Movable Automated Machines for Continuous Composite Production
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Solution Overview
Problem
Conventional manufacturing techniques for large and composite parts in aircraft structures are inefficient, as they rely on fixed-base machines and batch processing, which do not lend themselves to continuous flow manufacturing or efficient machine allocation.
Innovation Solution
A method and system that employs a plurality of automated machines on a production line, where at least one machine is movable between stations, monitored by a controller to reallocate machines based on capacity and workload requirements, optimizing efficiency by balancing workload across stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fixed-base machines and batch processing are used, then manufacturing simplicity is maintained, but productivity and machine utilization efficiency deteriorate
Solution Approach 1:
The system transitions from static fixed-base machines to dynamic movable automated machines that can be reallocated between stations based on real-time workload requirements. The controller continuously monitors machine capacity and workload, and automatically moves machines to optimize productivity while maintaining manageable complexity through automated decision-making.
Solution Approach 2:
Automated machines are designed to be universal and can perform functions at multiple stations along the production line. Instead of dedicated fixed-base machines for each station, the same machines can be deployed to different stations as needed, increasing overall productivity while the controller manages the complexity of allocation.
2Adaptability or versatility
If machines are stationary and dedicated to specific stations, then operational simplicity is maintained, but adaptability to workload changes deteriorates
Solution Approach 1:
The controller implements continuous feedback by monitoring machine capacity and workload requirements at each station. This feedback loop enables the system to adapt machine allocations dynamically in response to changing workload conditions, while the automated control system manages the complexity of real-time decision-making and machine movement coordination.
Solution Approach 2:
The system transitions from static machine assignments to dynamic reallocation based on real-time conditions. Machines are no longer permanently assigned to specific stations but can be moved to where they are most needed, providing adaptability while the automated controller manages the complexity of coordinating these dynamic changes.
3Loss of time
If batch processing with fixed tooling is used, then process stability is maintained, but cycle time and work in progress deteriorate
Solution Approach 1:
The system transitions from batch processing with idle periods to continuous flow manufacturing. Automated machines move continuously along the production line, performing operations at multiple stations without returning to base positions, eliminating non-productive time and reducing cycle time while the controller manages the complexity of coordinating continuous operations across multiple stations.
Solution Approach 2:
Machines operate in a dynamic continuous flow mode rather than static batch mode. Instead of completing one batch at a fixed location then moving to the next, machines continuously move through multiple stations performing operations, maximizing productive action time and reducing cycle time while automated control manages the system complexity.
Data Source
AI summary
A method for employing a plurality of automated machines to deposit composite material includes a first tool located in a first station and a second tool located in a second station. The first station and the second station are located on a production line. The first station includes at least one automated machine of the plurality of automated machines and the second station includes at least two automated machines of the plurality of automated machines. At least one of the automated machines is movable from the second station to the first station. The method includes monitoring machine capacity and workload requirements of the plurality of automated machines. The method further includes determining an efficiency threshold based upon the machine capacity and workload requirements. The method further includes reallocating at least one of the automated machines from the second station to the first station once the efficiency threshold is met.