Self-Driving Workpiece Conveyance for Flexible Assembly Flow
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Solution Overview
Problem
Existing industrial assembly processes are inefficient due to the need for fixed conveyance infrastructure and complex scheduling of mobile-transport units, which leads to uncertainties in production time and sequence requirements for unique finished goods.
Innovation Solution
A method and system utilizing self-driving vehicles that transport assemblies between workstations, planning paths and speeds based on mission instructions from a fleet-management system, allowing operations to be performed on the vehicle while in transit, and dynamically adjusting for obstructions and work periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed conveyance infrastructure (conveyor belts, chain conveyors) is used, then workpieces can be moved through assembly stages, but the system becomes inflexible and requires significant infrastructure installation
Solution Approach 1:
The patent replaces static conveyor infrastructure with dynamic mobile-transport units that can autonomously navigate the facility. These vehicles dynamically adapt their paths and schedules based on real-time conditions, eliminating the need for fixed conveyance infrastructure while maintaining continuous workpiece flow through the assembly process.
Solution Approach 2:
The patent substitutes mechanical conveyor systems with autonomous mobile vehicles equipped with sensors and control systems. This replacement transitions from rigid mechanical infrastructure to flexible programmable systems that use sensors, processors, and communication networks to coordinate transport operations.
2Ease of operation
If separate round trips are made by mobile-transport units for each work-cell operation, then workpieces can be delivered to specific work cells, but scheduling complexity increases significantly
Solution Approach 1:
The patent combines multiple separate transport operations into integrated missions. A single mobile-transport unit can perform multiple deliveries to different work cells in one continuous operation, and multiple units coordinate their missions to transport different workpieces simultaneously. This merging reduces the total number of trips and simplifies scheduling compared to individual round trips for each operation.
Solution Approach 2:
The patent enables continuous operation by allowing mobile-transport units to maintain motion and perform operations without returning to a home position between deliveries. Units can pick up new workpieces while en route to complete current deliveries, eliminating idle time and reducing scheduling complexity through overlapping operations.
3Reliability
If workpieces are stored at work cells until available, then operations can be completed in sequence, but production time uncertainty increases
Solution Approach 1:
The patent implements real-time feedback through sensors and communication systems that monitor workpiece locations, work cell availability, and vehicle status. This feedback enables dynamic scheduling adjustments, allowing the system to optimize delivery timing and reduce waiting time while ensuring operations complete in the correct sequence. The fleet-management system uses this information to coordinate arrivals and minimize production time uncertainty.
4Adaptability or versatility
If on-demand pick-up and delivery is used, then workpieces are transported only when needed, but assembly line efficiency decreases
Solution Approach 1:
The patent uses preliminary action by pre-planning missions and predicting work cell availability. The fleet-management system schedules mobile-transport units to arrive at work cells just in time for operations, rather than waiting for on-demand requests. This advance planning maintains on-demand responsiveness while improving efficiency through coordinated, timely deliveries that minimize work cell idle time.
Data Source
AI summary
Systems and methods for flexible conveyance in an assembly-line or manufacturing process are disclosed. A fleet of self-driving vehicles and a fleet-management system can be used to convey workpieces through a sequence of workstations at which operations are performed in order to produce a finished assembly. An assembly can be transported to a first workstation using a self-driving vehicle, where an operation is performed on the assembly. Subsequently, the assembly can be transported to a second workstation using the self-driving vehicle. The operation can be performed on the assembly while it is being conveyed by the self-driving vehicle.