manufacture a product. FMS is more of a philosophy

4
rather than a tangible item. FMS is the idea that faster is better and uses
machines to produce their products. Rather than using humans to perform
repetitive tasks a machine is used to perform that task 24 hours a day. FMS
uses computer numerical controlled machines (CNC) to form a work cell.
Each cell performs a specific task to assist in the manufacturing of a product.
Although FMS is fast and efficient it is not cheap as it requires a lot of
expensive machines in order to work. Typically, it costs millions of dollars to
introduce an FMS into a factory. Rather than using a complete FMS, most
companies use part of an FMS called a flexible manufacturing cell. This is
used to produce part of a product by machine and maybe part by other
methods. Often one or more box shifting machine’s are used in FMS to
connect work cells together.

Navigation

The wired sensor is placed on the bottom of the robot and is placed
facing the ground. A slot is cut in the ground and a wire is placed
approximately 1 inch below the ground. The sensor detects the radio
frequency being transmitted from the wire and follows it.

Guide Tape

Many light duty box shifting machines (some known as automated

guided carts or AGCs) use tape for the guide path. The tapes can be one of
two styles: magnetic or colored. The AGC is fitted with the appropriate
guide sensor to follow the path of the tape. One major advantage of tape
over wired guidance is that it can be easily removed and relocated if the
course needs to change. It also does not involve the expense of cutting the
factory or warehouse floor for the entire travel route. Additionally, it is
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considered a "passive" system since it does not require the guide medium to
be energized as wire does. Colored tape is initially less expensive, but lacks
the advantage of being embedded in high traffic areas where the tape may
become damaged or dirty. A flexible magnetic bar can also be embedded in
the floor like wire but works under the same provision as magnetic tape and
so remains unpowered or passive. Another advantage of magnetic guide tape
is the dual polarity; "control tags" of small pieces of magnetic tape may be
placed alongside the track to change states (speed, on/off/auto, etc.) of the
AGC based on polarity and sequence of the tags.

Laser Target Navigation

The wireless navigation is done by mounting retroreflective tape on

walls, poles or machines. The box shifting machine carries a laser
transmitter and receiver on a rotating turret. The laser is sent off then
received again the angle and (sometimes) distance are automatically
calculated and stored into the box shifting machine’s memory. The box
shifting machine has reflector map stored in memory and can correct its
position based on errors between the expected and received measurements. It
can then navigate to a destination target using the constantly updating
position.

Modulated Lasers

The use of modulated laser light gives greater range and accuracy
over pulsed laser systems. By emitting a continuous fan of modulated laser
light a system can obtain an uninterrupted reflection as soon as the scanner
achieves line of sight with a reflector. The reflection ceases at the trailing
edge of the reflector which ensures an accurate and consistent measurement
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from every reflector on every scan. The LS9 Scanner is manufactured by
Guidance Navigation Ltd and, by using a modulated laser; this system
achieves an angular resolution of ~ 0.1 mrad (0.006°) at 8 scanner
revolutions per second.

Pulsed Lasers

A typical pulsed laser scanner emits pulsed laser light at a rate of

14,400 Hz which gives a maximum possible resolution of ~ 3.5 mrad (0.2°)
at 8 scanner revolutions per second. To achieve a workable navigation, the
readings must be interpolated based on the intensity of the reflected laser
light, to identify the centre of the reflector.

Gyroscopic Navigation

Another form of an box shifting machine guidance is inertial

navigation. With inertial guidance, a computer control system directs and
assigns tasks to the vehicles. Transponders are embedded in the floor of the
work place. The box shifting machine uses these transponders to verify that
the vehicle is on course. A gyroscope is able to detect the slightest change in
the direction of the vehicle and corrects it in order to keep the box shifting
machine on its path. The margin of error for the inertial method is ±1 inch.
Inertial can operate in nearly any environment including tight aisles or
extreme temperatures.

Natural Features Navigation

Navigation without retrofitting of the workspace is called Natural

Features Navigation. One method uses one or more range-finding sensors,
such as a laser range-finder, as well as gyroscopes and/or inertial
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measurement units with Monte-Carlo/Markov localization techniques to
understand where it is as it dynamically plans the shortest permitted path to
its goal. The advantage of such systems is that they are highly flexible for
on-demand delivery to any location. They can handle failure without
bringing down the entire manufacturing operation, since box shifting
machines can plan paths around the failed device. They also are quick to
install, with less down-time for the factory.

Vision-Guidance

Vision-Guided box shifting machines can be installed with no

modifications to the environment or infrastructure. They operate by using
cameras to record features along the route, allowing the box shifting
machine to replay the route by using the recorded features to navigate.
Vision-Guided box shifting machines use Evidence Grid technology, an
application of probabilistic volumetric sensing, and was invented and
initially developed by Dr. Moravec at Carnegie Mellon University. The
Evidence Grid technology uses probabilities of occupancy for each point in
space to compensate for the uncertainty in the performance of sensors and in
the environment. The primary navigation sensors are specially designed
stereo cameras. The vision-guided box shifting machine uses 360-degree
images and build a 3D map, which allows the vision-guided box shifting
machines to follow a trained route without human assistance or the addition
of special features, landmarks or positioning systems.

