Flexible Conveyance System With Linear Motors
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Solution Overview
Problem
Conventional material handling systems for assembly-line fabrication, such as those in automotive manufacturing, face limitations including bulky transfer frames and carriers that hinder maintenance access, lack of flexibility, and require synchronized movement through stations, restricting independent operation and flexibility.
Innovation Solution
A flexible conveyance system utilizing station track segments with linear motors and actuation structures, including locating fixtures, elevators, lifts, and turnarounds, to position and displace carriers independently, allowing for precise alignment and movement between stations without the need for overhead conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional overhead track systems with transfer frames and carriers are used, then material handling can be achieved, but maintenance access is blocked and the system becomes bulky
Solution Approach 1:
The system divides the overhead conveyance function into separate segments: stationary overhead tracks remain fixed for structural support, while mobile robots provide the conveyance function. This segmentation eliminates the need for bulky transfer frames and carriers, creating clear maintenance access pathways underneath the tracks.
Solution Approach 2:
The patent replaces the mechanical transfer frame and carrier system with autonomous mobile robots that travel along overhead tracks. This substitution eliminates the physical bulk of traditional conveyance mechanisms while maintaining the material handling function, thereby improving maintenance access.
2Adaptability or versatility
If carriers are communally tied to overhead conveyer, then synchronized movement is achieved, but flexibility and independent operation are lost
Solution Approach 1:
The system segments the conveyance function by equipping each carrier with its own independent mobile robot. This allows each carrier to operate independently rather than being tied to a communal overhead conveyer, enabling flexible routing decisions at each station without complex synchronized control.
Solution Approach 2:
Each mobile robot on a carrier is self-contained and autonomously controls its own carrier's movement and operations. This self-service capability eliminates the need for complex centralized control systems that coordinate multiple carriers, thereby improving flexibility while reducing control complexity.
3Productivity
If constant movement pattern through stations is enforced, then synchronized processing is achieved, but carriers cannot bypass unnecessary stations and productivity is reduced
Solution Approach 1:
The system introduces dynamic routing capabilities where mobile robots can independently decide whether to stop at each station based on real-time production requirements. Carriers can dynamically bypass unnecessary stations or return to previous stations, transforming the rigid constant-movement system into a flexible adaptive system that optimizes throughput.
Solution Approach 2:
The patent enables variable movement parameters for each carrier, including speed, stopping decisions, and routing choices. Instead of enforcing a constant movement pattern, the system allows carriers to adjust their operational parameters based on station requirements, thereby improving productivity while maintaining operational simplicity.
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
This solution enhances flexibility and accessibility by enabling independent movement of carriers and stations, improving maintenance access and operational efficiency by allowing carriers to bypass unnecessary stations and move freely, thus streamlining the assembly process.
Implementation Method 1
At least one linear motor is disposed within the channel and cooperates with linear motors of the conveyance system track segments to receive and position a carrier on the station track segment
Data Source
AI summary
A conveyance system includes a plurality of feed-forward track segments aligned end-to end, each having an upwardly facing channel and at least one linear motor disposed in the channel. At least one carrier is supported for movement along the track segments. Each carrier includes at least one magnet that cooperates with the linear motors to move the carrier along the respective feed-forward track segments.