Modular Assembly Material Supply for Variable Build Sequences
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Solution Overview
Problem
In modular assembly processes, the unpredictable nature of assembly plans and variants complicates the efficient provision of materials to assembly stations, leading to inefficiencies in material staging and throughput.
Innovation Solution
A method and system utilizing a modular assembly plant with shopping carts and a transport system, where a neural network-controlled material supply system continuously monitors the assembly status and adjusts the material provision based on changing assembly specifications, ensuring timely and local delivery of components to assembly stations using driverless transport vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional assembly line production is used with predetermined assembly sequences, then material provision is simplified and standardized, but flexibility to handle assembly plan variants and changes is reduced
Solution Approach 1:
The patent implements dynamic assembly sequences where the assembly plan can change during production based on real-time conditions. The control system continuously monitors assembly status and adjusts the sequence of operations, allowing the system to adapt to different variants and unexpected situations rather than following a fixed predetermined sequence.
Solution Approach 2:
The system incorporates continuous feedback loops where the current assembly status is monitored and fed back to the control system. This feedback enables real-time adjustments to the assembly plan and material provision strategy, allowing the system to respond to changes in assembly requirements and optimize the production process dynamically.
2Area of stationary object
If just in time material supply is implemented, then material staging area is reduced, but reliability of material provision under unpredictable assembly plans deteriorates
Solution Approach 1:
The system performs preliminary actions by pre-calculating and preparing material provision plans based on predicted assembly sequences. The control system anticipates future material needs and initiates material retrieval and transport operations in advance, ensuring materials are available when needed even with changing assembly plans.
Solution Approach 2:
The material supply system operates continuously without interruption, with parallel retrieval and transport operations occurring simultaneously. The system maintains continuous material flow to assembly stations by coordinating multiple transport operations and predicting future material requirements, ensuring uninterrupted supply despite sequence changes.
3Loss of time
If modular assembly with driverless transport system is used, then throughput time is reduced, but complexity of coordinating material supply with variable assembly sequences increases
Solution Approach 1:
The system implements self-service by enabling the assembly system to automatically request and receive materials without external intervention. The control system autonomously coordinates material provision with assembly operations, with the assembly stations signaling their needs and the material supply system responding automatically, reducing coordination complexity through automation.
Solution Approach 2:
The material supply system is designed with universal capabilities to handle multiple assembly sequences and variants through a single integrated system. The control system can manage different assembly plans and coordinate with various transport operations using the same infrastructure, reducing overall complexity despite handling diverse assembly scenarios.
Data Source
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AI summary
The invention relates to a method for assembling an object using a modular assembly system which has multiple assembly stations, a material supply system which comprises multiple product baskets, and a transport system which comprises multiple transport vehicles. At least one assembly step is carried out using a respective assembly station. At the beginning of the assembly process, at least one original component is supplied which defines an original assembly state of the device to be assembled. Multiple assembly steps can be carried out for the device to be assembled according to an assembly specification, and each assembly step is carried out using an assembly station. The assembly station is supplied with material in order to carry out the assembly step. A current assembly state of a respective object to be assembled is monitored, and an assembly preview is provided for the object to be assembled, said preview comprising specifications for at least one assembly step yet to be carried out for the object to be assembled. The specifications comprise information regarding which material is to be supplied to an assembly station provided for carrying out the assembly step and at what time the material is supplied. The period of time remaining until the supply time for supplying the material is reached is ascertained from a current time.