Modular Production Units With Segmented Connectors
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Solution Overview
Problem
Existing production facilities face challenges in easily adapting to changes in process steps due to the need for frequent modifications in the control programs of transfer units and electrical systems, leading to inefficiencies and reduced productivity.
Innovation Solution
A production facility with separable production units connected via a guide rail and transfer means, where each unit has a processing section, control section, and connectors for easy electrical connection, allowing for flexible reconfiguration and parallel processing of workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If production units are electrically connected to an electric power line arranged above the production units individually, then each production unit can be powered independently, but it requires time and labor for constructing and reconstructing the electric system when the process step is changed, and also imposes restrictions on how the production units are arranged
Solution Approach 1:
The electric power supply system is segmented into modular connectors integrated with each production unit. Instead of individual connections to overhead power lines, each production unit has its own power connector that can be easily coupled and decoupled, eliminating the need for complex electric system construction and reconstruction when reconfiguring the production line.
Solution Approach 2:
The power connectors are designed with universal coupling mechanisms that can be integrated into the mechanical coupling structure between production units. This multi-functional connector serves both mechanical connection and electrical power supply functions, allowing production units to be arranged flexibly without restrictions from fixed electric power line arrangements.
2Adaptability or versatility
If a transfer unit is configured to be freely movable to any production unit, then the production facility can adapt to changes in process steps, but the control program for the transfer unit needs to be modified every time the process step is changed
Solution Approach 1:
The production line is segmented into independent production units with standardized interfaces. This segmentation allows for easy reconfiguration by simply adding or removing physical units without requiring complex control program modifications, as each unit operates independently with standardized coupling mechanisms.
Solution Approach 2:
The production units are designed with self-identifying features and standardized interfaces that automatically recognize their position and function in the production line. This self-service capability eliminates the need for manual control program modifications when reconfiguring, as the system automatically adapts to the new arrangement through the standardized connectors and identification mechanisms.
3Stability of the object's composition
If production units are coupled in a fixed electrical system arrangement, then the electric system is stable, but the production units cannot be freely rearranged and require time and labor for reconstructing the electric system
Solution Approach 1:
The electric system is segmented into modular power connectors integrated with each production unit. This modular approach maintains system stability through standardized connection interfaces while enabling flexible rearrangement of production units, as the segmented connectors can be easily coupled and decoupled without affecting the overall system stability.
Solution Approach 2:
The electric connection system transitions from a static fixed arrangement to a dynamic modular configuration. The power connectors are designed to be dynamically coupled and decoupled with the mechanical connection between production units, allowing the electric system to adapt flexibly to different production unit arrangements while maintaining stable power supply through the standardized connector interfaces.
Data Source
AI summary
Provided is a production facility (1), including: a plurality of production units (10A to 10E) coupled to each other in a separable manner; a guide rail (2) extending in a unit coupling direction; and transfer means (3) capable of sequentially transferring, by moving along the guide rail (2), a workpiece from the production unit (10A) toward the production unit (10E). Each of the plurality of production units (10A to 10E) includes: a processing section (13) configured to execute predetermined processing; a control section (14) configured to electrically control an operation of the processing section (13); a rail member (20) constructing the guide rail (2); and a slide member (30) constructing the transfer means (3). Each of the plurality of production units (10A to 10E) further includes: a connector (15, 15) configured to electrically connect the control section (14) thereof and the control section (14) of the adjacent production unit (10).