Wire Harness Formboard Manipulator with Elevator and Tilting Mechanism
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Solution Overview
Problem
The manual manipulation of large wire-harness formboards, which can weigh up to 150 pounds and measure up to 50 inches wide and 100 inches long, requires significant effort and often multiple operators, posing a challenge in efficiently transporting and positioning them at assembly workstations.
Innovation Solution
An apparatus comprising a base portion with a vertically movable elevator, a pivotably coupled tilting portion, and holders that allow for controlled movement and positioning of the formboards, including a low-friction surface for easy sliding and a self-contained power source for automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual manipulation of formboards is used, then device complexity is reduced, but ease of operation deteriorates due to bulk and weight requiring multiple operators
Solution Approach 1:
The patent replaces manual mechanical manipulation with an automated mechanical system comprising an elevator portion for vertical movement and a tilting portion for angular positioning. This substitution eliminates the need for multiple operators to manually handle the heavy formboards while providing controlled, precise movement through automated mechanical actuators.
Solution Approach 2:
The formboard manipulation system performs its own positioning and movement functions through integrated automated mechanisms. The elevator and tilting portions work together to automatically transport formboards from storage to workstations without requiring external manual intervention, enabling the system to serve itself in the material handling task.
2Productivity
If automated manipulation apparatus is introduced, then productivity is improved, but device complexity increases due to multiple movable portions and holders
Solution Approach 1:
The automated manipulation apparatus is divided into distinct functional segments: a base portion, an elevator portion for vertical movement, and a tilting portion for angular positioning. Each segment performs a specific function, allowing the complex task of formboard manipulation to be broken down into manageable, independently controlled components that can be optimized separately.
Solution Approach 2:
The apparatus employs dynamic, movable components including the elevator portion that can vertically translate and the tilting portion that can pivot to various angles. This dynamic design allows the system to adapt its configuration to different formboard sizes and workstation positions, enhancing productivity through flexible, automated adjustment rather than fixed mechanical structures.
3Loss of time
If formboards are transported manually, then device complexity remains low, but loss of time increases due to multiple operators and considerable effort required
Solution Approach 1:
The system performs preliminary positioning actions by using the elevator portion to vertically transport formboards to the desired height before the tilting portion rotates them into the final horizontal position at the workstation. This preliminary vertical positioning eliminates the need for operators to manually lift and carry heavy formboards, significantly reducing the time required for formboard deployment.
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
The apparatus facilitates the efficient and automated manipulation of large formboards, reducing manual effort and enabling single-operator handling, thereby improving workplace safety and productivity by allowing for easier transportation and positioning at workstations.
Implementation Method 1
a low-friction surface for easy sliding
Data Source
AI summary
In one aspect, an apparatus for manipulating a sheet includes a base portion, and an elevator portion coupled to the base portion, where the elevator portion is vertically movable relative to the base portion. The apparatus also includes a tilting portion pivotably coupled to the elevator portion, where a virtual plane is parallel to the tilting portion. In addition, the apparatus includes at least one first holder and at least one second holder coupled to the tilting portion, where at least one first holder and at least one second holder oppose each other.