Path Decision

box shifting machines have to make decisions on path selection. This

is done through different methods: frequency select mode (wired navigation
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only), and path select mode (wireless navigation only) or via a magnetic tape
on the floor not only to guide the box shifting machine but also to issue
steering commands and speed commands.

Frequency select mode

Frequency select mode bases its decision on the frequencies being

emitted from the floor. When an box shifting machine approaches a point on
the wire which splits the box shifting machine detects the two frequencies
and through a table stored in its memory decides on the best path. The
different frequencies are required only at the decision point for the box
shifting machine. The frequencies can change back to one set signal after
this point. This method is not easily expandable and requires extra guide
cutting meaning more money.

FORWARD SENSING CONTROL

Forward sensing control uses collision avoidance sensors to avoid

collisions with other box shifting machine in the area. These sensors include:
sonic, which work like radar; optical, which uses an infrared sensor; and
bumper, physical contact sensor. Most box shifting machines are equipped
with a bumper sensor of some sort as a fail safe. Sonic sensors send a
“chirp” or high frequency signal out and then wait for a reply from the
outline of the reply the box shifting machine can determine if an object is
ahead of it and take the necessary actions to avoid collision.[9] The optical
uses an infrared transmitter/receiver and sends an infrared signal which then
gets reflected back; working on a similar concept as the sonic sensor. The
problems with these are they can only protect the box shifting machine from
so many sides. They are relatively hard to install and work with as well.
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COMBINATION CONTROL

Combination control sensing is using collision avoidance sensors as

well as the zone control sensors. The combination of the two helps to
prevent collisions in any situation. For normal operation the zone control is
used with the collision avoidance as a fail safe. For example, if the zone
control system is down, the collision avoidance system would prevent the
box shifting machine from colliding.

SYSTEM MANAGEMENT

Industries with box shifting machines need to have some sort of

control over the box shifting machines. There are three main ways to control
the box shifting machine: locator panel, CRT color graphics display, and
central logging and report.

A locator panel is a simple panel used to see which area the box
shifting machine is in. If the box shifting machine is in one area for too long,
it could mean it is stuck or broken down. CRT color graphics display shows
real time where each vehicle is. It also gives a status of the box shifting
machine, its battery voltage, unique identifier, and can show blocked spots.
Central logging used to keep track of the history of all the box shifting
machines in the system. Central logging stores all the data and history from
these vehicles which can be printed out for technical support or logged to
check for up time.

Box shifting machine is a system often used in FMS to keep up,

Mohanraj transport, and connect smaller subsystems into one large
production unit. box shifting machines employ a lot of technology to ensure
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they do not hit one another and make sure they get to their destination.
Loading and transportation of materials from one area to another is the main
task of the box shifting machine. box shifting machine require a lot of
money to get started with, but they do their jobs with high efficiency. In
places such as Japan automation has increased and is now considered to be
twice as efficient as factories in America. For a huge initial cost the total cost
over time decreases.

VEHICLE TYPES

Box shifting machines Towing Vehicles were the first type introduced
and are still a very popular type today. Towing vehicles can pull a multitude
of trailer types and have capacities ranging from 8,000 pounds to 60,000
pounds. Box shifting machines Unit Load Vehicles are equipped with decks,
which permit unit load transportation and often automatic load transfer. The
decks can either be lift and lower type, powered or non-powered roller, chain
or belt decks or custom decks with multiple compartments.

Box shifting machines Pallet Trucks are designed to transport

palletized loads to and from floor level; eliminating the need for fixed load
stands. Box shifting machineS Fork Truck has the ability to service loads
both at floor level and on stands. In some cases these vehicles can also stack
loads in rack. Light Load box shifting machineS are vehicles which have
capacities in the neighborhood of 500 pounds or less and are used to
transport small parts, baskets, or other light loads though a light
manufacturing environment. They are designed to operate in areas with
limited space. box shifting machines Assembly Line Vehicles are an

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adaptation of the light load box shifting machineS for applications involving
serial assembly processes.

COMMON BOX SHIFTING MACHINE APPLICATIONS

Automated Guided Vehicles can be used in a wide variety of

applications to transport many different types of material including pallets,
rolls, racks, carts, and containers. box shifting machines excel in
applications with the following characteristics:

 Repetitive movement of materials over a distance

 Regular delivery of stable loads

 Medium throughput/volume

 When on-time delivery is critical and late deliveries are causing

inefficiency

 Operations with at least two shifts

 Processes where tracking material is important

RAW MATERIAL HANDLING

Box shifting machines are commonly used to transport raw materials

such as paper, steel, rubber, metal, and plastic. This includes transporting
materials from receiving to the warehouse, and delivering materials directly
to production lines.

