Modular Manufacturing System with Mobile Processing Modules
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Solution Overview
Problem
Traditional manufacturing systems for large components are costly and space-intensive, with robots often tied to specific cells and limited in versatility, leading to inefficiencies.
Innovation Solution
A modular manufacturing system featuring autonomous vehicles and sub-dimensional processing modules that can move and position themselves within an open factory space, coordinated by a central controller to process components in a flexible and efficient manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fully contained fabrication cells are used for manufacturing large components, then processing capability is provided, but capital cost and space consumption increase significantly
Solution Approach 1:
The fabrication cell is divided into separate mobile processing modules (welding module, grinding module, drilling module, etc.) that can be independently moved and repositioned. Each module contains its own processing equipment and can service the component at different locations, eliminating the need for a large fixed cell structure.
Solution Approach 2:
The processing modules are designed to be mobile rather than fixed, equipped with wheels or other movement mechanisms that allow them to be repositioned along the component or to different workstations. This dynamic capability replaces the static nature of traditional fabrication cells.
2Ease of manufacture
If dedicated processing equipment is mounted to and powered by a single cell, then particular features of the component can be created, but the system is tied to a specific location and reduces flexibility
Solution Approach 1:
Each processing function (welding, grinding, drilling) is separated into its own dedicated mobile module. These modules can be independently moved to different locations along the component or to different workstations, allowing flexible reconfiguration based on production needs.
Solution Approach 2:
The mobile processing modules are designed to service multiple locations and potentially multiple components. Each module contains the necessary equipment (power source, control system, processing tool) to perform its function anywhere along the component, making the system universally applicable rather than location-specific.
3Productivity
If robots are configured for use with a particular component in a production cell, then processing can be performed, but the use of the system is limited and value is reduced
Solution Approach 1:
The robotic processing modules are designed to be mobile and reconfigurable rather than fixed and dedicated. Each module can be moved to different components and repositioned along the component as needed, allowing the same module to work on multiple different components throughout its service life.
Solution Approach 2:
Each mobile processing module contains its own power source, control system, and processing equipment, making it a self-contained unit that can operate independently. This self-sufficiency allows modules to be easily moved and reconfigured without requiring connection to fixed infrastructure.
Data Source
AI summary
A system is provided for manufacturing a component within a factory. The system may have an autonomous vehicle configured to transport the component to an area within an open space of the factory and to secure the component at the area during processing of a designated volume of the component. The system may also have a plurality of processing modules each configured to process a portion of the component less than a whole of the designated volume, and a controller in communication with the autonomous vehicle and the plurality of processing modules. The controller may be configured to coordinate operations of the plurality of processing modules according to a programmed process plan.