Rotating Material Carousel for Accessible Workbench Replenishment
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Solution Overview
Problem
In manufacturing and assembly facilities, the 'L' or 'U' shaped workbench configurations lead to inaccessible materials for operators, disrupting production and wasting usable factory floor space due to materials being stored in rear portions, making it difficult for operators to access necessary components and for material handlers to replenish them without interrupting operations.
Innovation Solution
A material carousel with a rotating hub and adjustable support column, featuring a plurality of arms that can hold cable and/or harness assemblies or bins, allowing for the reconfiguration of arms and bins to optimize space usage, enabling operators to access materials easily and allowing material handlers to replenish without disrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If materials are stored in the rear portion of workbenches, then material storage capacity is improved, but operator accessibility to materials deteriorates
Solution Approach 1:
The patent transitions from two-dimensional workbench surface storage to three-dimensional vertical carousel structure. Materials are stored in bins mounted on a vertical carousel column, allowing operators to access materials at multiple height levels and angular positions, thereby maintaining high storage capacity while dramatically improving accessibility through rotational movement and elevated positioning.
Solution Approach 2:
The patent introduces a dynamically rotating carousel structure that can be manually or automatically positioned to bring any stored material bin into the operator's reach. This dynamic repositioning capability eliminates the static accessibility problems of rear workbench storage, allowing any stored material to be quickly accessed without operator strain or disruption to production flow.
2Productivity
If workbenches are arranged in L or U shaped configuration, then production workflow is improved, but usable factory floor space deteriorates
Solution Approach 1:
The patent utilizes vertical space by mounting carousels above workbenches rather than expanding horizontal footprint. This vertical dimension approach allows L or U shaped workbench configurations to maintain their production workflow advantages while the overhead carousel structures provide material storage without consuming additional floor space, effectively converting unused vertical volume into functional storage capacity.
3Quantity of substance
If material handlers replenish materials directly on the rear portion of workbenches, then material replenishment is achieved, but production operations are disrupted
Solution Approach 1:
The patent introduces the carousel structure as an intermediary between material handlers and production operators. Material handlers can replenish bins on the carousel from a centralized location away from the production line, while the carousel systematically delivers materials to operators as needed. This intermediary system eliminates direct interference with production operations during material replenishment activities.
Data Source
AI summary
A material carousel for manufacturing and/or assembly operations is provided. The carousel includes a hub fabricated from a low friction material wherein the hub has a polygonal shape. The carousel also includes a plurality of equally spaced arms which are press fit into the hub. Each arm is adapted to hold cable and/or harness assemblies or includes a bin for holding materials used for production operations. In addition, the carousel includes a support column that extends through the hub, wherein the hub is adapted to rotate about the support column. An adjustable support column is also provided for supporting the hub on the support column. Further, the carousel includes a peg mechanism for stopping rotation of the hub after a predetermined rotation angle.