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WORK-IN-PROCESS MOVEMENT

Work-in-Process movement is one of the first applications where

automated guided vehicles were used, and includes the repetitive movement
of materials throughout the manufacturing process. box shifting machines
can be used to move material from the warehouse to production/processing
lines or from one process to another.

PALLET HANDLING

Pallet handling is an extremely popular application for box shifting

machines as repetitive movement of pallets is very common in
manufacturing and distribution facilities. box shifting machines can move
pallets from the palletizer to stretch wrapping to the warehouse/storage
and/or to the outbound shipping docks.

FINISHED PRODUCT HANDLING

Moving finished goods from manufacturing to storage or shipping is

the final movement of materials before they are delivered to customers.
These movements often require the gentlest material handling because the
products are complete and subject to damage from rough handling. Because
box shifting machines operate with precisely controlled navigation and
acceleration and deceleration this minimizes the potential for damage
making them an excellent choice for this type of application.

TRAILER LOADING

Automatic loading of trailers is a relatively new application for

automated guided vehicles and becoming increasingly popular. box shifting
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machines are used to transport and load pallets of finished goods directly
into standard, over-the-road trailers without any special dock equipment. box
shifting machines can pick up pallets from conveyors, racking, or staging
lanes and deliver them into the trailer in the specified loading pattern.

Roll Handling

Box shifting machines are used to transport rolls in many types of

plants including paper mills, converters, printers, newspapers, steel
producers, and plastics manufacturers. box shifting machines can store and
stack rolls on the floor, in racking, and can even automatically load printing
presses with rolls of paper.

Container Handling

Container terminals showing a container being loaded onto an

unmanned automated guided vehicle.

box shifting machines are used to move sea containers in some maritime
container terminals. The main benefits are reduced labour costs and a more
reliable (less variable) performance. This use of box shifting machines was
pioneered by ECT in The Netherlands at the Delta terminal in the Port of
Rotterdam.

Primary Application Industries

Efficient, cost effective movement of materials is an important, and

common element in improving operations in many manufacturing plants and
warehouses. Because automatic guided vehicles (box shifting machines) can
delivery efficient, cost effective movement of materials, box shifting

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machines can be applied to various industries in standard or customized
designs to best suit an industry’s requirements. Industry’s currently utilizing
box shifting machines include (but are not limited to):

Pharmaceutical

Box shifting machines are a preferred method of moving materials in

the pharmaceutical industry. Because an box shifting machine system tracks
all movement provided by the box shifting machines, it supports process
validation and cGMP (current Good Manufacturing Practice).

CHEMICAL

Box shifting machines deliver raw materials, move materials to curing

storage warehouses, and provide transportation to other processing cells and
stations. Common industries include rubber, plastics, and specialty
chemicals.

MANUFACTURING

Box shifting machines are often used in general manufacturing of

products. box shifting machines can typically be found delivering raw
materials, transporting work-in process, moving finished goods, removing
scrap materials, and supplying packaging materials.

AUTOMOTIVE

Box shifting machine installations are found in Stamping Plants,

Power Train (Engine and Transmission) Plants, and Assembly Plants
delivering raw materials, transporting work-in process, and moving finished

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goods. box shifting machines are also used to supply specialized tooling
which must be changed.

BOX SHIFTING MACHINE AS MATERIALS HANDLING

EQUIPMENTS

Material handling equipment is all equipment that relates to the

movement, storage, control and protection of materials, goods and products
throughout the process of manufacturing, distribution, consumption and
disposal. Material handling equipment is the mechanical equipment involved
in the complete system.

Material handling equipment is generally separated into four main

categories: storage and handling equipment, engineered systems, industrial
trucks, and bulk material handling. Material handling equipment is used to
increase throughput, control costs, and maximize productivity

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 CHAPTER - 3

TYPES OF MATERIAL HANDLING EQUIPMENT

STORAGE AND HANDLING EQUIPMENT

Storage and handling equipment is a category within the material

handling industry. The equipment that falls under this description is usually
non-automated storage equipment. Products such as Pallet rack, shelving,
carts, etc. belong to storage and handling.

ENGINEERED SYSTEMS

Engineered systems are typically custom engineered material handling

systems. Conveyors, Handling Robots, box shifting machine and most other
automated material handling systems fall into this category. Engineered
systems are often a combination of products integrated to one system.

INDUSTRIAL TRUCKS

Industrial trucks usually refer to operator driven motorized warehouse

vehicles, powered manually, by gasoline or electrically. Industrial trucks
assist the material handling system with versatility; they can go where
engineered systems cannot. Forklift trucks are the most common example of
industrial trucks. Tow tractors and stock chasers are additional examples of
industrial trucks.

Bulk material handling

Bulk material handling equipment is used to move and store bulk

materials such as ore, liquids, and cereals. This equipment is often seen on
17
farms, mines, shipyards and refineries. This category is also explained in
Bulk material handling.

