Manufacturing Station Robot Integration for Cycle Time Reduction
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Solution Overview
Problem
Existing manufacturing stations face inefficiencies in utilizing time and space due to separate processes for loading, setup, and processing of workpieces, leading to suboptimal cycle times and robot utilization.
Innovation Solution
Integration of automatic and multifunctional loading robots within a protective partition, allowing for simultaneous loading, setup, and processing of workpieces, with a flexible design that includes multiple process areas and interchangeable tools, enabling efficient handling and preparation of workpieces for various processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If loading, setup, and processing are performed as separate sequential processes, then each process can be performed with dedicated equipment, but the cycle time increases and time utilization decreases
Solution Approach 1:
The patent combines loading, setup, and processing operations into a single integrated process area. The loading robot performs both loading and setup operations within the same protective partition where processing occurs, eliminating the need for separate sequential process areas and enabling overlapping of operation cycles.
Solution Approach 2:
The patent enables continuous operation by allowing the loading robot to perform setup operations on workpieces while other workpieces are being processed. The presentation robot continuously feeds workpieces from storage to the process area, ensuring that the processing equipment never idle and maintaining continuous productive action.
2Area of stationary object
If multiple separate process areas are used for loading and processing, then process steps can be clearly separated, but space utilization decreases and the facility requires more area
Solution Approach 1:
The patent merges the loading area and processing area into a single protective partition, with the workpiece storage area positioned within the working area of the loading robot. This consolidation reduces the total facility area required while maintaining clear functional separation through the coordinated operation of loading and presentation robots.
3Productivity
If dedicated loading equipment is used outside the protective partition, then loading can be performed separately, but time overlap with processing is prevented and overall efficiency decreases
Solution Approach 1:
The patent moves the loading robot inside the protective partition along with the processing equipment, enabling the loading and setup operations to occur within the same protected space. This allows the loading robot to perform setup operations while processing occurs simultaneously, maximizing time utilization.
Solution Approach 2:
The loading robot is designed with multi-functionality, performing both loading of workpieces onto the conveyor and setup operations on workpieces within the process area. The presentation robot similarly handles both retrieval from storage and presentation to the process area, reducing the need for dedicated single-function equipment.
Data Source
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AI summary
The invention relates to a manufacturing station and to a manufacturing process for workpieces (4), in particular car body parts, wherein the manufacturing station (2) has: a processing area (11), which has a working point (12) and a processing apparatus (13); a security partition (5), in particular a fence, which surrounds the processing area (11) and has a secure access point (6, 7, 8) for workpiece transport; and an automatic loading apparatus (16), which has loading robots (18, 19). The loading apparatus (16) loads and unloads workpieces (4) onto and off a conveyor means (22) and transports the workpieces (4) into and out of the processing area (11). The automatic and multifunctional loading apparatus (16) is arranged, together with a workpiece support (17), inside the security partition (5), wherein the workpiece support (17) is arranged within the working area of the loading robots (18, 19), and a loading robot (18) provides workpieces (4) unloaded there and carries out a setting-up procedure.