Autonomous Unwinder Transfer Scheduling for Continuous Tyre Production
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Solution Overview
Problem
The existing transfer operations for unwinders supplying elastomeric products to green tyre manufacturing machines are inefficient, leading to ergonomic issues, repetitive tasks, and potential stoppages in the manufacturing process due to limitations in the number of autonomous mobile platforms available.
Innovation Solution
A method and facility utilizing autonomous mobile platforms with evaluation and communication means to measure and optimize the unwinding of reels, allowing for precise timing of mission instructions to minimize downtime and increase productivity, featuring RFID unwinder identification, Bluetooth location tracking, and radar navigation for efficient movement and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If autonomous mobile platforms are used to transfer unwinders, then ergonomics and automation are improved, but productivity decreases when the number of mission instructions exceeds the number of available platforms
Solution Approach 1:
The system performs preliminary actions by measuring the quantity of product on reels in advance and determining the optimal timing for transfer missions before the manufacturing line stops. The control unit calculates when unwinders will be depleted and schedules platform missions accordingly, ensuring continuous operation without waiting for actual depletion events.
Solution Approach 2:
The system implements feedback mechanisms through measurement means that continuously monitor product quantity on reels and communicate this data to the control unit. This feedback loop enables the control unit to dynamically adjust mission scheduling based on real-time inventory levels, optimizing platform utilization and preventing manufacturing stoppages.
2Productivity
If more autonomous mobile platforms are deployed to handle increased mission instructions, then productivity is maintained, but device complexity and cost increase
Solution Approach 1:
By measuring product quantities in advance and calculating optimal transfer timing, the system maximizes the utilization of existing platforms. The control unit schedules missions to ensure platforms are continuously productive without requiring additional units, thereby maintaining productivity while avoiding increased system complexity.
Solution Approach 2:
The system changes operational parameters by optimizing mission timing and platform allocation based on real-time product quantity measurements. This dynamic parameter adjustment allows the existing fleet of platforms to handle increased mission volumes efficiently without requiring physical expansion of the platform fleet.
3Productivity
If buffer storage capacity is installed to prevent stoppages, then productivity is maintained, but device complexity and space requirements increase
Solution Approach 1:
The measurement means and communication system provide continuous feedback on product inventory levels, enabling the control unit to coordinate unwinder transfers precisely when needed. This feedback-driven approach eliminates the need for buffer storage by ensuring unwinders are replaced just-in-time to maintain continuous manufacturing operations.
Solution Approach 2:
The system enables self-service by automatically monitoring product quantities and scheduling transfers without requiring manual intervention or additional storage infrastructure. The control unit autonomously manages the coordination between measurement data, mission scheduling, and platform deployment, replacing what would traditionally require physical buffer capacity with intelligent resource management.
Data Source
AI summary
A method for transferring unwinders (36) using a transfer facility (38) comprising a control unit (39) for controlling the unwinders, and at least one autonomous mobile platform (40) is disclosed. The facility comprises measurement means for measuring the quantity of product wound on reels (22) supported by the unwinders and communication means. The method comprises the following successive operations: measuring the quantity of product wound on the reels and communicating the measured data to the control unit; on the basis of the measured data, determining the moment at which to transmit a removal or supply mission instruction to a mobile platform; transmitting to a mobile platform at the previously-determined moment, a mission instruction to remove or to supply a unwinder; and moving the mobile platform in such a way that it becomes positioned under a unwinder.