Machine Reconfiguration Guidance With Sequenced Warning Devices
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Solution Overview
Problem
The operations of assembling/disassembling and changing the configuration of operating machines are often complicated, time-consuming, prone to human errors, and require specialized operators, leading to inefficiencies and potential safety hazards.
Innovation Solution
A system and method utilizing a support structure with warning devices and a control unit to guide operators through the assembly/disassembly process, ensuring correct piece placement and coordination among multiple operators, using identification devices and a portable device for real-time instructions and verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual procedures are used for assembling/disassembling operations, then operators have flexibility in performing tasks, but human errors increase and operation time extends
Solution Approach 1:
The system incorporates detection devices that automatically detect whether pieces are correctly mounted or dismounted, providing real-time feedback to the control unit. This feedback mechanism eliminates human error in assessing operational status while automatically advancing the instructional sequence, thereby reducing both errors and operation time.
Solution Approach 2:
The patent replaces manual mechanical assessment by operators with an automated detection system using sensors and detection devices. This substitution eliminates human error in detecting operational status while the automated control unit manages the instructional sequence, reducing both errors and time loss.
2Ease of operation
If complex manual procedures are followed, then complete configuration changes can be achieved, but operation complexity and time consumption increase
Solution Approach 1:
The control unit stores pre-programmed sequences of instructions that define the correct order of operations for assembly and disassembly. By preparing these sequences in advance, the system guides operators through complex procedures in a simplified, step-by-step manner, reducing both operational difficulty and time consumption.
Solution Approach 2:
The system dynamically adapts the instructional sequence based on real-time detection of operational status. The control unit automatically advances or pauses instructions based on detected piece positions, making the complex procedure appear simpler and faster to the operator without sacrificing completeness.
3Productivity
If multiple operators work simultaneously on configuration changes, then operations can be completed faster, but coordination difficulties and errors increase
Solution Approach 1:
The detection devices continuously monitor the operational status and provide feedback to the control unit, which coordinates instructions for multiple operators. This centralized feedback mechanism ensures all operators are synchronized on the current operational state, maintaining coordination accuracy while enabling parallel work to increase productivity.
Solution Approach 2:
The control unit serves as a universal coordination center that manages instructions for multiple operators simultaneously. It integrates detection data from various parts of the machine and provides coordinated instructions to multiple operators, enabling parallel work without coordination errors.
4Manufacturing precision
If detailed manual instructions are consulted, then operational accuracy is maintained, but attention is diverted from manual operations increasing error risk
Solution Approach 1:
The control unit acts as an intermediary that processes detection data and generates appropriate instructional commands. Instead of requiring operators to consult detailed manuals, the system automatically provides relevant instructions based on detected operational status, maintaining precision while keeping operator attention focused on manual tasks.
Solution Approach 2:
The system replaces manual consultation of detailed instructions with an automated instructional system. The control unit automatically determines the next required action based on detection device feedback and provides concise guidance, eliminating the need for operators to divert attention to detailed manuals while maintaining placement accuracy.
Data Source
AI summary
A system for assisting an operator in operations of assembling/disassembling and/or change of configuration of an operating machine including a plurality of first areas provided with respective first pieces to be dismounted from the operating machine or configured to receive respective second pieces to be mounted on the operating machine. The system includes a support structure having a plurality of second areas provided with the second pieces or configured to receive the first pieces; a plurality of warning devices, each being associated to a respective area of the first areas and/or second areas; and a control unit operatively connected to the warning devices and configured to perform a predetermined sequence of commands correlated to operations of a predetermined sequence of operations of assembling/disassembling and/or change of configuration of the operating machine. The control unit is configured to selectively activate and deactivate the warning devices according to the sequence of commands.