High Density Manufacturing Cell Vertical Carousel
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Solution Overview
Problem
Existing manufacturing systems face inefficiencies in space utilization and material travel paths, limiting their ability to optimize floor space and increase production speed and flexibility.
Innovation Solution
A high-density manufacturing cell or carousel design featuring vertically stacked rotary platforms, external cylindrical housing, and a vertical walking beam with grippers that transfer products between platforms, allowing simultaneous processing and flexible layout planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional manufacturing systems are used, then production processes can be performed, but floor space utilization is poor and equipment footprint is large
Solution Approach 1:
The patent transitions from a traditional horizontal linear arrangement of manufacturing stations to a vertical three-dimensional carousel structure. Multiple product carriers are stacked vertically on rotating platforms, enabling simultaneous processing of multiple products at different heights. This vertical dimensionality change dramatically reduces the horizontal floor space required while maintaining high production throughput and efficiency.
2Length of stationary object
If linear manufacturing layouts are used, then material flow is simple, but material travel path is long
Solution Approach 1:
The patent reconfigures the material flow path from a long horizontal linear trajectory to a compact vertical circular path. Products are transferred between carriers through vertical movement within the carousel structure, reducing the overall material travel distance. The rotational mechanism enables efficient positioning and transfer at different vertical levels without requiring long horizontal conveyance paths.
Solution Approach 2:
The patent integrates multiple functions into the carousel structure: product carriers serve as both processing stations and transport units, while the rotating platforms combine positioning and transfer functions. This merging of functions reduces the need for separate material handling systems and minimizes the overall material travel path within a compact footprint.
3Area of stationary object
If multiple separate machines are used, then each process can be specialized, but equipment footprint is large
Solution Approach 1:
The patent designs the product carriers and processing stations with universal, interchangeable components that can accommodate different product types and process requirements. The modular carrier design allows for quick reconfiguration of tools, fixtures, and processing parameters, enabling the same carousel structure to perform multiple specialized functions. This multi-functionality reduces equipment footprint while maintaining process flexibility and adaptability.
Solution Approach 2:
The patent implements dynamically reconfigurable processing stations with adjustable tools, movable fixtures, and programmable control systems. These dynamic elements allow the equipment to adapt to different product configurations and process sequences, providing the flexibility of multiple specialized machines within a single compact carousel structure, thereby reducing the overall equipment footprint.
4Speed
If sequential product transfer is used, then processing is simplified, but production speed is limited
Solution Approach 1:
The patent implements continuous rotational movement of the carousel platforms, allowing multiple product carriers to be processed and transferred simultaneously at different vertical levels. This continuous motion eliminates idle time between transfers and enables overlapping processing cycles, significantly increasing production speed. The synchronized vertical and rotational movements ensure smooth, continuous product flow without interruptions.
Solution Approach 2:
The patent positions and prepares multiple product carriers in advance at different vertical levels before they reach the transfer point. The carousel system pre-positions carriers with required tools and fixtures, and sequences their arrival at transfer stations to enable continuous, high-speed operation. This preliminary preparation eliminates waiting time and maintains maximum production velocity.
Data Source
AI summary
A high density manufacturing cell or carousel for optimizing floor space usage to reduce equipment footprint and material travel path is disclosed. The carousel allows processing and transferring of products to be concurrently performed, minimising non-productive time. The manufacturing cell or carousel comprises: (a) a plurality of rotary platforms, (b) a plurality of vertical moving platforms, (c) a vertical walking beam, and (d) a load gripper and a unload gripper mounted to independent robots.