Flexible Fixture Orientation for Mixed Workpiece Assembly
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Solution Overview
Problem
In modern assembly lines, the manual process of determining and replacing fixtures for different workpieces introduces inefficiencies and delays, as each workpiece requires a specific fixture, leading to increased complexity and time consumption.
Innovation Solution
The implementation of flexible fixtures with automated systems that use detection devices, calibrators, and adjustable components to identify and orient workpieces correctly, allowing multiple workpiece types to be handled on the same assembly line, reducing manual intervention and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual determination of fixtures is used for each workpiece, then specific fixture matching is achieved, but assembly line efficiency deteriorates due to delays and manual intervention
Solution Approach 1:
The system enables self-service by allowing the workpiece to automatically identify itself through RFID tags or other detection methods. The workpiece type is automatically detected and the appropriate fixture is selected without manual intervention, resolving the contradiction between accurate matching and assembly line efficiency
Solution Approach 2:
The patent replaces manual mechanical operations with automated detection and control systems. Optical sensors, RFID readers, and computer-controlled fixture adjustment mechanisms substitute for manual fixture selection and positioning, maintaining accuracy while dramatically improving throughput
2Adaptability or versatility
If multiple different fixtures are used for different workpiece types, then workpiece specificity is improved, but system complexity worsens due to managing multiple fixture types
Solution Approach 1:
The patent implements universal fixtures that can accommodate multiple workpiece types through adjustable components and programmable positioning systems. A single fixture system performs multiple functions by adapting its configuration based on the detected workpiece type, eliminating the need for multiple specialized fixtures
Solution Approach 2:
The fixture system incorporates dynamic adjustment capabilities where components can be repositioned, reconfigured, or replaced automatically based on real-time detection of workpiece characteristics. This dynamic adaptability allows one fixture system to handle diverse workpiece types without manual reconfiguration
3Productivity
If automated detection and orientation systems are implemented, then assembly line efficiency is improved, but device complexity increases due to additional components
Solution Approach 1:
The patent merges detection, identification, and positioning functions into integrated systems. For example, RFID readers are combined with optical sensors and fixture adjustment mechanisms into unified automated workstations, reducing the number of separate components while maintaining automated functionality
Solution Approach 2:
The system introduces intelligent software controllers and sensors as intermediaries that coordinate between workpiece detection and fixture adjustment. These intermediaries automate the decision-making process, enabling high throughput without requiring complex mechanical systems for each individual adjustment
Data Source
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AI summary
A system and method for orienting a workpiece on an assembly line to prepare the workpiece for an operation is provided. The method includes positioning a flexible fixture on the assembly line. The flexible fixture has a base and at least one adjustable component. The workpiece is positioned on the flexible fixture. A first orientation of the workpiece relative to the flexible fixture is detected with a detection device and transmitted to a calibrator. The calibrator determines a difference between the detected first orientation of the workpiece and a predetermined fixture orientation and transmits instructions from the calibrator to the flexible fixture to move the workpiece from the detected first orientation to the predetermined fixture orientation. The workpiece is moved with the at least one adjustable component into the predetermined fixture orientation and is fixedly held with the adjustable component.