Apparatus, system and method for modular manufacture
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Solution Overview
Problem
Manufacturing of modern devices with increasing numbers of components and features is inefficient, leading to repetitive and awkward installations, workplace injuries, and throughput limitations due to manual labor and in-process inventory requirements.
Innovation Solution
A modular manufacturing approach using prefabricated snap-in, screw-in, or clip-in modules with integrated components and connectors, allowing for automated assembly and quality control offsite, reducing the need for manual labor and minimizing installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual installation of wiring harnesses and components is used, then flexibility in component placement is maintained, but production time increases and throughput decreases
Solution Approach 1:
The device is divided into modular assemblies, each containing pre-organized wiring harnesses and components. These modules can be independently manufactured and then quickly installed as complete units, dramatically reducing installation time and complexity while maintaining design flexibility.
Solution Approach 2:
Wiring harnesses and components are pre-assembled and pre-tested as complete modules before being installed in the final device. This preliminary preparation eliminates time-consuming on-site installation work and ensures proper configuration before deployment.
2Adaptability or versatility
If numerous fasteners and wiring are placed at awkward positions, then functional requirements are met, but workplace injuries increase and installation difficulty increases
Solution Approach 1:
By segmenting the device into modular assemblies with standardized interfaces, the patent eliminates the need for workers to manually install individual fasteners and wiring at awkward positions. Each module is pre-configured with proper fastening mechanisms, reducing repetitive strain injuries while maintaining functional adaptability.
3Productivity
If in-process inventory is stored at manufacturing stations, then assembly continuity is maintained, but floor space requirements increase and throughput is limited
Solution Approach 1:
Complete modular assemblies are pre-prepared and staged in centralized locations before final installation. This eliminates the need for extensive in-process inventory storage at multiple manufacturing stations, freeing up floor space while maintaining assembly continuity through ready-to-install modules.
Data Source
AI summary
The disclosure is of and includes at least an apparatus, system and method for modular manufacturing. The apparatus, system and method may include at least a device shell capable of providing at least the structure of a manufactured device, wherein the device shell comprises a plurality of receivers; a plurality of modules, each comprising a plurality of components suitable, in combination, to provide functional aspects to the manufactured device; a plurality of connectors externally associated with each of the plurality of modules, wherein the plurality of connectors are capable of being respectively received by ones of the plurality of receivers to thereby fasten each of the plurality of modules into the device shell.