Multi-Region Tool Operation for Higher Assembly Line Throughput
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Solution Overview
Problem
Assembly lines with multiple tools face throughput limitations due to the need for all tools to adapt to the slowest processing speed, leading to reduced efficiency and potential delays, especially when processing incomplete rows of components.
Innovation Solution
A device and method that allow tools to operate in multiple processing areas with shared sub-tracks, enabling each tool to process multiple rows partially and allowing subsequent tools to complete unprocessed points, thereby increasing overall assembly line throughput by optimizing tool utilization and reducing the need for tools to process complete rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all tools process complete rows sequentially, then each tool can operate independently and simply, but the assembly line throughput is limited by the slowest tool and tools cannot utilize their full capacity
Solution Approach 1:
The patent divides the component path into multiple sub-tracks (first sub-track, second sub-track, third sub-track) and assigns different tools to process different segments. Tool 1 processes components on the first sub-track, while tool 2 processes components on the second and third sub-tracks. This segmentation allows each tool to work on specific portions simultaneously, increasing overall throughput without requiring complex coordination for complete row processing.
Solution Approach 2:
The patent transitions from sequential one-dimensional tool operation to multi-dimensional parallel processing by introducing multiple sub-tracks that tools can access independently. Instead of tools moving along a single component path in sequence, they can simultaneously access different sub-tracks, effectively adding a spatial dimension to the processing architecture and enabling parallel operations that increase throughput.
2Productivity
If tools are assigned to process multiple rows, then throughput increases, but tools must wait for slower tools creating idle time
Solution Approach 1:
By segmenting the component path into multiple sub-tracks, the patent allows tool 2 to process components on the second sub-track while tool 1 processes the first sub-track, and vice versa. This segmentation eliminates idle time by ensuring that each tool continuously has work available on its assigned sub-tracks, maximizing capacity utilization without waiting for slower tools.
Solution Approach 2:
The patent enables continuous useful action for each tool by assigning them to different sub-tracks that can be processed independently and simultaneously. Tool 1 continuously processes the first sub-track while tool 2 continuously processes the second and third sub-tracks, eliminating idle time and ensuring that all tools operate at full capacity throughout the assembly line cycle.
3Productivity
If tools process incomplete rows, then overall throughput increases, but positioning accuracy and component handling become more difficult
Solution Approach 1:
The patent segments the component path into distinct sub-tracks, allowing tools to process complete sets of components on each sub-track independently. This segmentation maintains positioning accuracy by ensuring that each tool works on complete, organized groups of components rather than scattered individual components, while still achieving high throughput through parallel processing of multiple sub-tracks.
Data Source
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Figure 3a~3b
AI summary
The invention relates to devices and methods for operating at least two tools in a first and at least one second processing region, wherein in each processing region the tool is assigned to a number of processing points, through which first components carried by a component track are conveyed along a path through the first processing region and the at least second processing region; wherein the total number of tools in the device is less than the number of processing points in each processing region; wherein the path comprises a number of sub-paths, the number of sub-paths corresponding to the number of processing points; wherein the tool of each processing region is configured such that said tool, at each assigned processing point in its processing region, mounts second components in question on first components in question; and wherein the device comprises a control unit, which is configured to perform the following according to a conveying movement of the component track along the path: (i to position the tool at one or more of the processing points in its processing region and (ii to operate the tool in order to mount first and second components in question at the processing point in question, such that, in the first region, (i selected first components which are conveyed on the component track along a first sub-path and (ii selected first components which are conveyed on the component track along a second sub-path are processed by means of the tool of the first region and, in the second region, (i selected first components which are conveyed on the component track along a third sub-path and (ii the first components which are conveyed on the component track along the second sub-path and are not processed in the first region are processed by means of the tool of the second region.