Component Preparation Device with Return Mechanism
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Solution Overview
Problem
Existing manufacturing systems face inefficiencies and reliability issues due to excess and incorrectly oriented components on the provision platform, leading to long cycle times and detection errors caused by the robot arm or gripper obstructing camera views during removal processes.
Innovation Solution
A production system with a component supply device featuring a feed device and a return device, both driven by an oscillating conveyor, ensures excess components are returned and incorrectly oriented ones are re-oriented, using an overhead conveyor and component sensors to maintain platform cleanliness and optimize component detection from below, allowing parallel feeding and reduced cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot arm or gripper is used to remove components from the provision platform, then component removal is automated, but the robot arm obstructs the camera view during removal process causing detection errors
Solution Approach 1:
The patent changes the detection dimension by positioning the camera below the provision platform to detect components from underneath, while the robot arm operates from above. This spatial separation in vertical dimensions eliminates the obstruction problem, allowing simultaneous component detection and robot arm operation without interference.
2Device complexity
If excess components are left on the provision platform, then component supply is simplified, but cycle times increase due to waiting for component availability
Solution Approach 1:
The patent implements a vibration mechanism that automatically manages the provision platform by shaking it to dislodge excess components and guide them toward overflow channels. This self-service mechanism continuously clears the platform without external intervention, ensuring a component is always available for removal and eliminating waiting times.
Solution Approach 2:
The vibration mechanism performs preliminary action by continuously preparing the provision platform in advance, shaking off excess components and positioning the next component for removal before it is needed. This proactive approach ensures component availability is maintained without waiting for the previous component to be removed.
3Quantity of substance
If the provision platform area is increased to accommodate multiple components, then component availability improves, but the area available for component detection increases leading to more detection errors
Solution Approach 1:
The patent extracts excess components from the provision platform area by implementing overflow channels that remove unnecessary components. This maintains a minimal component count on the platform (ideally one component at a time), ensuring the camera can detect the component without interference from surrounding components while still maintaining continuous availability.
4Manufacturing precision
If a vibratory conveyor is used to feed components, then component orientation and separation improve, but dust and dirt particles are generated causing contamination
Solution Approach 1:
The patent converts the harmful effect of vibration-generated dust and dirt into a beneficial cleaning mechanism. The same vibration that orients components also dislodges dust and dirt particles, guiding them toward overflow channels where they are removed. Thus, the vibration serves dual purposes: orienting components and cleaning the system.
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 system enhances the reliability and efficiency of component supply and removal by automatically managing excess components, preventing contamination, and ensuring continuous component availability without waiting times, thereby optimizing the manufacturing process.
Implementation Method 1
an overhead conveyor, with the overhead conveyor preferably comprising an Archimedean screw or a vibrating conveyor with a conveying path that runs spirally upwards
Implementation Method 2
the feed device and the return device are driven by a conveyor drive, preferably an oscillating conveyor drive
Data Source
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AI summary
The invention relates to a component preparation device (1) for a production plant (2), comprising: at least one preparation platform (5, 6) and at least one feeding unit (3, 4) for feeding components (10) to the preparation platform (5, 6). In order to return excess or incorrectly oriented components to the process, at least one return device (8, 9) is provided, extending from the region of the preparation platform (5, 6) and leading into the feeding unit (3, 4), preferably in the starting region thereof. The invention also relates to a production plant for producing assemblies (30) from individual components (10) and to a method for preparing and removing components (10) in a production plant (2).