Parallel Assembly Cells for Flexible Manufacturing
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Solution Overview
Problem
Traditional assembly lines in manufacturing are inefficient due to their serial process nature, which limits flexibility, leads to resource wastage, and requires extensive retooling and space, making them unsuitable for producing a variety of products or adjusting to changing demands.
Innovation Solution
A method and apparatus for assembling complex products in a parallel process system using computerized assembly and test cells, where subcomponents and base components are transported and assembled automatically, allowing for flexible production and efficient use of space through a transport system that includes overhead gantries or robotic arms, enabling the assembly and testing of multiple products in a compact setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a serial assembly line is used to assemble complex products, then the assembly process can be completed with dedicated workstations, but the system requires extensive space, extensive retooling for different products, and cannot easily adjust to changing production demands
Solution Approach 1:
The system divides the assembly process into independent parallel cells, each capable of performing complete assembly operations. This segmentation allows each cell to be independently controlled and reconfigured, enabling the system to switch between different product types without extensive retooling of the entire assembly line.
Solution Approach 2:
Each assembly cell is designed with universal capabilities to handle multiple product types through programmable robots and modular tooling. The cells can be reconfigured via software control to assemble different complex products, eliminating the need for dedicated workstations for each product type.
2Productivity
If a serial assembly line with multiple workstations is used, then complete assembly operations can be performed, but the space requirements become extensive and resource wastage occurs
Solution Approach 1:
Multiple assembly operations that would traditionally require separate workstations are merged into integrated parallel cells. Each cell combines material handling, assembly operations, and quality inspection in a compact configuration, significantly reducing the total floor space required while maintaining complete assembly capability.
Solution Approach 2:
The system transitions from a linear serial arrangement to a three-dimensional parallel configuration with overhead material handling. This dimensional change allows multiple assembly cells to be stacked or arranged vertically, reducing the horizontal footprint while maintaining productivity.
3Productivity
If assembly lines are dedicated to specific components and models, then efficient assembly of that specific product can be achieved, but retooling is required when production demands change
Solution Approach 1:
The assembly cells incorporate programmable robots and modular tooling that can be dynamically reconfigured through software control. This dynamic adaptability allows the system to switch between different product types without physical retooling, maintaining assembly efficiency while responding to changing production demands.
Solution Approach 2:
The system changes operational parameters through programmable control rather than physical reconfiguration. By modifying software parameters, tool sequences, and robot paths, the assembly cells can efficiently produce different products without the complexity and time associated with physical retooling operations.
4Reliability
If the transport system stops to allow operations at each workstation, then quality control can be performed, but downtime occurs and productivity is reduced
Solution Approach 1:
The parallel cell configuration with decoupled material handling allows each cell to operate continuously without being blocked by operations at other cells. Quality control operations proceed simultaneously in parallel cells, maintaining continuous production flow while ensuring quality standards are met through integrated inspection capabilities in each cell.
Data Source
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AI summary
A method and apparatus for assembling a complex product (12) in a parallel process system wherein a collection of components are provided for assembling the complex product. The present invention involves transferring the collection of the components to one of a plurality of similar computerized assembly cells (20) through the use of a transport system (18). The collection of components is automatically assembled into the complex product through the use of the computerized assembly cells. The complex product is then transferred from one of the assembly cells to a computerized test cell (22), where the complex product is tested to ensure for the proper dimensioning and functioning of the complex product. The complex product is then transferred from the test cell via the transport system to either a part reject area or conveyor (24), if the complex product is defective, or to an automatic dunnage load or part return system (26), if the complex product is not defective.