• Pallet

• Forklift truck

• Conveyor belt

• Automated Storage and Retrieval System

• Carton flow

• Mezzanine (architecture)

The Materials Handling Equipments are classified into four basic

types, viz., conveyors, cranes and hoists, trucks and auxiliary equipment.

CONVEYERS:

These are gravity or powered devices, commonly used for moving

loads from point to point over fixed paths. The various types of conveyors
are:

(a) Belt conveyor- Motor driven belt, usually made of rubberized fabric or
mental fabric on a rigid frame.

(b) Chain conveyor- Motor driven chain that drags materials along a metal
slide base.

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(c) Roller conveyor- Boxes, large parts or units loads roll on top of a series
of rollers mounted on a rigid frame. The rollers may be powered or un
powered.

(d) Pneumatic conveyor- High volume of air flows through a tube, carrying
materials along with air flow. The other types of conveyors are bucket
conveyors, screw conveyors,

pipeline conveyor, vibratory conveyor, tube conveyor, trolley conveyor and

chute or gravity conveyors. Advantages of conveyors are that they do not
require operators, will move a large volume of products and are inexpensive
to operate.

CRANES, ELEVATORS AND HOISTS:

These are overhead devices used for moving varying loads

intermittently between points within an area, fixed by supporting and
binding rails:

(a) Cranes are devices mounted on overhead rails or ground level wheels or
rails. They lift, swing and transport large and heavy materials. Examples are
Gantry Crane, Jib Crane and Electrically Operated Overhead Crane (EOTC).

(b) Elevators are a type of cranes that lift materials- usually between floors
of building.

(c) Hoists are devices which move materials vertically and horizontally in a
limited area. They are used primarily, when materials must be lifted prior to
being moved from one point to another. Examples of hoists are air hoists,
electric hoist and chain hoists.

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(d) Industrial Trucks: These devices are used for moving mixed or uniform
loads intermittently over variable paths. They are electric, diesel, gasoline or
liquefied petroleum, gas powered vehicles equipped with beds, forks, arms
or other holding devices. Examples are fork- lift trucks, pallet trucks, tractor
with trailers, hand trucks and power trolleys.

AUXILIARY EQUIPMENTS:

These are devices or attachments used with handling equipment to

make their use more effective and versatile. Examples are ramps,
positioners, pallets, containers and turn tables.

MISCELLANEOUS HANDLING EQUIPMENTS:

I. Pipe lines, which are closed tubes that transport liquids by means of
pumps or gravity.

II. Automated guided vehicle (box shifting machine) systems- These devices
do not require operators and provide a great deal of flexibility in the paths
they travel and the function they perform. The box shifting machines are
controlled by signals sent through wires embedded in the floor or inductive
tape on the floor surface. A remote control computer is needed to control the
movement of box shifting machines

III. Automatic transfer devices which automatically grasp materials hold

them firmly while operations are being performed and moved them to other
locations.IV. Industrial robots- A robot is a mechanism which has movable
arm like projection with a gripper on the end that can perform a variety of
repetitive tasks. Robots usually have a built in control that can be re-
programmed and hence they are very versatile.
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The following are examples of material handling applications:

* Transferring parts from one conveyor to another

* Transferring parts from a processing line to a conveyor

* Loading bins and fixtures for subsequent processing

* Moving parts from a warehouse to a machine

* Transporting explosive devices

* Transfer of parts from a machine to an overhead conveyor

The process design and the principles of efficient materials handling

provide the framework for selecting specific materials handling devices and
the core of the materials handling system. Each of the handling devices
discussed above has its own unique characteristics and advantages and
disadvantages.

EVALUATION OF MATERIALS HANDLING PERFORMANCE:

Like any other materials activity, materials handling function should

also be evaluated to judge its effectiveness. The performance of materials
handling function can be evaluated with the help of several ratios such as the
following:

1. Materials handling labor ratio.

2. Direct labor handling ratio.

3. Management/ Operation ratio.

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 4. Manufacturing cycle efficiency ratio

5. Space utilization efficiency ratio.

6. Equipments utilization ratio.

7. Ratio of total number of moves to the total number of operations.

8. Percentage of usable cubic footage usually occupied.

9. Materials handling costs as percentage of manufacturing expenses

TYPES OF BOX SHIFTING MACHINES

 box shifting machineS towing vehicle

 box shifting machineS unit load carriers

 box shifting machineS pallet trucks

 box shifting machineS forklift trucks

 box shifting machineS light-load transporters

 box shifting machineS assembly-line vehicles

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BOX SHIFTING MACHINES TOWING VEHICLES

 First type of box shifting machine 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).

BOX SHIFTING MACHINES UNIT LOAD CARRIERS

 To transport individual unit load onboard the vehicle.

 Equipped with powered or non-powered roller, chain or belt

deck, or custom deck.

 Loads can be moved by Pallet truck, forklift truck, automatic

loading/unloading equipment, etc.

