Decentralized Assembly Sequencer with Wireless Communication
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Solution Overview
Problem
Existing product assembly systems require extensive wiring and lack flexibility, necessitating reconfiguration of wiring and reprogramming when manufacturing processes change.
Innovation Solution
A decentralized system with autonomous devices, each equipped with a presence sensor, signalling member, microcontroller, and communication interface, allowing for efficient management of assembly sequences and easy adaptation to new processes through a learning phase and communication line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a centralized sequencer with wiring to each storage bin is used, then the assembly sequence can be controlled, but the wiring infrastructure becomes unwieldy and the system lacks flexibility
Solution Approach 1:
The centralized sequencer is divided into distributed sequencers, with each storage bin having its own sequencer unit. This segmentation eliminates the need for extensive wiring to a central control point, as each unit independently manages its own sequencing logic while communicating with others via wireless communication.
Solution Approach 2:
Physical wiring connections are replaced with wireless communication between sequencer units. The mechanical/electrical infrastructure of cables and connectors is substituted by radio frequency or other wireless communication protocols, dramatically reducing physical complexity.
2Reliability
If extensive wiring is used to connect all components, then the system can function, but adapting to new manufacturing processes requires redone wiring and full reprogramming
Solution Approach 1:
The system transitions from a static wired configuration to a dynamic wireless network where sequencer units can be easily added, removed, or repositioned. The wireless communication allows the system topology to adapt dynamically to different manufacturing layouts without physical reconfiguration.
Solution Approach 2:
Each sequencer unit is designed as a universal module that can function with any storage bin and communicate with any other sequencer unit. This standardized interface and wireless communication protocol allow the same hardware to adapt to different manufacturing processes through software configuration rather than physical rewiring.
3Productivity
If a centralized control system is used, then assembly sequences can be managed, but the system requires unwieldy wiring and reconfiguration for process changes
Solution Approach 1:
Each sequencer unit autonomously manages its own storage bin and assembly steps, making decisions locally rather than requiring constant communication with a central controller. This self-service capability reduces the complexity of centralized control and eliminates the need for extensive wiring to a central point.
Solution Approach 2:
The sequencer units are pre-configured with assembly sequence logic and can independently execute their programmed instructions. This preliminary programming allows each unit to operate autonomously without requiring real-time reconfiguration or complex centralized coordination during operation.
Data Source
AI summary
The invention relates to a device (D2) employed in a system for facilitating the assembly of a product, said assembly being carried out by following one or more assembly sequences, an assembly sequence comprising several successive assembly steps graded by execution ranks, said device comprising:a presence sensor (C2),at least one signalling member (V2),a sequencer (SQ2) connected to the presence sensor (C2) and to the signalling member (V2), said sequencer comprising a microcontroller designed to manage said assembly sequence.The invention also relates to a system for facilitating the assembly of a product comprising several devices (D2) connected together via a communication line.