Serial Multi-Up Effector With Rotary Bin Changeover

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Solution Overview

Problem

Automated assembly lines face challenges in reliably picking and placing multiple parts with variable orientations or random movements, requiring frequent human intervention for bin replacement, which disrupts the assembly process and necessitates large footprints for conveyor systems.

Innovation Solution

A serial multi-up effector with movable individual effectors, capable of rotating or extending to adapt to different orientations, and a rotary table that allows for seamless bin replacement without stopping the assembly line, enabling continuous operation while ensuring worker safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple robots are used to increase the delivery rate of placed parts, then the productivity is improved, but the device complexity and cost increase

Engineering Contradiction:

Improvedelivery rate of placed partsVSAvoidnumber of robots

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple individual effectors are combined into a single multi-up effector assembly that can pick up multiple parts simultaneously. This merging approach achieves the productivity of multiple robots while reducing device complexity by using one integrated unit instead of multiple separate robots

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-up effector is divided into multiple individual effectors, each capable of independently picking up a part. This segmentation allows the single assembly to perform the function of multiple robots while maintaining the ability to handle multiple parts in parallel

Inventive Principle:

Principle #1Segmentation

2Productivity

If existing multi-up effectors are used to pick up multiple parts simultaneously, then the processing speed is increased, but the reliability decreases when parts have variable orientations or random movements

Engineering Contradiction:

Improveprocessing speedVSAvoidability to retrieve multiple parts

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The individual effectors are made movable relative to the common support structure, allowing them to dynamically adjust their positions and orientations to accommodate parts with variable orientations or random movements. This dynamic adaptability maintains reliability while preserving the high processing speed of simultaneous multi-part pickup

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The effector assembly can change its geometric parameters (positions and orientations of individual effectors) to match the actual state of parts being picked. This parameter adjustment capability ensures reliable pickup of parts regardless of their initial orientation or movement, while maintaining the speed advantage of parallel operation

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If bins are periodically replaced with human intervention, then the assembly line can continue operation, but the loss of time occurs due to stopping the assembly line

Engineering Contradiction:

Improvebin replacement capabilityVSAvoidassembly line stopping time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

Multiple bins are prepared in advance and positioned in different locations of the rotary table. When one bin is being used, another bin is already in position ready for immediate replacement. This preliminary preparation eliminates assembly line stopping time, as bin replacement occurs seamlessly during normal operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The rotary table enables continuous bin replacement without interrupting the assembly line operation. While one bin is being depleted, the rotary table can rotate to bring a fresh bin into position, ensuring the picking operation continues uninterrupted and eliminating idle time

Inventive Principle:

Principle #20Continuity of useful action

4Extent of automation

If a conveyor belt is used to move bins in and out of the picking location, then the automation level is improved, but the area occupied increases

Engineering Contradiction:

Improvebin movement automationVSAvoidfootprint of conveyor system

Core Design Contradiction:

Extent of automationVSArea of stationary object

Solution Approach 1:

Instead of using a linear conveyor belt that occupies horizontal floor space, the system uses a rotary table that utilizes vertical space and rotational movement. This dimensional change from linear to rotational configuration reduces the horizontal footprint while maintaining automated bin movement capability

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20230399182A1Serial multi-up effector and rotary table for use in an automated assembly line

Publication Date: 2023.12.14 ATS AUTOMATION TRACKING SYST INC

AI summary

A serial multi-up effector can be used in an automated assembly line in order pick parts from a parts bin one after the other before placing them at a desired location. In an automated assembly line, a parts bin will be depleted of parts and need to be replaced with a full parts bin. The bin replacement may be replaced using a rotary table that allows an empty bin to be replaced with a full bin. Additionally, the rotary table allows for filling of the empty bins while the full bins are being used to pick parts from.