BOX SHIFTING MACHINES PALLET TRUCKS

 No special device is needed for loading except the loads should

be on pallet

 Limited to floor level loading and unloading with palletized

load

 Widely used in distribution functions

 Capacity 1000-2000 lb

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BOX SHIFTING MACHINES FORKLIFT TRUCKS

 Ability to pickup and drop palletized load both at floor level

and on stands.

 Pickup and drop off heights can be different

 Vehicle can position its fork according to load stands with

different heights

 Very expensive

 Selected where complete automation is necessary/required.

BOX SHIFTING MACHINES LIGHT LOAD TRANSPORTERS

 Capacity < 500lb

 To handle light and small loads/parts over moderate distances

 Distribute between storage and number of workstations

 Speed 100ft/min, turning radius 2ft

 For areas with restricted space

BOX SHIFTING MACHINES ASSEMBLY-LINE VEHICLES

 Variation of an light load transporter

 For serial assembly processes

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  As the vehicle moves from one station to another, succeeding
assembly operations are performed

 This kind provides flexibility for the manufacturing processes

 Lower expenses and ease of installation

 Complex computer control and extensive planning is required

to integrate the system.

IMPORTANT ISSUES FOR BOX SHIFTING MACHINE

 Guidance system

 Routing

 box shifting machineS control systems

 Load transfer

 Interfacing with other subsystems

BOX SHIFTING MACHINES GUIDANCE SYSTEM

The goal of an box shifting machineS guidance system keep the box
shifting machine on track/predefined path

SELECTION OF BOX SHIFTING MACHINE

One of the major advantage of box shifting machine is ease in

modification given by the guidance system for changing the guide path at
low cost compare to conveyors, chains, etc. Another benefit is: guide path is
flexible which means intersection of path is possible. Generally, guide path
25
does not obstruct another systems. The guidance systems can be selected
based on the type of box shifting machine selected, its application,
requirement and environmental limitation.

 Wire-guided

 Optical

 Inertial

 Infrared

 Laser

 Teaching type

WIRE-GUIDED:

An energized wire is rooted along the guide path. The antenna of the
box shifting machine follows the rooted wire.

OPTICAL:

Colorless florescent particles are painted on the concrete/tiled floor.

Photosensors are used to track these particles.

INERTIAL:

The guide path is programmed on a microprocessor which is fixed on

the box shifting machine. Sonar system is incorporated for finding obstacles.

INFRARED:

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Infrared light transmitters are used to detect the position of the vehicle.
Reflectors are affixed on the top of vehicle to reflect the light.

TEACHING TYPE:

Box shifting machine learns the guide path by moving the required
route. Sends the information to the host computer. A continuous wire is used
to loop the frequencies.

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 CHAPTER – 4

LITERATURE REVIEW

BOX TRANSFER MECHANISM, THROUGH KINEMATIC LINK

P.R. Kothule1 , M.R. Chavan2 , S.P. Bhalerao

There has been a serious demand for intermittent movement of

packages in the industries right from the start. Though the continuous
movement is more or less important in the same field of the sporadic motion
has become essential. The objective of this study is to design a mechanism
that delivers this stop and move motion using the mechanical linkages. The
advantage of this system over the conveyor system is that the system has a
time delay between moving packages and this delay can be used to introduce
any alterations in the package or move the package for any other purpose
and likewise. While in the normal conveyor mechanism such actions cannot
be performed unless programmed module is used to produce intermittent
stopping of the belt which is basically costly. The prototype design requires
an electric motor, shafts and the frame of which, the frame and platform on
which the packages are moved is fabricated. All the links are made up of
normal MS (mild steel) and wood including the head which has a direct
contact with the boxes that are to be moved. The system is expected to move
as heavy packages as 2 KGs approximately. The aim of the project work is
to design and fabricate a box moving mechanism that makes much easier to
move with the so called quad staying machines by means of which a box
blank is folded or set-up into box like form. These set-up boxes are
transferred by means of a conveyor to an operator, who picks up the boxes
and places and centers’ them on wrappers with which the boxes are to be
28
covered. The boxes and wrappers are then conveyed to a box wrapping
machine where the wrapper is folded around and glued to the box. Usually,
the operation of the wrapping machine is controlled by means of a switch
actuated by the box forming machine so that their operating speeds are
related to each other.

The box shifting mechanism plays a major role in industries, the

process of transporting or shifting products from one place to another was to
be maintained by conveyors only. So we just successfully altered this with a
box shifting mechanism using the kinematics links and a motor. We had just
implemented our basic mechanical knowledge and designing skills for
designing and fabricating this project successfully. Thus this project work
might be useful in all industries. For practical applications this is fabricated
for light duty operation. Its height, weight and other mechanical designs may
be not suitable for any other heavy operation or work on hardened material.
We are proud that we have completed the work with the limited time
successfully. The project works with satisfactory conditions. We are able to
understand the difficulties in maintaining the tolerances and also quality. We
have done to our ability and skill making maximum use of available
facilities.

