Component Feed Unit Preparation With Dual Conveyance Robots
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Solution Overview
Problem
The existing loading operations for component supply units require significant manual labor and result in complex management due to work-in-process components that cannot be diverted to other uses, despite some automation efforts.
Innovation Solution
A component supply unit set-up system incorporating a container warehouse, unit storage shed, operation table, container conveyance robot, and unit conveyance robot to automate the conveyance of component containers and supply units, reducing manual labor and optimizing operations before and after loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading operation is used, then flexibility in handling component supply units is maintained, but labor requirements and management complexity increase significantly
Solution Approach 1:
The system divides the component supply unit preparation process into distinct functional zones: a storage area for component supply units, a loading area for container loading operations, and a conveyance area for transporting loaded units to the component mounter. This spatial segmentation allows automated robots to handle specific tasks in designated areas, reducing management complexity while maintaining operational flexibility.
Solution Approach 2:
A conveyance robot acts as an intermediary between the loading area and the component mounter, automatically transporting loaded component supply units. This intermediary device eliminates the need for manual handling and tracking of work-in-process units, thereby reducing labor requirements and management complexity without sacrificing operational flexibility.
2Productivity
If loading operation is performed ahead of schedule, then production plan is ensured, but work-in-process component supply units accumulate and require additional management
Solution Approach 1:
The system performs loading operations in advance by maintaining a storage area where component supply units are pre-loaded with containers before being needed at the component mounter. This preliminary action ensures production plans are met while the automated conveyance system manages the timing and transport of loaded units, preventing accumulation and reducing management complexity.
Solution Approach 2:
The system incorporates control mechanisms that monitor the status of component supply units throughout the process. This feedback enables intelligent decision-making about when to load, store, or convey units, ensuring that work-in-process inventory is optimized rather than accumulated, thereby maintaining productivity without increasing management complexity.
3Extent of automation
If automated container loader is used, then labor saving in loading operation is achieved, but related operations before and after loading still require manual labor
Solution Approach 1:
The system merges the automated container loader with automated conveyance robots and a centralized control system. The container loader automates the loading operation, while conveyance robots automatically transport both empty component supply units to the loading area and loaded units to the component mounter. This combination eliminates all manual operations before and after loading, achieving comprehensive automation and improving ease of operation.
Data Source
AI summary
A component supply unit set-up system includes a container warehouse configured to store multiple component containers for containing multiple components, a unit storage shed configured to store multiple component supply units used when the component, which is contained in the component container, is supplied in a mounting operation performed by a component mounter, a work table disposed between the container warehouse and the unit storage shed and used for a loading operation of loading the component supply unit with the component container, a container conveyance robot configured to convey the component container between the container warehouse and the work table, and a unit conveyance robot configured to convey the component supply unit between the unit storage shed and the work table.