Matrix Conveyor Layout for Flexible Assembly Line Reconfiguration
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Solution Overview
Problem
Existing conveyor systems in automated assembly lines lack efficiency and flexibility, particularly in terms of space utilization and the ability to easily reconfigure processing nodes.
Innovation Solution
A matrix conveyor system comprising multiple transport conveyors and transfer conveyors, arranged in a matrix configuration to efficiently move components through various processing stations, with modular automation nodes that can be easily reconfigured and replaced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional linear conveyor systems are used, then the assembly line can move components through processing stations, but the space utilization is poor and reconfiguration is difficult
Solution Approach 1:
The conveyor system is divided into multiple independent conveyor sections (first conveyor, second conveyor, third conveyor) that can operate independently. Each conveyor can be controlled separately, allowing individual sections to be reconfigured or maintained without affecting the entire system. This segmentation enables flexible reconfiguration of processing nodes while maintaining overall system functionality.
Solution Approach 2:
The patent transitions from a traditional linear one-dimensional conveyor arrangement to a two-dimensional matrix configuration. Multiple conveyors are arranged in parallel rows with transfer conveyors creating a grid-like structure, allowing components to move in multiple directions (horizontal and vertical). This dimensional change provides numerous possible paths through the system, dramatically increasing reconfiguration flexibility and adaptability.
2Adaptability or versatility
If multiple parallel conveyors are added to improve flexibility, then reconfiguration capability increases, but the system complexity and space requirements increase
Solution Approach 1:
The conveyor system employs a nested arrangement where transfer conveyors are positioned between and connect the parallel conveyors. The transfer conveyors operate in the spaces between the main conveyors, creating a compact nested structure. This nesting allows multiple conveyor paths to coexist in a reduced footprint by utilizing vertical and lateral spacing efficiently.
Solution Approach 2:
By arranging conveyors in a two-dimensional matrix rather than a single linear sequence, the system packs more conveyor capacity into a smaller overall footprint. The parallel arrangement with transfer points creates a compact grid structure that utilizes space more efficiently than extended linear configurations, reducing the total area required while maintaining multiple reconfiguration options.
3Ease of operation
If linear motors are used to control individual pallets, then motion control independence is achieved, but the system cost and complexity increase
Solution Approach 1:
The system divides the conveyor into multiple independent sections, each with its own drive mechanism. This segmentation allows individual pallets or groups of pallets to be controlled independently at each conveyor section. The modular control architecture enables easy adjustment of individual segments without affecting the entire system, improving ease of operation while keeping control complexity manageable through distribution.
Data Source
AI summary
A matrix conveyor system comprises a first plurality of conveyors arranged generally parallel to each other and a second plurality of conveyors arranged generally perpendicularly to the first plurality of conveyors. A plurality of processing stations are arranged along edges of matrix conveyor parallel to the first plurality of conveyors. Each of the first and second plurality of conveyors are controlled in order to selectively move one or more pallets through one or more of the plurality of processing stations.