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 CHAPTER - 5

COMPONENTS USED

DC POWER SUPPLY

DC MOTOR

LINK MECHANISM

FRAME

30
 CHAPTER – 6

COMPONENT DESCRIPTION

DC POWER SUPPLY

A power supply is an electronic device that supplies electric energy to

an electrical load. The primary function of a power supply is to convert one
form of electrical energy to another. As a result, power supplies are
sometimes referred to as electric power converters. Some power supplies are
discrete, stand-alone devices, whereas others are built into larger devices
along with their loads. Examples of the latter include power supplies found
in desktop computers and consumer electronics devices.

Every power supply must obtain the energy it supplies to its load, as
well as any energy it consumes while performing that task, from an energy
source. Depending on its design, a power supply may obtain energy from
various types of energy sources, including electrical energy transmission
systems, energy storage devices such as a batteries and fuel cells,
electromechanical systems such as generators and alternators, solar power
converters, or another power supply. All power supplies have a power input,
which receives energy from the energy source, and a power output that
delivers energy to the load. In most power supplies the power input and
output consist of electrical connectors or hardwired circuit connections,
though some power supplies employ wireless energy transfer in lieu of
galvanic connections for the power input or output. Some power supplies
have other types of inputs and outputs as well, for functions such as external
monitoring and control

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TRANSFORMER

A transformer is an electrical device that transfers electrical energy

between two or more circuits through electromagnetic induction. A varying
current in one coil of the transformer produces a varying magnetic field,
which in turn induces a voltage in a second coil. Power can be transferred
between the two coils through the magnetic field, without a metallic
connection between the two circuits. Transformers are devices used in
electrical circuits to change the voltage of electricity flowing in the circuit.
Transformers can be used either to increase the voltage (called "stepping
up") or decrease the voltage ("step down").

A transformer needs an alternating current that will create a

changing magnetic field. A changing magnetic field also induces a changing
voltage in a coil. ... The primary coil is connected to an AC supply. An
alternating current passes through a primary coil wrapped around a soft iron
core.

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TYPES
 Laminated core.
 Toroidal.
 Autotransformer.
 Variable autotransformer.
 Induction regulator.
 Polyphase transformer.
 Grounding transformer.

CORES

Transformers generally have one of two types of cores: Core Type and
Shell Type. These two types are distinguished from each other by the
manner in which the primary and secondary coils are place around the steel
core. Core type - With thistype, the windings surround the laminated core.

BRIDGE RECTIFIER

A diode bridge is an arrangement of four (or more) diodes in a bridge

circuit configuration that provides the same polarity of output for either
polarity of input.

When used in its most common application, for conversion of an

alternating current (AC) input into a direct current (DC) output, it is known
as a bridge rectifier. A bridge rectifier provides full-wave rectification from a
two-wire AC input, resulting in lower cost and weight as compared to a
rectifier with a 3-wire input from a transformer with a center-tapped
secondary winding.

DC MOTOR

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 Workings of a brushed electric motor with a two-pole rotor (armature)
and permanent magnet stator. "N" and "S" designate polarities on the inside
axis faces of the magnets; the outside faces have opposite polarities. The +
and -signs show where the DC current is applied to the commutator which
supplies current to the armaturecoils

A DC motor is any of a class of electrical machines that converts

direct current electrical power into mechanical power. The most common
types rely on the forces produced by magnetic fields. Nearly all types of DC
motors have some internal mechanism, either electromechanical or
electronic, to periodically change the direction of current flow in part of the
motor. Most types produce rotary motion; a linear motor directly produces
force and motion in a straight line.

DC motors were the first type widely used, since they could be
powered from existing direct-current lighting power distribution systems. A
DC motor's speed can be controlled over a wide range, using either a
variable supply voltage or by changing the strength of current in its field
windings. Small DC motors are used in tools, toys, and appliances. The

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universal motor can operate on direct current but is a lightweight motor used
for portable power tools and appliances. Larger DC motors are used in
propulsion of electric vehicles, elevator and hoists, or in drives for steel
rolling mills. The advent of power electronics has made replacement of DC
motors with AC motors possible in many applications. Electromagnetic
motors

A simple DC motor has a stationary set of magnets in the stator and an

armature with one or more windings of insulated wire wrapped around a soft
iron core that concentrates the magnetic field. The windings usually have
multiple turns around the core, and in large motors there can be several
parallel current paths.

The ends of the wire winding are connected to a commutator. The

commutator allows each armature coil to be energized in turn and connects
the rotating coils with the external power supply through brushes. The
sequence of turning a particular coil on or off dictates what direction the
effective electromagnetic fields are pointed. By turning on and off coils in
sequence a rotating magnetic field can be created. These rotating magnetic
fields interact with the magnetic fields of the magnets (permanent or
electromagnets) in the stationary part of the motor (stator) to create a force
on the armature which causes it to rotate. In some DC motor designs the
stator fields use electromagnets to create their magnetic fields which allow
greater control over the motor.

