Paternoster Conveyor Module for Ergonomic Part Supply
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing production lines face inefficiencies in supplying parts and components to assembly stations, leading to operator discomfort and potential health risks due to prolonged postures and efforts during assembly operations.
Innovation Solution
The introduction of a production line module equipped with a paternoster conveyor system that includes automated drawers, allowing for efficient and ergonomic supply of parts and components to assembly stations, with the ability to position drawers at convenient heights and tilt for easy access, and flexibility in adapting to different assembly sequences and part variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional part supply methods are used at assembly stations, then operators can access parts, but operators experience physical strain and discomfort due to prolonged postures and efforts
Solution Approach 1:
The paternoster conveyor system dynamically positions drawers at different heights and locations around the assembly station, allowing operators to access parts at ergonomically optimal positions rather than fixed locations. The system adapts to operator needs by providing continuous movement and repositioning of part containers.
Solution Approach 2:
The system transitions from a single-plane, fixed-position part supply method to a three-dimensional, multi-level paternoster conveyor that distributes parts vertically and horizontally around the operator, eliminating the need for awkward postures and reaching movements.
2Reliability
If fixed part supply positions are used, then parts are available to operators, but operators must assume harmful postures for prolonged periods
Solution Approach 1:
The paternoster conveyor continuously moves and repositions drawers to dynamic locations around the assembly station, ensuring parts remain accessible while eliminating fixed, ergonomically poor positions. The system adapts to maintain optimal access points throughout the production cycle.
Solution Approach 2:
The system automatically delivers parts to optimal positions without requiring operators to reach, bend, or strain themselves. The automated conveyor service replaces manual part retrieval, eliminating harmful physical actions while ensuring continuous part availability.
3Ease of operation
If manual part retrieval is used, then operators can access parts, but assembly efficiency is reduced due to time spent on part handling
Solution Approach 1:
The paternoster conveyor operates continuously, constantly delivering parts to optimal access positions without interruption. This eliminates the intermittent, time-consuming manual retrieval process by maintaining continuous part flow to the operator throughout the assembly cycle.
Solution Approach 2:
The automated conveyor system performs the time-consuming part retrieval function automatically, freeing the operator to focus solely on assembly tasks. The system serves itself by continuously circulating and positioning drawers without operator intervention.
4Productivity
If traditional logistics systems are used for part distribution, then parts are supplied to assembly stations, but the system lacks flexibility for different assembly sequences and part variations
Solution Approach 1:
The paternoster conveyor system dynamically reconfigures drawer positions and contents to match different assembly sequences and part requirements. The system adapts its operation in real-time to accommodate variations in production demands without requiring physical reconfiguration of the entire logistics infrastructure.
Solution Approach 2:
The single paternoster conveyor system serves multiple assembly stations with different part requirements and assembly sequences. The universal system can be programmed to handle various part types, configurations, and delivery schedules, replacing multiple dedicated fixed systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances operator comfort and productivity by ensuring efficient part supply and logistics, reducing physical strain and enabling flexible adaptation to changing production demands without interrupting the assembly process.
Implementation Method 1
said rear hook assembly being designed to move, in this condition, into a position of optical-beam interception, in which a first interception element forming part of the rear hook assembly intercepts a first optical beam emitted by a first optical sensor
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A production line (1) comprises at least one assembly station (2) which is electronically controlled, in which a chain-conveyor device (3) feeds with continuous motion a plurality of pallets (5) carrying parts to be assembled. The production line (1) further comprises at least one module for carrying containers (A) provided with a plurality of part-holder containers (C) for supplying parts to said at least one assembly station (2). The module (A) comprises a plurality of drawers (C) associated to a paternoster conveyor system.