Asynchronous Cable Assembly Transport for Flexible Station Layout
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Solution Overview
Problem
Existing systems for assembling electrical cables are limited by synchronous movement of workpiece carriers, leading to underutilization of process stations with shorter processing times and rigidly fixed distances between stations, which restricts production capacity and flexibility.
Innovation Solution
An asynchronous and pitch-free transport device with independently driven workpiece carriers allows for flexible arrangement of process stations, enabling simultaneous processing at multiple stations and flexible spacing, utilizing the machine base with a welded frame for stability and adjustable supports to reduce manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If synchronous movement of workpiece carriers is used, then the system structure is simple and fixed, but the production capacity is limited by the longest processing time and process stations with short processing times remain underutilized
Solution Approach 1:
The patent applies dynamics by transitioning from synchronous to asynchronous movement of workpiece carriers. Each workpiece carrier is independently controllable, allowing different carriers to move at different times and speeds based on processing requirements. This dynamic control enables process stations with short processing times to be revisited multiple times within a cycle, maximizing their utilization and overall production capacity.
Solution Approach 2:
The system segments the workpiece carriers into independently controlled units, each capable of autonomous movement and positioning. This segmentation allows the transport system to be divided into multiple independent zones that can operate semi-autonomously, enabling flexible routing and timing for each carrier without being constrained by a unified synchronous cycle.
2Adaptability or versatility
If fixed pitch transport is used, then the transport device is simple to control, but the distance between process stations is rigidly fixed and space utilization is poor
Solution Approach 1:
The transport device implements dynamic positioning where workpiece carriers can be stopped, started, and positioned at variable locations along the transport path. This allows the distance between process stations to be flexibly adjusted based on processing requirements and available space, rather than being fixed by a predetermined pitch.
Solution Approach 2:
The control system acts as an intermediary between the transport device and process stations, coordinating their operations. This intermediary control enables flexible station arrangement by managing the timing and positioning of workpiece carriers dynamically, allowing stations to be placed at optimal locations without being constrained by fixed pitch requirements.
3Area of stationary object
If process stations are arranged with fixed distances, then the system layout is simple, but the available space is not optimized and neighboring stations cannot be flexibly arranged
Solution Approach 1:
The system employs dynamic positioning of workpiece carriers that allows process stations to be arranged at variable distances and locations. This enables optimization of space utilization by placing stations closer together where processing is fast or farther apart where processing is slow, without requiring a fixed pitch structure.
Solution Approach 2:
The transport system allows different local conditions for different sections of the production line. Each segment between process stations can have different characteristics (speed, timing, positioning) optimized for the specific processing requirements of neighboring stations, rather than applying a uniform fixed pitch throughout the entire system.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A module (2) for a system (1) for the assembly of electrical cables comprises a machine base on which at least one process station for processing electrical cables can be mounted, and an asynchronous and pitch-free transport device for transporting at least one of the electrical cables to and/or away from the at least one process station.