Assembly Line Replenishment Apparatus with Automated Carrier Transfer
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Solution Overview
Problem
Conventional assembly lines require excessive manpower and manual operations for replenishment, leading to errors, decreased efficiency, and potential line stoppages due to inadequate timely reporting of object shortages.
Innovation Solution
A replenishment apparatus with a usage storage area and a spare storage area, featuring a fixing carrier, a counter, a moving carrier, and a controller, which automates the movement of objects from the spare storage area to the usage area when the remaining number of objects reaches zero, ensuring continuous operation and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replenishment operation is used, then flexibility and simplicity are maintained, but productivity decreases and errors increase
Solution Approach 1:
The replenishment system performs self-service through automated detection and replenishment operations. The detection device automatically monitors object quantities, and the replenishment device automatically transfers objects from spare storage to usage storage without requiring manual intervention, thereby improving productivity while maintaining operational simplicity
Solution Approach 2:
The patent replaces manual mechanical operations with automated systems. The detection device uses sensors or vision systems to detect object quantities, and the replenishment device uses automated mechanical arms or conveyors to transfer objects, substituting human labor with automated mechanical and electronic systems to enhance efficiency
2Reliability
If manual detection of object shortage is used, then system simplicity is maintained, but reliability decreases due to human error
Solution Approach 1:
The detection device provides continuous feedback on object quantities in the usage storage area. When the detected quantity falls below a threshold or reaches zero, the system generates a signal that triggers the replenishment operation, ensuring accurate and timely detection without relying on manual inspection
Solution Approach 2:
The detection system performs self-service by automatically monitoring and reporting object quantities. The detection device continuously tracks the number of objects and autonomously identifies when replenishment is needed, eliminating human error while maintaining system simplicity through automated self-monitoring
3Productivity
If automated replenishment is implemented, then productivity increases, but use of energy increases
Solution Approach 1:
The replenishment system operates periodically rather than continuously. The detection device monitors object quantities and triggers replenishment operations only when needed (when quantity reaches zero or threshold), allowing the system to remain idle during normal operation and consume energy only during active detection and replenishment cycles
Solution Approach 2:
The system uses self-service detection and triggered replenishment to avoid continuous energy consumption. The automated nature allows the system to perform replenishment only when necessary, optimizing energy usage while maintaining high productivity through on-demand automated operations
Data Source
AI summary
The present invention is related to a replenishment method and device in an assembly line. A usage storage area for storing a first object set and a spare storage area for storing a second object set are defined in the replenishment apparatus. The replenishment apparatus comprises a fixing carrier in the usage storage area and a moving carrier in the spare storage area. The replenishment method comprises driving the moving carrier to move the second object set in the spare usage area to the fixing carrier in the usage storage area when a remaining number of objects in the first object set carried in the fixing carrier is zero and the first object set in the fixing carrier is removed; and moving the moving carrier to leave the fixing carrier and recover to the spare usage area.