Rear Suspension Member Transfer Assembly Buffering

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Solution Overview

Problem

Conventional methods for transferring rear suspension members from a sub-assembly line to a main assembly line often result in downtime due to the lack of a buffer between the two lines, causing main assembly line operations to be held up while waiting for the next rear suspension member to be transferred.

Innovation Solution

A rear suspension member transfer assembly comprising a first lifter, a buffer, and a second lifter, where the first lifter retrieves and transports the member laterally between the lines, the buffer holds and positions the member through multiple resting points, and the second lifter raises it for installation, allowing continuous assembly and reducing downtime.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional floor-mounted arms and transfer dollies are used to maneuver the rear suspension member, then the transfer operation can be performed, but the main assembly line operations are held up waiting for the next RSM to be transferred, resulting in downtime

Engineering Contradiction:

Improveassembly line productivityVSAvoiddowntime during RSM transfer

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by having the first RSM lifter retrieve and position RSMs on the buffer in advance, before they are needed by the main assembly line. This allows RSMs to be prepared and staged ahead of time, eliminating waiting time when the main line needs them.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The buffer assembly acts as an intermediary between the sub-assembly line and the main assembly line. It temporarily stores RSMs and decouples the two lines, allowing them to operate independently without holding each other up during transfer operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If no buffer is provided between the sub-assembly line and the main assembly line, then the system structure remains simple, but the main assembly line must wait for RSM transfer operations to complete

Engineering Contradiction:

Improvecontinuous assembly capabilityVSAvoidtransfer assembly structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The buffer assembly serves as an intermediary storage system between the sub-assembly line and main assembly line. It temporarily holds RSMs and decouples the two production lines, allowing them to operate independently without synchronization delays.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the first RSM lifter travels laterally between assembly lines to retrieve and transport RSMs, then the RSM can be transferred between lines, but the operation requires coordination and may cause delays

Engineering Contradiction:

ImproveRSM retrieval and transport operationVSAvoidtime for lateral transport and coordination

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The first RSM lifter performs preliminary retrieval and positioning actions, placing RSMs on the buffer before they are needed. This advance preparation eliminates the need for time-critical lateral transport operations when the main assembly line requires an RSM.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The buffer assembly acts as an intermediary that receives RSMs from the first lifter and makes them available to the second lifter. This decouples the lateral transport operation from the main assembly line timing, allowing the lifter to operate at its own pace without causing delays.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11352209B2Rear suspension member transfer assemblies and methods

Publication Date: 2022.06.07 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC

AI summary

A rear suspension member (RSM) transfer assembly for transferring an RSM from a sub-assembly line to a main assembly line includes a first RSM lifter, an RSM buffer, and a second RSM lifter. The first RSM lifter is configured to travel laterally between the sub-assembly line and the main assembly line. The first RSM lifter includes a lifting body and a rotatable arm configured to retrieve the RSM from the sub-assembly line and transport the RSM to the main assembly line. The RSM buffer is configured to receive the RSM from the first RSM lifter and transport the RSM through a plurality of resting positions. The second RSM lifter is configured to receive the RSM from the RSM buffer and raise the RSM into position for installation on a vehicle.