Machine Reconfiguration Guidance Using Sequenced Part Verification
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Solution Overview
Problem
The operations of assembling/disassembling and/or change of configuration of operating machines are often complex, time-consuming, and prone to human errors, leading to inefficiencies and safety risks, especially when multiple operators are involved.
Innovation Solution
A system and method that utilize warning devices and a control unit to guide operators through the correct sequence of operations, ensuring that the right pieces are mounted or dismounted from the operating machine to the support structure, using identification devices and verification signals to prevent errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual procedures and paper manuals are used to guide operators, then the system complexity remains low, but the operation time increases and error rates rise
Solution Approach 1:
The patent replaces manual procedures and paper manuals with an automated computer-based system that provides real-time guidance, warnings, and verification. This substitution of mechanical/manual systems with automated electronic systems reduces operation time and errors while managing complexity through software-based solutions.
Solution Approach 2:
The system enables self-service by allowing the machine to automatically guide operators through assembly/disassembly procedures, provide warnings about incorrect actions, and verify completion of steps without requiring external manual intervention or consultation of paper manuals.
2Productivity
If multiple operators work simultaneously on the machine, then the operation speed increases, but coordination difficulties and error risks increase
Solution Approach 1:
The system implements feedback mechanisms that provide real-time information to all operators about the current state of the machine and the steps being performed. This feedback loop ensures that multiple operators are coordinated through centralized control, reducing errors while maintaining high operation speed.
Solution Approach 2:
The control system serves multiple functions simultaneously: it guides individual operators, coordinates between multiple operators, provides warnings, verifies completion, and manages the overall assembly/disassembly process. This multi-functionality allows the system to handle complex multi-operator scenarios effectively.
3Reliability
If specialized operators are used to perform assembly/disassembly operations, then the operation accuracy increases, but the cost and training requirements increase
Solution Approach 1:
The system makes operators self-sufficient by providing them with all necessary guidance, warnings, and verification through the automated control system. This eliminates the need for specialized knowledge and extensive training, as the system itself becomes the expert guide for all operators regardless of their background.
Solution Approach 2:
The patent replaces the need for specialized human expertise with an automated computer-based guidance system that encapsulates all the knowledge and procedures. This substitution allows any operator to perform complex assembly/disassembly tasks with the same accuracy previously requiring specialized training.
4Adaptability or versatility
If pieces are stored in a warehouse and need to be selected and transported to the machine, then the availability of different configurations is maintained, but the operation time and error risks increase
Solution Approach 1:
The system performs preliminary actions by pre-organizing pieces in the warehouse according to the assembly/disassembly sequence and providing advance guidance to operators about which pieces to retrieve next. This preliminary organization and guidance reduces the time needed for piece selection and transport while maintaining versatility.
Data Source
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AI summary
A system (1) for assisting an operator in operations of assembling/disassembling and/or change of configuration of an operating machine (100) comprising a plurality of first areas (120) provided with respective first pieces (111) to be dismounted from said operating machine (100) or configured to receive respective second pieces (112) to be mounted on said operating machine (100). The system (1) comprises: - at least one support structure (10) comprising a plurality of second areas (20) provided with said second pieces (112) or configured to receive said first pieces (111); - a plurality of warning devices (30), each warning device (30) being associated to a respective area of said plurality of first areas (120) and/or of said plurality of second areas (20); - a control unit (60) operatively connected to said warning devices (30) and configured to perform a predetermined sequence of commands correlated to at least some operations of a predetermined sequence of operations of assembling/disassembling and/or change of configuration of the operating machine (100). The control unit (60) is configured to selectively activate and deactivate said warning devices (30) according to said sequence of commands.