Pallet Transfer Control for Worker-Delayed Machining Flow
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Solution Overview
Problem
The pallet transfer system faces inefficiencies due to delayed worker operations, leading to increased numbers of machining completed pallets in storage, which hinders the progression of workpieces to the next production process, thereby reducing productivity.
Innovation Solution
Implementing a control program that prioritizes the transfer of machining completed pallets to the work station by forcibly transferring them from the work station to storage when the worker is occupied, allowing the machined workpieces to be sent to the next production process, and utilizing a data-driven approach to manage transfer priorities and timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the worker performs work on another pallet at the work station, then the worker can handle multiple tasks, but the machining completed pallet cannot be transferred to the work station and must be temporarily stored, increasing storage congestion and reducing productivity
Solution Approach 1:
The control device acts as an intermediary that coordinates between the worker's operations and the pallet transfer system. It monitors worker status and automatically adjusts transfer timing, allowing the worker to perform tasks without interruption while ensuring completed pallets are transferred at appropriate moments, thus resolving the conflict between worker flexibility and system productivity
Solution Approach 2:
The control device preliminarily determines transfer timing by monitoring worker status before actual transfer occurs. It prepares transfer sequences in advance based on predicted worker availability, ensuring that pallets are transferred immediately when the worker becomes available, thereby maintaining high productivity while accommodating worker operational needs
2Adaptability or versatility
If the machining completed pallet is temporarily stored in the pallet storage unit due to worker unavailability, then the work station remains available for other tasks, but the number of stored pallets increases and productivity decreases
Solution Approach 1:
The control device implements continuous feedback by monitoring both worker status and pallet storage status. When the number of stored pallets reaches a threshold or the worker becomes available, the system automatically initiates transfer operations, creating a closed-loop control that minimizes storage congestion and transfer delays while maintaining work station availability
Solution Approach 2:
The system dynamically adjusts transfer timing based on real-time conditions. Instead of fixed scheduling, the control device flexibly determines when transfers occur based on worker availability and storage status, optimizing the balance between work station utilization and minimizing pallet storage time losses
3Reliability
If the pallet transfer system waits for worker completion before transferring machining completed pallets, then worker safety and operational flow are maintained, but the machined workpieces cannot be sent to the next production process promptly
Solution Approach 1:
The control device preliminarily identifies and queues machining completed pallets for transfer while the worker is still occupied. Once the worker completes their task, the pre-planned transfer sequence executes immediately, ensuring both operational safety during worker tasks and prompt transfer to maintain production flow
Solution Approach 2:
The system maintains continuous useful action by overlapping worker operations with pallet preparation for transfer. The control device ensures that while the worker is performing tasks, pallets are prepared and queued for immediate transfer upon worker completion, eliminating idle time and maintaining continuous production flow without compromising safety
Data Source
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AI summary
A technique of appropriately controlling transfer order of a pallet is provided. A pallet transfer system (10) includes a transfer device (300) that transfers a pallet to which a workpiece is attachable, a pallet storage (200) that stores a plurality of pallets, a work station (500) where a worker performs work of attaching the workpiece to the transferred pallet, a machine tool (400) that machines the workpiece attached on the pallet at the work station (500), and a control device (50) that controls the transfer device (300). The control device (50) transfers a second pallet from the work station (500) to the pallet storage (200) when the machining of the workpiece attached to a first pallet is completed in a state where the first pallet is in the machine tool (400) and the second pallet is in the work station (500), and the control device (50) transfers the first pallet from the machine tool (400) to the work station (500) after completion of the transfer of the second pallet from the work station (500) to the pallet storage (200), or in parallel with the transfer of the second pallet from the work station (500) to the pallet storage (200).