Different number of stator and armature fields as well as how they are
connected provide different inherent speed/torque regulation characteristics.
The speed of a DC motor can be controlled by changing the voltage applied

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to the armature. The introduction of variable resistance in the armature
circuit or field circuit allowed speed control. Modern DC motors are often
controlled by power electronics systems which adjust the voltage by
"chopping" the DC current into on and off cycles which have an effective
lower voltage.

Today DC motors are still found in applications as small as toys and

disk drives, or in large sizes to operate steel rolling mills and paper
machines. Large DC motors with separately excited fields were generally
used with winder drives for mine hoists, for high torque as well as smooth
speed control using thyristor drives. These are now replaced with large AC
motors with variable frequency drives.

If external power is applied to a DC motor it acts as a DC generator, a

dynamo. This feature is used to slow down and recharge batteries on hybrid
car and electric cars or to return electricity back to the electric grid used on a
street car or electric powered train line when they slow down. This process
is called regenerative braking on hybrid and electric cars. In diesel electric
locomotives they also use their DC motors as generators to slow down but
dissipate the energy in resistor stacks. Newer designs are adding large
battery packs to recapture some of this energy.

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BRUSHED

A brushed DC electric motor generating torque from DC power

supply by using an internal mechanical commutation. Stationary permanent
magnets form the stator field. Torque is produced by the principle that any
current-carrying conductor placed within an external magnetic field
experiences a force, known as Lorentz force. In a motor, the magnitude of
this Lorentz force (a vector represented by the green arrow), and thus the
output torque,is a function for rotor angle, leading to a phenomenon known
astorque ripple) Since this is a single phase two-pole motor, the commutator
consists of a split ring, so that the current reverses each half turn ( 180
degrees).

Advantages of a brushed DC motor include low initial cost, high

reliability, and simple control of motor speed. Disadvantages are high
maintenance and low life-span for high intensity uses. Maintenance involves
regularly replacing the carbon brushes and springs which carry the electric
current, as well as cleaning or replacing the commutator. These components
are necessary for transferring electrical power from outside the motor to the
spinning wire windings of the rotor inside the motor. Brushes consist of
conductors.

BRUSHLESS

Typical brushless DC motors use one or more permanent magnets in

the rotor and electromagnets on the motor housing for the stator. A motor
controller converts DC to AC. This design is mechanically simpler than that
of brushed motors because it eliminates the complication of transferring

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power from outside the motor to the spinning rotor. The motor controller can
sense the rotor's position via Hall effect sensors or similar devices and can
precisely control the timing, phase, etc., of the current in the rotor coils to
optimize torque, conserve power, regulate speed, and even apply some
braking.

Advantages of brushless motors include long life span, little or no

maintenance, and high efficiency. Disadvantages include high initial cost,
and more complicated motor speed controllers. Some such brushless motors
are sometimes referred to as "synchronous motors" although they have no
external power supply to be synchronized with, as would be the case with
normal AC synchronous motors.

UNCOMMUTATED

Homopolar motor – A homopolar motor has a magnetic field along the

axis of rotation and an electric current that at some point is not parallel to the
magnetic field. The name homopolar refers to the absence of polarity
change. Homopolar motors necessarily have a single-turn coil, which limits
them to very low voltages. This has restricted the practical application of this
type of motor.

Ball bearing motor – A ball bearing motor is an unusual electric motor

that consists of two ball bearing-type bearings, with the inner races mounted
on a common conductive shaft, and the outer races connected to a high
current, low voltage power supply. An alternative construction fits the outer
races inside a metal tube, while the inner races are mounted on a shaft with a
non-conductive section (e.g. two sleeves on an insulating rod). This method
has the advantage that the tube will act as a flywheel. The direction of
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rotation is determined by the initial spin which is usually required to get it
going.

PERMANENT MAGNET STATORS

A PM motor does not have a field winding on the stator frame, instead
relying on PMs to provide the magnetic field against which the rotor field
interacts to produce torque. Compensating windings in series with the
armature may be used on large motors to improve commutation under load.
Because this field is fixed, it cannot be adjusted for speed control.

PM fields (stators) are convenient in miniature motors to eliminate the

power consumption of the field winding. Most larger DC motors are of the
"dynamo" type, which have stator windings. Historically, PMs could not be
made to retain high flux if they were disassembled; field windings were
more practical to obtain the needed amount of flux. However, large PMs are
costly, as well as dangerous and difficult to assemble; this favors wound
fields for large machines. To minimize overall weight and size, miniature
PM motors may use high energy magnets made with neodymium or other
strategic elements; most such are neodymium-iron-boron alloy. With their
higher flux density, electric machines with high-energy PMs are at least
competitive with all optimally designed singly fed synchronous and
induction electric machines.

WOUND STATORS

A field coil may be connected in shunt, in series, or in compound with

the armature of a DC machine (motor or generator)

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 There are three types of electrical connections between the stator and
rotor possible for DC electric motors: series, shunt/parallel and compound
(various blends of series and shunt/parallel) and each has unique
speed/torque characteristics appropriate for different loading torque
profiles/signatures.

