Stocker Driving System with Manual-Auto Port Conversion
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Solution Overview
Problem
The existing stocking systems for liquid crystal display (LCD) manufacturing face bottlenecks during sudden increases in demand and are vulnerable to malfunctions, leading to shutdowns when automatic input/output ports fail.
Innovation Solution
A stocker driving system with manually operated ports that can be converted to automatic operation to handle increased loads and serve as backups in case of failures, utilizing a mode conversion controller and a stocker master controller to manage input/output operations between automatic and manual guided vehicle ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If only automatic AGV input/output ports are used, then automation level is improved, but system reliability deteriorates when malfunctions occur
Solution Approach 1:
The patent introduces manually operable input/output ports as a pre-prepared backup mechanism. When automatic AGV ports malfunction, the system can switch to manual operation mode, preventing complete system shutdown. This cushioning mechanism ensures continuous operation and improves reliability while maintaining high automation during normal conditions.
2Device complexity
If only a pair of AGV input/output ports are installed, then device complexity is reduced, but productivity deteriorates during sudden demand increases
Solution Approach 1:
The patent makes the input/output ports dynamic by enabling switching between automatic and manual operation modes. During normal operation, automatic mode handles standard throughput. During sudden demand increases, manual ports can be activated to supplement automatic ports, dynamically increasing system capacity without permanently complicating the device structure.
Solution Approach 2:
The manually operable ports serve multiple functions: they act as backup during malfunctions, capacity supplements during high demand, and provide operational flexibility. This multi-functionality allows the system to handle various scenarios without requiring separate dedicated systems for each function.
3Productivity
If manual ports are converted to automatic mode, then productivity is improved during peak demand, but ease of operation deteriorates due to operational complexity
Solution Approach 1:
The control system automatically manages the conversion between manual and automatic modes based on system needs. The controller receives signals about demand levels and malfunction conditions, then automatically configures the appropriate operation mode without requiring complex manual intervention from operators, maintaining ease of operation while improving productivity.
Data Source
AI summary
Disclosed is a stocking system that effectively copes with contingencies such as a sudden increase in the number of units to be stocked or malfunctions that render a port disabled. The stocking system includes a plurality of input ports and output ports that are operated automatically, and in input/output port that is normally operated manually, but is configurable to be operated automatically in conjunction with the other input ports and output ports. The stocking system also includes a conversion controller for switching the input/output port between manual and automatic mode.