Reconfigurable Manufacturing Modules for Flexible Biochemical Processing
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Solution Overview
Problem
Existing assembly lines for manufacturing biological or chemical materials are difficult to scale or reconfigure due to the challenges of moving heavy equipment, requiring significant space and time, and are limited by stationary utility systems and fixed connections.
Innovation Solution
A manufacturing module system comprising a work station, transportation segment, pick and place robot, and movement mechanism that allows for modular, scalable, and reconfigurable assembly line configurations, enabling easy movement and connection of modules with integrated utility connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional assembly line equipment is moved to scale or reconfigure production, then production parameters can be changed, but the process becomes difficult, time-consuming, and expensive due to heavy equipment weight and size
Solution Approach 1:
The assembly line is divided into discrete, modular workstations that can be independently moved and reconfigured. Each workstation is a self-contained unit with standardized interfaces, allowing flexible reconfiguration without moving entire fixed assembly lines. This segmentation enables adaptability while reducing the effective weight that needs to be moved at any one time.
Solution Approach 2:
The system transitions from static, fixed assembly lines to dynamic, movable workstations. The workstations are designed with mobility features such as wheels, casters, or robotic positioning systems that enable them to be easily relocated and repositioned along the production line, transforming the rigid assembly line into a flexible, reconfigurable system.
2Adaptability or versatility
If assembly line equipment is rearranged to change production parameters, then product variety or production volume can be adjusted, but the assembly line must be taken offline causing production downtime
Solution Approach 1:
Multiple workstation configurations are pre-designed and pre-positioned along the production line. When reconfiguration is needed, workstations simply move between pre-prepared positions rather than requiring complex real-time adjustments. This preliminary preparation of positions and pathways minimizes downtime during reconfiguration events.
Solution Approach 2:
The system enables continuous production during reconfiguration through features such as parallel processing paths, buffer storage areas, and the ability to reconfigure one section while other sections continue operating. This maintains the flow of materials and products, preventing complete line shutdowns during adaptation.
3Adaptability or versatility
If heavy equipment is moved using transportation equipment like forklifts or cranes, then reconfiguration can occur, but the process becomes expensive and complex
Solution Approach 1:
Workstations are equipped with self-propulsion capabilities such as integrated motors, drive systems, or automated guidance features that enable them to move themselves to new positions without requiring external forklifts or cranes. This self-service mobility reduces the complexity of the overall transportation system and eliminates the need for heavy external equipment.
4Reliability
If stationary transportation systems and utility systems are used, then stable operations are maintained, but reconfiguration becomes difficult due to fixed connection positions
Solution Approach 1:
Utility connections such as power, data, and pneumatic lines are designed with universal, standardized interfaces that can connect to multiple positions along the production line. These multi-functional connection points can serve different workstations in different configurations, allowing utility systems to adapt to reconfigured layouts without requiring fixed, dedicated connections for each workstation position.
Data Source
AI summary
Disclosed are apparatuses, systems, and methods for processing materials, including biological or chemical materials. A manufacturing module may include a work station configured to perform a process involving equipment capable of use with biological or chemical material, a first transportation segment that is configured to connect and disconnect with a second transportation segment such that when connected, a carrier of the biological or chemical material can be transported from the first transportation segment to the second transportation segment, a pick and place robot configured to move an element between the first transportation segment and the work station; and a movement mechanism configured to allow the work station, the first transportation segment, and the pick and place robot to be moved as a single unit. A system may include a plurality of manufacturing modules that are reconfigurable to a plurality of configurations.