Serpentine Conveyor Operator Access and Workpiece Positioning
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Solution Overview
Problem
Current power transmission device assembly methods using synchronous or non-synchronous assembly lines often result in inefficiencies due to limited operator access and flexibility, leading to reduced output as operators are restricted to one side of the workpiece and required to move excessively, resulting in underutilization of manpower and redundant tooling.
Innovation Solution
A conveyor system with a serpentine path allowing a single operator to access a workpiece at multiple positions along a continuous loop, enabling efficient movement between stations without crossing the conveyor and providing access to both sides of the workpiece, thereby optimizing operator placement and reducing unnecessary movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operators are positioned on opposite sides of the conveyor track to access both sides of the workpiece, then both sides of the workpiece can be accessed, but the number of operators required increases and manpower efficiency decreases
Solution Approach 1:
The conveyor system is segmented into multiple sections (first section, second section, third section) that allow a single operator to access the workpiece at different locations along the serpentine path, eliminating the need for multiple operators on opposite sides
Solution Approach 2:
The operator positioning is changed from a two-dimensional arrangement (opposite sides of the conveyor) to a three-dimensional serpentine configuration where the operator can access the workpiece from a single location at multiple points along the folded conveyor path
2Device complexity
If the conveyor system uses a straight or carousel configuration, then the assembly line structure is simple, but operators have limited access to the workpiece and must walk large distances
Solution Approach 1:
The conveyor system uses a serpentine (curved/folded) path configuration instead of a straight line, allowing the operator to remain in one location while the workpiece passes by at multiple stations along the curved path
Solution Approach 2:
Multiple workstations are merged into a compact serpentine configuration that allows a single operator to service multiple stations without walking large distances, combining the functions of what would traditionally require multiple operators
3Ease of operation
If multiple operators are positioned at the same station to perform operations on both sides of the workpiece, then both sides can be serviced, but operator downtime increases and productivity decreases
Solution Approach 1:
The workpiece access points are segmented into multiple discrete stations along the serp conveyor path, allowing different operations to be performed at different locations rather than requiring multiple operators at a single station
Solution Approach 2:
The serpentine conveyor configuration enables continuous workpiece movement through multiple access points, ensuring that operators can continuously perform operations without idle time while the workpiece passes by at different stations
Data Source
AI summary
A method of assembling a power transmission device includes positioning an operator along a conveyor system such that the operator may perform multiple operations to a single workpiece at more than one workstation as the workpiece moves along the conveyor system. The assembly method relates to both closed-loop and open-ended conveyor systems.