Operator Guidance Lighting for Adaptive Manual Assembly

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Solution Overview

Problem

In modern production lines, particularly in the automotive sector, operators face challenges in performing manual assembly operations quickly and correctly due to varying sequences of assembly operations on pallets, which current solutions fail to address effectively.

Innovation Solution

A programmable device equipped with an assembly tool, input device, lighting system, and sensor, and electronic control system that learns and adapts to the operator's actions in real-time, providing intuitive guidance through projected graphic instructions to ensure correct assembly operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated assembly systems are used to assist operators, then assembly operations can be performed more efficiently, but the system complexity and cost increase significantly

Engineering Contradiction:

Improveassembly operations efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system automatically records the operator's assembly actions through sensors and cameras during a learning phase, then uses this recorded data to provide real-time guidance without requiring complex pre-programming. The system serves itself by learning from observation rather than requiring extensive external configuration.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces complex mechanical automation systems with a software-based guidance system that uses sensors, cameras, and visual displays to assist operators. This substitution maintains productivity benefits while significantly reducing mechanical complexity and cost.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If the assembly sequence is fixed and pre-programmed, then the system can operate reliably, but it cannot adapt to varying production requests and component variations

Engineering Contradiction:

Improveassembly operations correctnessVSAvoidadaptation to varying production requests

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system transitions from static pre-programmed sequences to dynamic adaptive sequencing by continuously observing the operator's actions and adjusting the guidance sequence in real-time based on the actual assembly being performed, allowing it to handle varying production requests while maintaining reliability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system performs preliminary learning by recording the operator's assembly actions during a initial phase, storing this data for future reference. This preliminary action enables the system to quickly adapt to new assembly sequences without extensive reprogramming, maintaining both reliability and adaptability.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the system requires extensive programming and configuration, then it can handle complex assembly sequences, but the setup time and operational complexity increase

Engineering Contradiction:

Improvehandling complex assembly sequencesVSAvoidsetup time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system eliminates extensive manual programming by automatically recording assembly sequences through sensors and cameras during a learning phase. This self-service approach allows the system to handle complex assembly sequences while minimizing setup time, as the complexity is captured automatically rather than programmed manually.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system creates a digital copy of the actual assembly process by recording the operator's actions, tool positions, and component locations. This copying approach enables the system to replicate complex assembly sequences accurately without requiring manual programming of each step, significantly reducing setup time.

Inventive Principle:

Principle #26Copying

4Ease of operation

If visual guidance is provided continuously, then the operator receives constant instructions, but the operator may become overwhelmed and lose autonomy

Engineering Contradiction:

Improveoperator guidance clarityVSAvoidinterface complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The system provides visual guidance selectively rather than continuously, offering instructions only when the operator needs them based on the recorded learning sequence. This partial action approach maintains ease of operation by providing necessary guidance while avoiding information overload, and reduces interface complexity by activating guidance only when relevant.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS11366492B2Programmable device provided in a production environment for assisting an operator

Publication Date: 2022.06.21 COMAU SPA

AI summary

A programmable device (D) arranged in a production environment, to assist an operator (O) in performing manual assembly operations carried out by the operator (O), particularly during assembly operations performed on pieces (P) transported by pallets (5) in a production line (1). The device (D) comprises an assembly means usable by the operator (O), a lighting device (4) for lighting a work area in which the operator (O) works, a sensor (6) configured to detect the position of the assembly means, an input device (10) usable by the operator, and an electronic control system (8) configured to memorize a learning sequence including a sequence of manual assembly operations.