Cable Transfer Line Routing for Higher Assembly Station Utilization
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Solution Overview
Problem
Current cable harness production systems are limited by the variety of materials used in contact parts and individual wire seals, leading to low automation levels and poor utilization of stations due to linearly linked cross-transfer systems, which become costly and error-prone.
Innovation Solution
A displacement device with a transport system and grippers that connects multiple assembly systems to stations, allowing for flexible assignment and utilization of materials, featuring an input sorting system, transfer lines, and an output sorting system to manage and distribute assembled cables efficiently, enabling higher material variety and station utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a linearly linked cross-transfer system is used to connect assembly stations, then the structure is simple and easy to implement, but the system becomes costly and error-prone while maintaining the same output, and stations for rarely used contact parts have very low utilization
Solution Approach 1:
The patent implements a dynamic transport system where the number and configuration of transport lines can be flexibly adjusted based on production demands. Multiple transport lines can be actively used during high-demand periods for common contact parts, while lines for rare contact parts can be deactivated or repurposed, enabling the system to adapt its complexity to match actual utilization needs and avoid the inefficiency of fixed linear structures
Solution Approach 2:
The transport system is designed with universal, interchangeable components that can serve multiple functions. Transport lines can be dynamically assigned to different contact parts based on demand, and assembly stations can handle various types of contact parts through configurable tooling. This multi-functionality allows the same physical infrastructure to support both high-volume common parts and low-volume rare parts efficiently
2Adaptability or versatility
If additional assembly stations are added to handle more material variety, then the system can accommodate more contact parts and seals, but the overall structure becomes more costly and error-prone
Solution Approach 1:
Instead of expanding the system horizontally by adding more linear stations, the patent introduces vertical dimensionality through multiple overlapping transport lines that operate in parallel. This allows the system to accommodate greater material variety by routing different contact parts through different lines to appropriate stations, effectively adding capacity without proportionally increasing structural complexity or error probability
Solution Approach 2:
The patent introduces intelligent routing and control systems as intermediaries between the transport lines and assembly stations. These intermediaries optimize the flow of different contact parts through the system, dynamically assigning tasks to available stations and coordinating transport line operations. This intermediary layer enables the system to handle diverse materials efficiently without requiring a proportional increase in physical infrastructure
3Adaptability or versatility
If stations are maintained for rarely used contact parts in a linear system, then all contact parts can be handled, but the stations have very low utilization and the system becomes less efficient
Solution Approach 1:
The transport system dynamically routes contact parts based on real-time demand and station availability. When common contact parts are being produced, the system actively utilizes multiple transport lines and assembly stations. When rare contact parts need to be produced, the system dynamically reconfigures routing to activate previously underutilized stations, ensuring high utilization rates across all stations regardless of the contact part type being produced
Data Source
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AI summary
A transfer device is proposed for transporting a pre-assembled cable from one of a plurality of assembly machines to one of a plurality of assembly stations. The device comprises a transport system and a plurality of transport grippers, wherein the transport system is configured to connect the plurality of assembly machines to the plurality of assembly stations, and wherein the transport grippers are configured to transport a pre-assembled cable along the transport system from one of the plurality of assembly machines to one of the plurality of assembly stations.The transport system comprises an inbound sorting system, at least one transfer line, and an outbound sorting system, wherein the inbound sorting system is configured to connect the plurality of assembly systems to a first end of the at least one transfer line, and wherein the outbound sorting system is configured to connect a second end of the at least one transfer line to the plurality of assembly stations.