Dynamic Conveyor Switching for Robotic Motion Devices
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Solution Overview
Problem
Current robotic systems lack automatic switching to alternate conveyors when production machines become non-operational, requiring manual intervention and resulting in significant production downtime.
Innovation Solution
A conveyor system and method that dynamically switches active work associated with motion devices by using load balance groups and feedback data from production machines to selectively control motion devices, ensuring continuous operation with operational conveyors and minimizing part misses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual switching to alternate conveyors is implemented when production machines become non-operational, then robots can be redirected to operational conveyors, but significant production downtime occurs due to manual intervention requirements
Solution Approach 1:
The system implements automatic feedback mechanisms where sensors detect the operational state of production machines and conveyors, and the controller automatically receives this feedback data to determine when switching to alternate conveyors is necessary, eliminating manual intervention and reducing production downtime
Solution Approach 2:
The robotic system performs self-switching to alternate conveyors based on automated detection of production machine state changes, allowing the system to service itself by redirecting robots without requiring external manual intervention, thereby maintaining continuous productivity
2Loss of time
If automatic switching to alternate conveyors is implemented using sensor detection, then production downtime is reduced, but redundant sensing occurs causing parts to be missed by robots
Solution Approach 1:
The system dynamically adjusts the sensing and switching process by activating sensors only when state changes are detected, and by coordinating the timing of robot movements with conveyor switching to eliminate redundant sensing operations, thereby maintaining high picking efficiency while enabling automatic switching
Solution Approach 2:
The controller receives feedback data about production machine state changes in advance and initiates the conveyor switching process before parts are affected, allowing robots to continue their picking operations without interruption or redundancy, thus preventing part misses while reducing production downtime
3Extent of automation
If robots continuously monitor production machine states for automatic switching, then switching responsiveness is improved, but system complexity increases
Solution Approach 1:
The controller is designed with multi-functionality, serving both as the primary control unit for robot operations and as the feedback reception unit for production machine state monitoring, eliminating the need for separate dedicated monitoring devices and reducing overall system complexity while maintaining high automation
Data Source
AI summary
A conveyor system and a method for dynamically switching an active work associated with a motion device, the system including a plurality of conveyors for moving at least one part, at least one production machine associated with at least one of the conveyors, at least one motion device to move the at least one part, a controller associated with the at least one motion device, wherein the controller is in data communication with the at least one production machine to receive a feedback data therefrom, the feedback data representing a state of the production machine, and a software system executed by the controller to dynamically and selectively control the at least one motion device in response to the feedback data.