Robotic Pallet Transfer for Continuous Workpiece Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing systems with robotic devices experience periods of non-operation during workpiece changeouts, reducing production throughput and increasing labor costs due to the need for manual loading and unloading.
Innovation Solution
A manufacturing system with a manufacturing cell that includes multiple pallets, robotic devices, and a transport system allowing continuous operation by coordinating the movement of pallets between processing stations, enabling robotic devices to operate on one workpiece while another is transferred, thus minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and unloading of workpieces is performed, then labor costs increase and production throughput decreases, but the system structure remains simple
Solution Approach 1:
The system divides the workpiece handling process into separate functional modules: robotic devices for processing, pallets for workpiece support, and transport devices for movement. This segmentation allows each component to operate independently and simultaneously, enabling continuous production without manual intervention while maintaining manageable system complexity through modular design.
Solution Approach 2:
The manufacturing system implements continuous operation by coordinating multiple pallets and processing stations. While one pallet is being processed by a robotic device, another pallet is being transported or prepared, eliminating idle time and ensuring the robotic device continuously performs useful work without manual loading/unloading interruptions.
2Productivity
If robotic devices operate continuously, then production throughput increases, but safety risks increase due to human presence in work envelope
Solution Approach 1:
The system extracts the hazardous function of manual workpiece handling from the production process and replaces it with automated robotic devices. Human operators are removed from the immediate work envelope during robotic operation, eliminating safety risks associated with human presence while maintaining continuous production throughput through automated pallet loading and unloading.
3Productivity
If multiple processing stations are added to enable continuous operation, then production throughput increases, but device complexity increases
Solution Approach 1:
The pallet design serves multiple functions: it supports workpieces during processing, facilitates automated transport between stations, and enables quick changeover. This multi-functionality allows the system to achieve continuous operation with minimal additional processing stations, as the same pallet infrastructure supports both processing and transport operations.
Solution Approach 2:
The transport device acts as an intermediary between processing stations, automatically moving pallets without requiring additional manual handling stations. This intermediary function enables continuous operation by bridging the gap between processing cycles, maintaining production throughput while avoiding the need for complex multi-station manual handling systems.
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A manufacturing system (100) for processing workpieces (186) includes a manufacturing cell (102), a plurality of pallets (160) supporting workpieces (186), and at least one robotic device (200) configured to operate on the workpieces. The manufacturing system (100) also includes first and second processing stations (306, 308) configured to support any one of the pallets (160) in fixed position relative to the robotic device (200). The manufacturing system (100) additionally includes at least one transport device (400) configured to transport any one of the pallets (160) to and from each of the first and the second processing stations (306, 308). In addition, the manufacturing system (100) includes a controller (104) configured to coordinate the operation of the manufacturing cell (102) in a manner allowing the robotic device (200) to continuously operate on a workpieces (186) supported by a pallet (160) at the first processing station (306), while another pallet (160) is transported to or from the second processing station (308).