Chain Conveyor Obstacle Detection and Operator Ergonomics
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Solution Overview
Problem
In continuous moving production lines, there is a need to enhance production efficiency, ensure correct and safe manual assembly operations, monitor assembly status, accommodate parts of different types and sizes, and reduce operator physical stress while maintaining ease and speed of operation.
Innovation Solution
A production line with a movable implement for operators to perform assembly tasks alongside continuously moving pallets, equipped with front and rear hook units for pallet engagement and obstacle detection, automated component drawers, and a human machine interface for guidance and feedback, allowing operators to work ergonomically and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly operations are executed by operators on continuously moving pallets, then productivity is improved, but operator safety and ease of operation deteriorate due to physical stress and safety risks
Solution Approach 1:
The implement is designed to be freely movable along the transport direction of pallets, allowing operators to position it dynamically as they follow moving pallets. This dynamic positioning capability enables operators to perform assembly tasks ergonomically while maintaining safety, resolving the contradiction between productivity improvement through continuous movement and operator safety/comfort
Solution Approach 2:
The implement acts as an intermediary tool between the operator and the continuously moving pallets. It provides a stable working platform that moves with the pallets while allowing the operator to maintain a safe distance and ergonomic posture, thus improving productivity without compromising operator safety and comfort
2Productivity
If continuous movement of pallets is maintained through assembling stations, then productivity is improved, but the ability to detect and respond to obstacles deteriorates
Solution Approach 1:
The rear hook unit is equipped with optical sensors that provide continuous feedback about obstacles in the path of moving pallets. When an obstacle is detected, the system generates a command signal to stop the chain conveyor, maintaining continuous production flow while enabling real-time obstacle detection and response
Solution Approach 2:
The optical sensors are positioned in advance to detect obstacles before they become a problem. The rear hook unit moves to an optical beam interception position proactively, allowing the system to stop the conveyor before obstacles can cause damage or safety issues, thus maintaining continuous production while enabling early obstacle detection
3Manufacturing precision
If automated systems are introduced to assist operators, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The implement is designed as a multi-functional device that combines mechanical support, optical sensing, and control capabilities in a single integrated structure. This universality allows automated assistance functions to be added without proportionally increasing overall system complexity, thereby improving assembly correctness while managing device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables immediate reporting of obstacles, ensures correct operation and safety, facilitates easy and efficient manual assembly, and provides continuous monitoring of assembly status, reducing operator stress and improving productivity.
Implementation Method 1
said rear hook unit being also adapted to move, in this condition, to an optical beam interception position, in which a first interception element which is part of the rear hook unit intercepts a first optical beam emitted by a first optical sensor
Data Source
AI summary
A production line including a chain conveyor for moving part transporting pallets through an electronically controlled workstation. The workstation includes an implement for use by a workstation user which is freely movable along the transport direction of the pallets within the workstation. The workstation may further include a plurality of automated drawers containing components for manual assembly operations in the workstation. The chain conveyor includes front hook and rear hook units to engage the pallet for movement along the production line. When the pallet is prevented from further movement by an obstacle, the chain rear hook moves from a pallet engaged position to a position whereby an optical beam is interrupted. On interruption of the optical beam, a command signal is generated which causes the conveyor to stop.