Multi-Arm Rail Transfer Control for Flexible Workpiece Handling

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Solution Overview

Problem

Conventional tooling assemblies in manufacturing facilities lack flexibility and require extensive manual adjustments and multiple configurations for different workpieces, leading to inefficiencies and increased costs due to the need for multiple sets of tooling assemblies and end-effectors.

Innovation Solution

A workpiece transfer system with multiple arms coupled to a movable rail, featuring a supervisory controller that retrieves motion plans based on task identification information to automatically configure the arms for specific workpieces, allowing for efficient transfer between workstations without the need for extensive manual adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional tooling assemblies with rigid mounts and fixed configurations are used, then structural stability is maintained, but flexibility and adaptability for different workpieces are severely limited

Engineering Contradiction:

Improveadaptability to different workpiecesVSAvoidcomplexity of tooling assembly configurations

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The tooling assembly incorporates adjustable and reconfigurable components that allow dynamic modification of the assembly configuration. The end-effector can be repositioned along the tubular member, and the tubular member itself can be reconfigured, enabling the same tooling assembly to adapt to different workpiece geometries and requirements without requiring multiple fixed configurations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The tooling assembly is designed as a universal system that can handle multiple workpiece types and configurations. By combining the adjustable end-effector, reconfigurable tubular member, and modular components, a single tooling assembly can perform multiple functions and accommodate various workpiece shapes, sizes, and operational requirements, eliminating the need for multiple specialized tooling sets.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple sets of tooling assemblies and end-effectors are maintained for different workpieces, then adaptability is improved, but inventory costs and storage requirements increase

Engineering Contradiction:

Improvecapability to handle different workpiecesVSAvoidnumber of tooling assemblies to be stored

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If manual adjustment of tooling assemblies is performed for each workpiece configuration, then adaptability is achieved, but time consumption and operational efficiency decrease

Engineering Contradiction:

Improveconfiguration flexibility for different workpiecesVSAvoidtime required for tooling adjustments

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system incorporates automated control mechanisms that enable the tooling assembly to self-adjust to different workpiece configurations. The controller receives workpiece identification or configuration data and automatically actuates the adjustable components, such as repositioning the end-effector and reconfiguring the tubular member, without requiring manual intervention. This self-service capability dramatically reduces adjustment time and maintains high adaptability.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system employs feedback mechanisms where the controller monitors the current configuration state and automatically makes adjustments based on the required workpiece specifications. Sensors and feedback loops ensure that the tooling assembly reaches the correct configuration, reducing the time and expertise needed for manual adjustment while maintaining precise adaptability to different workpieces.

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If numerous tooling assemblies are purchased and maintained for different workpieces, then coverage of all workpiece types is improved, but operational costs and maintenance requirements increase

Engineering Contradiction:

Improvecoverage of different workpiece typesVSAvoidcost and complexity of maintaining multiple tooling sets

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20240367920A1Control System and Methods for a Workpiece Transfer System Having Multiple Arms Coupled to a Moveable Rail

Publication Date: 2024.11.07 NORGREN AUTOMATION SOLUTIONS LLC

AI summary

An example method includes receiving task identification information indicative of a manufacturing task to be performed on a workpiece, wherein the workpiece transfer system comprises a rail and a plurality of arms coupled to the rail, wherein each arm comprises (i) a plurality of arm linkages coupled at respective joints, (ii) an arm controller in communication with the supervisory controller, and (iii) respective joint controllers in communication with the arm controller and configured to actuate respective rotary actuators at the respective joints to move the plurality of arm linkages relative to each other: retrieving a motion plan corresponding to the manufacturing task and the workpiece: sending command signals to respective arm controllers to communicate respective command signals to the respective joint controllers and execute the motion plan; and once the final desired configuration is achieved, commanding the respective arm controllers to lock the respective joints.