Variable-Height Barrier Reach Measurement System
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Solution Overview
Problem
In the manufacturing industry, particularly in automobile assembly, there is a need to accurately and systematically measure the reach of assembly line workers at varying barrier heights to optimize task assignment and design tasks that match employee capabilities.
Innovation Solution
A system comprising a variable-height barrier with a sensing and recording device and a marking device that records data points as the worker bends forward, allowing for the conversion of these points into an interpolated arc, enabling precise measurement of reach capabilities at multiple barrier heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual measurement methods are used to assess worker reach, then the measurement process is simple and quick, but the measurement precision and systematic data collection are insufficient
Solution Approach 1:
The patent replaces manual visual estimation and simple tape measure methods with an automated electronic measurement system that uses sensors, data processing units, and digital recording to capture reach measurements, thereby improving precision while managing complexity through automation
Solution Approach 2:
The system creates a digital copy of the physical reach measurement process by recording data points, generating interpolated arcs, and storing results in a database, allowing for precise reproduction and analysis of reach capabilities without requiring repeated physical measurements
2Adaptability or versatility
If multiple barrier heights are tested to comprehensively assess worker capabilities, then the task assignment optimization improves, but the measurement time and process complexity increase
Solution Approach 1:
The system performs preliminary measurements at multiple barrier heights (24, 30, 36, 42, 48, 54, 60 inches) during the initial assessment, capturing comprehensive reach data across all relevant heights in one testing session, which then enables optimized task assignment without requiring repeated measurements for different heights
Solution Approach 2:
The measurement process continuously collects data points as the worker moves through the reach motion at each barrier height, maintaining continuous measurement throughout the motion arc rather than taking discrete spot measurements, thereby efficiently capturing complete reach profiles across multiple heights
3Loss of information
If detailed reach data is collected at multiple heights, then the task design optimization improves, but the data processing complexity increases
Solution Approach 1:
The system provides immediate feedback by displaying the interpolated reach arc on a screen during the measurement process, allowing verification of data quality in real-time, and automatically processes the collected data points into meaningful reach profiles that inform task design decisions
Solution Approach 2:
The complex measurement data is segmented into discrete data points that are individually recorded and then processed through interpolation algorithms to generate the continuous reach arc, breaking down the complex information into manageable components that can be systematically analyzed
Data Source
AI summary
A method and apparatus for measuring a subject's ability to perform a varying range of barrier reaches is provided. The apparatus includes a barrier having a substantially horizontal upper surface at a height above a base point. A sensing and recording device is positioned adjacent to the barrier for sensing and recording a plurality of data points. A marking device for grasping by the subject engages the sensing and recording device for creating the plurality of data points as the subject bends forward against the barrier. The data points are recorded and converted into an interpolated arc reflecting the subject's reach at the barrier height.