Assembly Workstation Visual Guidance and Automated Step Verification
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Solution Overview
Problem
In small series production, achieving assembly quality, time, and reproducibility comparable to large series is challenging due to the inefficiency of training phases and increased error rates, as workers must perform multiple assembly steps without adequate training, leading to higher production costs.
Innovation Solution
An assembly workstation equipped with a display for visualizing assembly steps, a database for storing visualization data, and automated tools that determine completion of assembly steps, allowing workers to start immediately and reducing training time, while ensuring quality and reproducibility through data transmission and parameter verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If workers perform multiple assembly steps without intensive training, then productivity is maintained for small series, but assembly quality and reproducibility deteriorate due to increased error rates
Solution Approach 1:
The patent introduces a visual display system as an intermediary between the assembly instructions and the worker. The display shows images or video sequences of assembly steps, serving as a mediator that guides the worker without requiring intensive training. This resolves the contradiction by providing quality guidance (improving reliability) while maintaining quick assembly pace (preserving productivity).
Solution Approach 2:
The patent implements a feedback mechanism where the system automatically determines when an assembly step is completed and provides guidance for the next step. The display updates in real-time based on completion detection, creating a closed-loop feedback system that maintains quality without requiring worker training for judgment, thus improving reliability while preserving productivity.
2Reliability
If intensive training is provided for each assembly step, then assembly quality and reproducibility improve, but training time increases which is not amortized in small series production
Solution Approach 1:
The patent applies preliminary action by pre-programming assembly instructions, images, and video sequences into the system before production begins. The display system is prepared in advance with all necessary guidance materials, eliminating the need for time-consuming training during small series production. This resolves the contradiction by providing quality guidance upfront (improving reliability) without requiring ongoing training time (preserving productivity).
Solution Approach 2:
The patent uses copying by displaying images or video sequences that replicate the assembly process visually. Instead of training workers through repeated physical practice, the system creates visual copies of the correct assembly steps and displays them for reference. This eliminates training time while maintaining quality, resolving the contradiction between reliability and time loss.
3Reliability
If automated means are used to determine assembly step completion, then reproducibility increases immensely, but device complexity increases due to additional sensors and data transmission systems
Solution Approach 1:
The patent replaces manual determination of assembly completion with automated detection systems. Sensors detect physical parameters (torque, position, etc.) and automatically determine when a step is complete, substituting mechanical human judgment with automated sensing. This resolves the contradiction by dramatically improving reproducibility through automation while the complexity increase is offset by eliminating training requirements and quality variations.
Data Source
Figure 1~2
Figure 3~5
AI summary
The assembly workstation (1) comprises a tool (5) and an assembly step, which is connected with an assembly controller (3). A display (4) for visualizing the particular upcoming assembly step and a database for storing the visualization data are connected to the assembly controller. A machine readable code or a Radio-frequency identificationchip is applied for identification marking.