Industrial IoT Architecture for Production Line Balance Control

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Solution Overview

Problem

Current production line balancing methods are time-consuming, labor-intensive, and prone to errors due to manual data collection and processing, leading to increased costs and potential overcapacity, especially when dealing with multiple production lines.

Innovation Solution

An Industrial Internet of Things (IoT) system with a five-platform structure, including a user platform, service platform, management platform, sensor network platform, and object platform, which enables centralized data processing and transmission, reducing manual labor and errors by automating the collection and calculation of production line balance rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual data collection and processing methods are used to calculate production line balance rates, then the process can be completed with simple tools, but it becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvesimplicity of toolsVSAvoidtime consumption

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical data collection and calculation methods with an automated computer-based system. Sensors automatically collect working hour data from production equipment, and a computer automatically calculates the production line balance rate using the formula: balance rate = (sum of working hours of all workstations) / (number of workstations × bottleneck time) × 100%. This substitution eliminates manual labor and significantly reduces time consumption while maintaining simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If manual data collection is performed for multiple production lines, then flexibility in handling different production scenarios is maintained, but the workload increases and errors become more frequent

Engineering Contradiction:

ImproveflexibilityVSAvoidworkload

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent creates a universal automated system that can handle multiple production lines simultaneously. The computer-based calculation system processes data from numerous workstations across different production lines using the same algorithm, making the system adaptable to various production scenarios while reducing the workload. The system automatically identifies bottleneck workstations and calculates balance rates for each production line without requiring separate manual processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system enables self-service by automatically collecting data from sensors on production equipment and performing calculations without human intervention. The computer automatically processes working hour data, identifies bottlenecks, and generates balance rate results, eliminating the need for manual data collection and reducing both workload and error frequency while maintaining flexibility for different production configurations.

Inventive Principle:

Principle #25Self-service

3Productivity

If production line balance rate is increased to improve overall efficiency, then waiting time at each workstation decreases, but manufacturing costs increase and equipment load becomes excessive

Engineering Contradiction:

Improveoverall efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent implements a feedback mechanism where the automatically calculated production line balance rate provides real-time information about production line performance. This feedback enables managers to monitor the balance rate and make informed decisions about whether to pursue further balancing improvements. By having accurate, easily obtainable balance rate data, the system allows for optimized decision-making that balances productivity gains against increasing costs and equipment load, preventing excessive pursuit of balance rate improvement.

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If manufacturing parameters are adjusted to change production line balance rate, then production requirements can be met, but verification requires recalculating the balance rate which increases time and cost

Engineering Contradiction:

ImproveadjustabilityVSAvoidverification time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent replaces manual verification processes with automated computer-based recalculation. When manufacturing parameters are adjusted, the system automatically recalculates the production line balance rate using the same automated process that initially measured it. This substitution makes verification quick and inexpensive, enabling frequent adjustments and easy verification without significant time or cost investment, thereby improving adaptability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11579593B1Industrial Internet of Things and methods for controlling production line balance rate

Publication Date: 2023.02.14 CHENGDU QINCHUAN IOT TECH CO LTD

AI summary

The present disclosure relates to an Industrial Internet of Things (IoT) and a method for controlling a balance rate of a production line. The Industrial IoT includes an user platform, a service platform, a management platform, a sensor network platform, and an object platform interacting in sequence, the service platform adopts a centralized arrangement, the management platform adopts an independent arrangement, and the sensor network platform adopts a rear sub-platform arrangement.