Manipulator Arm Assembly Layout for Shorter, Flexible Production Lines
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Solution Overview
Problem
Existing assembly plants for multicomponent items face challenges in achieving high productivity and flexibility, as they require multiple stationary assembly stations, leading to increased resource use and prolonged production times.
Innovation Solution
An assembly method and plant that allows sub-assemblies to be assembled in a suspended-in-air position, using manipulator arms to form a joint assembly, which is then positioned directly onto a receiving component without additional support, reducing the need for stationary assembly stations and enabling simultaneous pre-assembly of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple stationary assembly stations are used to assemble multicomponent items, then assembly operations can be performed, but the assembly line length increases and resource consumption increases
Solution Approach 1:
The patent transitions from traditional horizontal assembly stations to a vertical assembly configuration where components are assembled in a suspended-in-air position. The manipulator arms operate in a three-dimensional workspace above the receiving component, eliminating the need for multiple sequential horizontal stations and reducing the overall assembly line length.
Solution Approach 2:
The patent combines multiple assembly operations into a single integrated assembly station. Instead of having separate stations for different assembly tasks, the manipulator arms can perform multiple assembly operations simultaneously or sequentially at one location, merging the functionality of what would traditionally require multiple stations.
2Ease of manufacture
If multiple stationary assembly stations are used, then assembly operations can be completed, but production time increases
Solution Approach 1:
The patent enables continuous assembly operations by eliminating the need for components to be transported between multiple stationary stations. The receiving component remains in a fixed position while manipulator arms bring sub-assemblies to it, allowing assembly operations to proceed without interruption and reducing total production time.
Solution Approach 2:
The patent allows sub-assemblies to be prepared and positioned in advance by the manipulator arms before final assembly. The system can pre-position multiple sub-assemblies and then quickly assemble them onto the receiving component, reducing the actual assembly time and overall production cycle.
3Ease of manufacture
If traditional assembly stations are used, then assembly can be performed, but flexibility to adapt to construction variants is reduced
Solution Approach 1:
The patent employs dynamic manipulator arms that can be reprogrammed and repositioned to accommodate different construction variants. Unlike fixed assembly stations, the manipulator arms can adapt their movement paths, gripping positions, and assembly sequences through software control, enabling quick adaptation to different product configurations without physical reconfiguration.
Solution Approach 2:
The manipulator arms serve multiple functions: they can grasp different types of sub-assemblies, position them in various orientations, and perform different assembly operations. This universal capability allows a single assembly station to handle multiple product variants, increasing flexibility and adaptability.
Data Source
AI summary
A method for assembling sub-assemblies to a receiving component in an assembly plant involves providing at least one assembly station, one or more sub-stations proximal to the assembly station, and at least one assembly device, the receiving component temporarily stopping in the assembly station, picking at least two sub-assemblies from the one or more sub-stations, and keeping the receiving component in a stationary status at least during assembling, by the at least one assembly device, the two sub-assemblies with the receiving component. In the stationary status, the receiving component remains in a same assembly status and/or in a same position and/or does not undergo other operations until the receiving component receives the at least two sub-assemblies. An assembly plant and an assembly line including the assembly plant are provided.