Disassemblable Mast for Paint Conveyor Ergonomics
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Solution Overview
Problem
The existing paint conveyor systems for motor vehicle body parts are limited by ergonomic constraints, restricting the loading height to 170 cm, which reduces the load capacity and production efficiency, especially with larger body parts like bumper skins, as they cannot accommodate multiple parts simultaneously due to overcrowding and spatial constraints.
Innovation Solution
A disassemblable mast system composed of two parts that can be automatically coupled and decoupled by robots, allowing the mast to reach higher heights in automated areas and maintaining ergonomic loading heights in manual areas, enabling more parts to be painted simultaneously and improving operational ergonomics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the loading height is increased above 170 cm to improve production capacity, then more parts can be painted simultaneously, but ergonomic constraints make manual loading and unloading difficult or impossible
Solution Approach 1:
The mast is divided into two separate parts: a lower part that remains at ergonomic height for manual operations, and an upper part that extends higher for increased capacity. This segmentation allows the system to simultaneously achieve both ergonomic loading conditions and higher production capacity by enabling automated assembly of the two-part mast structure.
2Productivity
If the number of paint conveyors is doubled to increase production capacity, then more parts can be painted, but the investment cost becomes unthinkable
Solution Approach 1:
The mast structure transitions from a fixed single-piece design to a dynamic two-part configurable system. The lower and upper parts can be assembled and disassembled automatically, allowing the same physical infrastructure to accommodate varying production requirements without requiring additional paint conveyor installations.
3Adaptability or versatility
If larger body parts like bumper skins are painted, then product variety is improved, but fewer parts can fit on one support device due to overcrowding
Solution Approach 1:
The support capacity is extended vertically by adding the upper mast part, utilizing the vertical dimension rather than horizontal space. This allows larger body parts like bumper skins to be painted while maintaining adequate spacing, as the extended height provides additional room for part arrangement without increasing horizontal footprint.
Data Source
Figure 1A~1B
Figure 2~3
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AI summary
The invention concerns a component support device (10) for supporting components (20) when painting said components (20), comprising at least one support member (30, 40) for supporting one of the components (20) and supported by a substantially vertical support mast (50), characterized in that the support mast (50) comprises at least one lower portion (60) and one upper portion (70) which can be assembled and disassembled