Assembly Pallet Pin Changeover for Continuous Line Reconfiguration
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Solution Overview
Problem
Current assembly line changeover processes incur significant downtime due to the need to manually reconfigure pallets when switching between different components, as the configuration of pallets with components on them cannot be altered.
Innovation Solution
A system and method for automatically changing location pins on pallets using a pin changing unit with a pin grabber and linear actuators, allowing for efficient reconfiguration of pallets on a return line without interrupting the assembly line's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual changeover of pallets is performed, then the assembly line can be repurposed for new components, but significant downtime is incurred
Solution Approach 1:
The system performs preliminary actions by pre-configuring pallets with required location pins before they enter the assembly line. The off-line pallet preparation station prepares pallets in advance with the correct pin configurations, so when pallets arrive at the assembly line, they are already ready for the specific component model, eliminating changeover downtime.
Solution Approach 2:
The patent introduces an intermediary off-line pallet preparation station that acts as a mediator between pallet reconfiguration and the main assembly line. This intermediary system handles all pin insertion and pallet configuration operations separately, allowing the main assembly line to continue operating without interruption while pallets are prepared in the background.
2Adaptability or versatility
If empty pallets are run through the assembly line for manual reconfiguration, then pallet configuration can be changed, but assembly line operation is interrupted
Solution Approach 1:
Pallets are reconfigured with the correct location pins before entering the assembly line at the off-line preparation station. This preliminary configuration ensures that when pallets enter the assembly line, no further changes are needed, maintaining continuous production flow.
Solution Approach 2:
The off-line pallet preparation station serves as an intermediary system that handles all pallet modification operations outside the main assembly line. This separation allows the assembly line to maintain continuous operation while pallets are prepared and configured in the background system.
3Adaptability or versatility
If location pins are manually inserted into pallet sockets, then pallet configuration can be changed, but changeover time increases
Solution Approach 1:
The pin insertion device is designed to automatically insert location pins into pallet sockets without requiring manual intervention. The system uses automated mechanisms including pin storage magazines, transfer mechanisms, and precision positioning systems that perform the entire pin insertion process autonomously, dramatically reducing reconfiguration time.
Solution Approach 2:
The patent replaces manual mechanical pin insertion with an automated mechanical system. The automated pin insertion device uses controlled mechanical movements, precision positioning, and automated handling to insert pins rapidly and accurately, eliminating the time-consuming manual operation while maintaining configuration accuracy.
Data Source
AI summary
A system and method can change location pins on a pallet for an assembly line. The system may include a plurality of pallets, each pallet including at least a first and second sockets configured to receive a location pin. The system may include a pin changing unit located between a top assembly line and a lower return line. The pin changing unit may include a pin grabber configured to engage the location pin within the first socket. The pin changing unit may include a horizontal linear actuator configured to move the pin grabber and the engaged location pin into alignment with the second socket. The pin changing unit may include a vertical linear actuator configured to extend the pin grabber into engagement with the location pin and retract the pin grabber away from the location pin.