Automated Component Supply Unit Loading With Robot Conveyance

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Solution Overview

Problem

Existing component loading operations for component supply units are labor-intensive and require significant manual intervention, complicating management and increasing work-in-process units that cannot be diverted to other uses.

Innovation Solution

A component supply unit set-up system that includes a container warehouse, unit storage shed, container loader, container conveyance robot, and unit conveyance robot to automate the loading and related operations, enabling automated conveyance and loading of component containers and supply units.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual loading operation is performed by human hand, then flexibility in handling component supply units is maintained, but labor intensity increases and management complexity increases

Engineering Contradiction:

ImproveFlexibility in handling component supply unitsVSAvoidManagement complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The system enables automated self-service through the container loader that automatically loads component containers onto component supply units without human intervention. The management section coordinates the entire process, allowing the system to serve itself by automatically managing the loading operations and tracking component supply unit status.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced with an automated loading mechanism. The container loader uses automated mechanical systems to perform the loading operation, substituting human hand operations with machine-based automation that reduces labor intensity while maintaining operational capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If loading operation is performed ahead of schedule to ensure production plan, then production requirements are met, but work-in-process component supply units increase and cannot be diverted to other uses

Engineering Contradiction:

ImproveProduction plan achievementVSAvoidWork-in-process component supply units

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The management section implements feedback control by monitoring the status of component supply units and coordinating loading operations based on actual production needs. This allows the system to perform loading operations at optimal times rather than always ahead of schedule, reducing unnecessary work-in-process inventory while ensuring production requirements are met.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts loading operations based on real-time production requirements. Rather than static scheduled loading, the management section coordinates loading operations flexibly, allowing component supply units to be loaded and diverted to other uses as needed, reducing the loss of time associated with idle work-in-process units.

Inventive Principle:

Principle #15Dynamics

3Extent of automation

If automated container loader is introduced to reduce labor, then loading operation is automated, but operations before and after loading (conveyance from storage shed) still require manual intervention

Engineering Contradiction:

ImproveLoading operation automationVSAvoidManual intervention in conveyance operations

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system merges multiple operations into an integrated automated process. The container conveyance robot and unit conveyance robot work together with the container loader to create a unified automated system that handles conveyance and loading operations, eliminating the need for separate manual intervention in conveyance tasks.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conveyance robots are designed with multi-functionality to perform various conveyance tasks. The container conveyance robot handles component containers from the container warehouse to the container loader, while the unit conveyance robot handles component supply units from the unit storage shed to the container loader and back, providing universal automated conveyance capability that replaces manual operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12432893B2Component supply unit arrangement handling system

Publication Date: 2025.09.30 FUJI CORP

AI summary

A component supply unit set-up system includes a container warehouse configured to store multiple component containers for containing multiple components, a unit storage shed configured to store multiple component supply units used when the component, which is contained in the component container, is supplied in a mounting operation performed by a component mounter, a work table disposed between the container warehouse and the unit storage shed and used for a loading operation of loading the component supply unit with the component container, a container conveyance robot configured to convey the component container between the container warehouse and the work table, and a unit conveyance robot configured to convey the component supply unit between the unit storage shed and the work table.