General-Purpose Cell Robot Motion Range Layout
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Solution Overview
Problem
Existing production systems face limitations in versatility and efficiency due to restricted line layout flexibility, high costs, and reduced production capacity, particularly in changing production configurations and accommodating various product types, as they require extensive pallets and conveyors, and are constrained by the size and operation area of robots and workpieces.
Innovation Solution
A production system with a general-purpose cell configuration that includes a base unit, parts supply unit, and processing area, where the robot has a wide motion range extending beyond the base unit, allowing for flexible line layouts and reduced costs by eliminating the need for pallets and conveyors, and enabling efficient processing and transportation through a bucket-brigade method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a production system uses traditional conveyor-based cell configuration with dedicated pallets for each workpiece type, then workpiece transportation and processing can be achieved, but the system requires a large number of pallets, increases device complexity, and limits production capacity
Solution Approach 1:
The patent applies universality by using a single standardized tray that can hold multiple different workpiece types simultaneously. The tray is designed with a standardized structure that accommodates various workpieces through different positioning methods (direct placement, fixtures, or nesting), eliminating the need for dedicated pallets for each workpiece type. This multi-functional tray serves as a universal carrier for diverse products.
Solution Approach 2:
The patent merges the functions of multiple dedicated pallets into a single standardized tray. Instead of having separate pallets for different workpiece types, the system combines these functions by allowing one tray to hold and transport multiple different workpieces together, thereby reducing the total number of pallets needed and simplifying the overall system.
2Productivity
If a production system uses conveyor-based transportation, then workpiece transport between cells is achieved, but the production capacity is limited by the conveyor's transportation capacity
Solution Approach 1:
The patent extracts the conveyor system from the production line configuration. Instead of using conveyors to transport trays between cells, the system allows cells to directly exchange trays with each other through adjacent positioning. This removes the conveyor infrastructure and its capacity limitations, enabling cells to operate at their full processing speed without being bottlenecked by conveyor throughput.
3Ease of operation
If a production system uses robots placed on cell bases, then assembling operations can be performed, but the operation area is restricted by the base size and tray dimensions
Solution Approach 1:
The patent resolves the space conflict by utilizing vertical dimension. The robot is positioned on the side wall of the base unit rather than on the top surface, allowing the robot's operational arm to extend over the tray and work area without occupying horizontal space on the base. This vertical positioning enables a larger effective operation area while maintaining a compact base footprint.
Data Source
AI summary
In a production system general-purpose cell for general-purpose use in processing and transportation of a received workpiece in a production system of processing and delivering the workpiece, the production system general-purpose cell includes a base unit having a planar shape of quadrangle and supporting at least a robot for use in transportation of the workpiece such that the robot is movable on the planar area of quadrangle, a parts supply unit for supplying parts of the workpiece to the robot supported by the base unit, and a processing area extending outside the base unit. The robot supported by the base unit having a motion range set in a range from inside to outside the base unit in a form including at least part of the processing area.