SERIES CONNECTION

A series DC motor connects the armature and field windings in series

with a common D.C. power source. The motor speed varies as a non-linear
function of load torque and armature current; current is common to both the
stator and rotor yielding current squared (I^2) behavior.

A series motor has very high starting torque and is commonly used for
starting high inertia loads, such as trains, elevators or hoists.[2] This
speed/torque characteristic is useful in applications such as dragline
excavators, where the digging tool moves rapidly when unloaded but slowly
when carrying a heavy load.

A series motor should never be started at no load. With no mechanical

load on the series motor, the current is low, the counter-EMF produced by
the field winding is weak, and so the armature must turn faster to produce
sufficient counter-EMF to balance the supply voltage. The motor can be
damaged by overspeed. This is called a runaway condition.

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 Series motors called universal motors can be used on alternating
current. Since the armature voltage and the field direction reverse at the
same time, torque continues to be produced in the same direction. However
they run at a lower speed with lower torque on AC supply when compared to
DC due to reactance voltage drop in AC which is not present in DC.

Since the speed is not related to the line frequency, universal motors
can develop higher-than-synchronous speeds, making them lighter than
induction motors of the same rated mechanical output. This is a valuable
characteristic for hand-held power tools. Universal motors for commercial
utility are usually of small capacity, not more than about 1 kW output.
However, much larger universal motors were used for electric locomotives,
fed by special low-frequency traction power networks to avoid problems
with commutation under heavy and varying loads.

SHUNT CONNECTION

A shunt DC motor connects the armature and field windings in

parallel or shunt with a common D.C. power source. This type of motor has
good speed regulation even as the load varies, but does not have the starting
torque of a series DC motor. It is typically used for industrial, adjustable
speed applications, such as machine tools, winding/unwinding machines and
tensioners.

COMPOUND CONNECTION

A compound DC motor connects the armature and fields windings in a

shunt and a series combination to give it characteristics of both a shunt and a
series DC motor. This motor is used when both a high starting torque and

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good speed regulation is needed. The motor can be connected in two
arrangements: cumulatively or differentially. Cumulative compound motors
connect the series field to aid the shunt field, which provides higher starting
torque but less speed regulation. Differential compound DC motors have
good speed regulation and are typically operated at constant speed.

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 CHAPTER - 7

BLOCK DIAGRAM

Motor/Handle

Operating Shafts

Crank Rocker
Mechanism
Function

Box on the Bed

Shifting
Operation

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 CHAPTER - 8

WORKING PRINCIPLE

In this project there is a bed over which the boxes are shifted from one
place to other. A hanger and crank link is provided through which the power
is transmitted. A linkage is a mechanism formed by connecting two or more
levers together. Linkages can be designed to change the direction of a force
or make two or more objects move at the same time.

Many different fasteners are used to connect linkages together. A

number of members are connected to a moving bar that transmits the motion
of the linkage to move the boxes in every motion.

An electric motor is an electrical machine that converts electrical

energy into mechanical energy. A motor is provided which can be rotated,
the rotation of the motor provides power to the link which is transmitted to
the shaft. Every time the motor is rotated, the power is transmitted to the
shaft through the links which in turn moves the boxes.

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 CHAPTER - 9

ADVANTAGES

 Unobstructed movement

 Easy to change guide path system

 Greater reliability

 Less environmental problems

 Box shifting machine can be replaced by another, in case of failure.

 Lower investment

 Higher operating savings on long run

 Minimal labor cost

 Easy maintenance

 Easy to interface with other systems

 Best choice for FMS

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APPLICATIONS

 Small Scale Industries

 Large Scale Industries

 Food Industries

 Packing based Industries

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 CHAPTER – 10

CONCLUSION

Thus the design and fabrication of the box shifting machine was done
according to the given requirements and automation was done. The various
parts of the box shifting machine were designed according to the required
and available specifications. The box shifting machine can be used not only
for small miniature setups but also for large scale industries which has mass
production.

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 CHAPTER - 11

REFERENCES

1. “Automatic Guided Vehicle-Description”. Swisslog. 5 March 2006

2. "Webb Automatic Guided Carts". Jervis B. Webb Company 2008

3. “Flexible Manufacturing Systems”. University of Kentucky. 5 March

2006

4. “Nav 200 Absolute Navigation System”. Mobile Platforms. 5 March

2006

5. “The Basics of Automated Guided Vehicles”. box shifting machine

Systems. Savant. 5 March 2006

6. "Guidance options for box shifting machines" Jervis B. Webb Company,

2007.

7. Specifications for Platforms

8. http://www.seegrid.com "Seegrid Corporation, 2012"

9. “Sonar sensor and mounting”. University of Birmingham. 5 March 2006

10. "Tow Type box shifting machines " Hi-Tech Robotic Systemz Ltd.

India, 2009.

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