Multi-Station Conveyor Layout to Cut Factory Dead Space
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Solution Overview
Problem
Existing working systems with parallel work stations face challenges in minimizing installation area and dead space while maintaining productivity, as the size of work stations cannot be substantially changed due to accessibility limitations for maintenance.
Innovation Solution
A working system with work stations arranged in series, where each station includes conveying units and positioning units to efficiently convey and work on workpieces, allowing for reduced installation area and dead space by juxtaposing and connecting conveying units between stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If work stations are disposed in parallel to increase productivity, then the number of workpieces processed per unit time increases, but a wide dead space is formed and installation area increases
Solution Approach 1:
The patent transitions from a parallel arrangement (horizontal dimension) to a series arrangement with vertical stacking of conveying units. By utilizing the vertical dimension and stacking conveying units one above another, the system maintains parallel processing capability while significantly reducing the horizontal footprint and dead space in the factory layout.
Solution Approach 2:
The patent implements nesting by placing conveying units and work stations in a hierarchical structure where one conveying unit is positioned above another. The fourth conveying unit is connected to the downstream portion of the second conveying unit, creating a nested configuration that allows multiple work stations to occupy overlapping spatial volumes, thereby reducing overall installation area.
2Loss of time
If work stations are disposed in parallel to shorten cycle time, then actual cycle time decreases, but dead space region increases
Solution Approach 1:
By stacking conveying units vertically and connecting them in series, the patent eliminates the lateral dead space that would normally exist between parallel work stations. The vertical arrangement allows workpieces to be processed in parallel through different conveying units while maintaining a compact horizontal footprint, thus reducing dead space while preserving cycle time improvements.
3Area of stationary object
If distance between work stations is shortened to reduce installation area, then installation area decreases, but maintenance accessibility is compromised
Solution Approach 1:
The patent divides the conveying system into discrete, modular conveying units (first, second, third, and fourth conveying units) that are connected in series. Each conveying unit can be independently accessed and maintained, and the modular design allows maintenance personnel to reach each unit without requiring excessive clearance between work stations, thus maintaining accessibility while reducing overall installation area.
4Area of stationary object
If work stations are arranged in series to reduce dead space, then installation area decreases, but productivity may be reduced compared to parallel arrangement
Solution Approach 1:
The patent designs the conveying units to serve multiple functions: they convey workpieces sequentially through the series arrangement while also enabling parallel processing capabilities. Each conveying unit can handle workpieces independently, and the system can dynamically route workpieces through different paths, thus maintaining high productivity while achieving compact installation through the series configuration.
Data Source
AI summary
A working system includes a first work station and a second work station. The first work station includes a first conveying unit, a second conveying unit, a first positioning unit, and a first work unit that carries out a predetermined work for a workpiece positioned on the first conveying unit. The second work station includes a third conveying unit, a fourth conveying unit, a second positioning unit, and a second work unit that carries out a predetermined work for the workpiece positioned on the fourth conveying unit. The third conveying unit is connected to a downstream portion of the first conveying unit, and the fourth conveying unit is connected to a downstream portion of the second conveying unit.