Modular Workpiece Basket Inserts for Flexible Production Changeovers
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Solution Overview
Problem
Conventional workpiece baskets require replacement when manufacturing processes change, as their design is fixed and cannot adapt to variations in workpiece design or production station requirements.
Innovation Solution
A modular workpiece basket system comprising a frame and replaceable workpiece carrier inserts, where the inserts are held by a detachable holding device, allowing for easy adaptation to different workpieces and processes by swapping inserts and combining them with various frames, enabling flexible configuration and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the entire workpiece basket is replaced when manufacturing processes change, then the workpiece basket can be adapted to new workpiece designs or production requirements, but material waste increases and resource utilization decreases
Solution Approach 1:
The workpiece basket is divided into a frame and interchangeable workpiece carrier inserts. The frame serves as a reusable base structure while the inserts can be swapped to accommodate different workpiece designs, eliminating the need to replace the entire basket and reducing material waste.
Solution Approach 2:
The frame is designed as a universal base that can accommodate multiple types of workpiece carrier inserts. This multi-functionality allows the same frame to serve different production requirements by simply changing the inserts, improving adaptability without increasing material consumption.
2Ease of manufacture
If conventional fixed-design workpiece baskets are used, then the structure is simple and easy to manufacture, but they cannot adapt to variations in workpiece design or production station requirements
Solution Approach 1:
The basket system is segmented into a simple, easy-to-manufacture frame and separate workpiece carrier inserts. The frame maintains structural simplicity while the interchangeable inserts provide the necessary adaptability to different workpiece designs and production requirements.
Solution Approach 2:
The workpiece basket transitions from a static, fixed-design structure to a dynamic system where workpiece carrier inserts can be exchanged. This allows the basket to adapt its configuration based on production needs while maintaining the simplicity of the base frame structure.
3Reliability
If complete workpiece baskets are replaced instead of individual components, then compatibility issues are resolved, but resource efficiency and material utilization deteriorate
Solution Approach 1:
The system separates the frame from the workpiece carrier inserts, allowing only the inserts to be replaced when compatibility issues arise. This ensures reliable adaptation to different production stations while preserving the reusable frame, thereby improving resource efficiency.
Solution Approach 2:
Instead of discarding the entire workpiece basket when compatibility is needed, only the specific workpiece carrier inserts are replaced while the frame is recovered and reused. This selective replacement approach maintains compatibility requirements while maximizing resource utilization.
Data Source
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AI summary
A workpiece basket system comprises at least one interchangeable workpiece carrier insert (3) and a frame (1) with a holding device (16, 25) for the at least one workpiece carrier insert (3) that can be inserted into or is inserted into the frame (1), such that when at least one workpiece carrier insert (3) is inserted, the frame (1) and the at least one workpiece carrier insert (3) together form a workpiece basket (5). The frame (1) is designed such that several frames (1) can be stacked on top of each other, and the holding device (16, 25) is designed such that it holds the workpiece carrier insert (3) releasably.