Modular Production Cell with Vision-Guided Interchangeable Modules
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Solution Overview
Problem
Robotic manufacturing cells are time-consuming to set up and reconfigure for different tasks, leading to prolonged downtime and limited adaptability, as they are typically programmed for specific processes and require complete reconfiguration for changes.
Innovation Solution
A modular production cell with interchangeable production modules, a vision system for identity and location determination, and standardized interfaces for rapid reconfiguration, allowing for flexible adaptation to various tasks and incremental changes without requiring complete reprogramming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a production cell is programmed for a specific process, then the process execution is reliable and precise, but the adaptability to different tasks deteriorates and reconfiguration becomes time-consuming
Solution Approach 1:
The production cell is divided into independent, interchangeable production modules that can be individually selected and replaced. Each module encapsulates specific processing capabilities, allowing the system to be reconfigured by swapping modules rather than reprogramming the entire cell. This segmentation enables reliable execution of specific processes while maintaining high adaptability to different tasks.
Solution Approach 2:
The production cell transitions from a static, fixed configuration to a dynamic, reconfigurable system. Modules can be added, removed, or replaced based on task requirements, allowing the system to adapt its capabilities dynamically. The standardized interfaces ensure that dynamic reconfiguration maintains process reliability through consistent connection and communication protocols.
2Duration of action of stationary object
If a production line is programmed to perform a specific process for its whole lifetime, then programming stability is maintained, but the ability to perform another action deteriorates and only incremental improvements are possible
Solution Approach 1:
The production line is segmented into modular units with standardized interfaces. This allows the system to maintain stable, proven module configurations for reliability while enabling complete process transformation by replacing entire modules rather than attempting to modify fixed programming over the system's lifetime.
Solution Approach 2:
The standardized module interfaces create a universal platform that can support multiple different process configurations. A single production line infrastructure can perform different actions by swapping modules, eliminating the need for permanent, task-specific programming and enabling both stability and versatility throughout the system's operational lifetime.
3Adaptability or versatility
If production modules are exchanged for rapid reconfiguration, then adaptability to different tasks is improved, but the complexity of interface standardization and module compatibility increases
Solution Approach 1:
Universal standardized interfaces are designed to handle multiple functions including mechanical mounting, electrical power and signal connections, and data communication. This multi-functionality in a single interface standard reduces the number of separate standardization requirements while enabling rapid module exchange and maintaining system compatibility.
Solution Approach 2:
The module interfaces incorporate self-aligning and self-locking mechanisms that automatically ensure proper connection when modules are exchanged. This self-service capability reduces the complexity of precise interface alignment and ensures compatibility without requiring complex external alignment procedures or extensive programming configuration.
4Adaptability or versatility
If the production cell is reconfigured by removing and placing other production modules, then adaptability to different tasks is improved, but the time required for module exchange and system reinitialization increases
Solution Approach 1:
Production modules are pre-configured and pre-tested outside the production cell before installation. The standardized interfaces are pre-aligned and connection protocols are pre-established, so that when modules are exchanged during reconfiguration, the physical connection and system recognition occur rapidly without requiring extensive on-site setup or programming, thereby minimizing downtime.
Solution Approach 2:
Manual alignment and connection procedures are replaced with automated mechanical interfaces that feature self-aligning guides, quick-connect mechanisms, and automated electrical contacts. This substitution of manual mechanical operations with automated mechanical systems dramatically reduces the time required for module exchange while maintaining connection reliability.
Data Source
Figure 1~3
AI summary
A production cell (31) comprises • at least one robot (32) arranged to handle products (37); • at least one buffer area (34) for intermediate storage of products (37) inside the production cell (31); • a vision system with cameras (36) arranged to determine, based on images from the cameras (36), the identity and the location of objects in the production cell (31); and • a plurality of production modules (33), each production module (33) comprising at least one Hardware Module (3) configured to process products (37); • a plurality of module attachment locations (38), each module attachment location (38) being configured to connect with an interface section (337) of a production module (33) through at least a physical connection and a power connection.