Autonomous Partially Assembled Vehicles for Conveyor-Free Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle manufacturing methodologies rely on fixed assembly lines with conveyers, which restrict optimization of assembly station use and cause all vehicles to be affected if the conveyer breaks down.
Innovation Solution
A partially assembled vehicle equipped with a chassis, wheels, drive system, navigation system, central platform controller, and safety sensor guidance system, enabling it to autonomously transport itself through the assembly process by identifying and visiting necessary assembly stations, performing diagnostics, and adjusting its route based on test results and external control instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed assembly line with conveyer is used, then assembly sequence is enforced and controlled, but assembly station use cannot be optimized and all vehicles are affected if the conveyer breaks down
Solution Approach 1:
The patent transforms the static fixed assembly line into a dynamic system where vehicles autonomously navigate to assembly stations. Each vehicle determines its own route and sequence based on real-time conditions, allowing the system to adapt to individual vehicle needs while maintaining overall production flow. This dynamic approach resolves the contradiction by enabling both optimization (vehicles choose efficient paths) and reliability (individual vehicle failures don't halt the entire line).
Solution Approach 2:
The patent segments the centralized conveyer control into individual vehicle control units. Each vehicle has its own controller that independently manages navigation, station selection, and assembly operations. This segmentation allows each vehicle to optimize its own assembly station usage while the system as a whole maintains reliability through distributed control - if one vehicle fails, others continue unaffected.
2Productivity
If a fixed assembly line conveyer is used, then assembly process is standardized, but assembly station use is restricted and productivity is reduced
Solution Approach 1:
The patent implements self-service by equipping each vehicle with autonomous navigation and decision-making capabilities. Vehicles independently determine their own assembly sequences, navigate to stations, and manage their assembly processes without external conveyer control. This self-service approach boosts productivity through optimized routing while the complexity is contained within individual vehicle units rather than the entire system.
Solution Approach 2:
The patent replaces the mechanical conveyer system with electronic and software-based autonomous navigation systems. Instead of physical conveyer belts enforcing movement, vehicles use sensors, processors, and control algorithms to navigate autonomously. This substitution reduces mechanical complexity while enabling higher productivity through flexible, intelligent route optimization.
3Reliability
If the conveyer breaks down, then all vehicles are affected, but switching to autonomous operation requires additional control systems
Solution Approach 1:
The patent creates a dynamic control architecture where vehicles can operate in multiple modes - autonomous normal operation and autonomous failure recovery. The same autonomous navigation system serves dual purposes: routine vehicle guidance and failure response management. This dynamic multi-functionality improves reliability without proportionally increasing complexity, as the system adapts its behavior based on operational conditions rather than requiring separate dedicated systems.
Solution Approach 2:
The autonomous control system is designed as a universal platform that handles multiple functions: normal navigation, station identification, assembly coordination, and failure recovery. This multi-functional design improves system robustness by enabling autonomous operation under various conditions while containing complexity within a single integrated control architecture rather than requiring separate systems for each function.
Data Source
AI summary
A partially assembled vehicle that autonomously completes its own assembly, including a chassis, wheels that are rotationally coupled to the chassis, a drive system mounted on the chassis and in operational communication with the wheels, a navigation system, a central platform controller, and a position determining system. Added thereto is a safety sensor guidance system and a controller circuit programmed to begin a temporary takeover of the central platform controller, responsive to an external fleet control. The temporary takeover including the steps of identifying a plurality of assembly stations that the partially assembled vehicle must visit to complete its own assembly; constructing a sequence in which to visit each of the plurality of assembly stations; and commanding the drive system to propel and steer the partially assembled vehicle through the sequence of the plurality of assembly stations, responsive to sensor input from the safety sensor guidance system.