Assembly Line Event Synchronization for Precise Component Traceability
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Solution Overview
Problem
Existing manufacturing systems struggle to efficiently trace components in assembly lines due to individual device clocks lacking synchronization, leading to difficulties in detecting faults and recalling defective products.
Innovation Solution
A two-level synchronization method and system that synchronizes timestamps across devices in an assembly line, converting local timestamps to a common reference timestamp for efficient tracing of entities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If each device in the assembly line operates with its own individual clock, then each device can independently record events with timestamps, but the timestamps from different devices cannot be accurately correlated to trace components through the assembly line
Solution Approach 1:
The patent introduces a master clock as an intermediary time reference that all devices in the assembly line synchronize to. This master clock acts as a mediator between individual device clocks, providing a common reference timestamp that enables accurate correlation of events across different devices while preserving traceability information throughout the assembly line.
Solution Approach 2:
The system implements a feedback mechanism where each device compares its local clock timestamp with the master clock timestamp and calculates a time difference. This feedback loop allows devices to adjust their timestamps by adding the calculated time difference, ensuring that all timestamps are accurately correlated to the common reference time, thereby resolving the timestamp accuracy issue.
2Productivity
If data from multiple devices is transmitted to a central entity for processing, then centralized analysis can be performed, but data congestion, delays, re-ordering, and loss occur during transmission
Solution Approach 1:
The patent applies preliminary action by synchronizing timestamps at the source (each device) before data transmission occurs. By pre-correlating timestamps using the master clock reference and time difference calculations, the system ensures that temporal relationships are preserved in the data itself, eliminating the need for complex post-transmission synchronization and reducing centralized processing delays.
3Reliability
If existing systems use batch numbers and manufacturing dates for tracing components, then some level of traceability is achieved, but efficient tracking and recall cannot be performed when defects are detected due to lack of synchronized timestamps
Solution Approach 1:
The patent replaces the mechanical/manual tracing system (using batch numbers and manufacturing dates) with an automated time-synchronization system. By implementing master clock-based timestamp correlation across all devices, the system automatically tracks component movement and events in real-time, enabling efficient defect detection and rapid recall operations without manual intervention.
Data Source
AI summary
Present disclosure relates to method and synchronization system for synchronizing plurality of events associated with one or more processes in assembly line for tracing entity. Initially, information related to plurality of events associated with one or more processes from one or more devices is received, where each of the plurality of events comprises respective first timestamp. Upon receiving, the first timestamp between each of the plurality of events is synchronized by performing first level and second level synchronization. The synchronization converts first timestamp into second timestamp with respect to common reference timestamp. Further, the synchronization system may identify one or more defects based on quality value assigned to entity. Thus, the present disclosure helps the synchronization system to efficiently trace entity when a defect is identified and replaces/repairs the entity.