Sub-pallet Machining Facility Conveyance System

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Solution Overview

Problem

Existing machining facilities face inefficiencies in conveying and setup of workpieces due to the need for large robots to handle main pallets, which become cumbersome and require multiple gripper hands for various workpiece sizes and weights, leading to poor conveyance and setup efficiency.

Innovation Solution

A machining facility utilizing a sub-pallet system that allows for flexible orientation and quick positioning of a sub-pallet gripper, with a conveyor system that includes a swiveling mechanism and cleaning station, enabling efficient conveyance and cleaning of sub-pallets, reducing the size and complexity of the conveyor system compared to handling main pallets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a robot with one arm is used to grip and convey main pallets with workpieces, then the robot can perform loading and unloading operations, but the conveyance efficiency is poor and the robot size becomes large

Engineering Contradiction:

Improveconveyance efficiencyVSAvoidrobot size

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The pallet system is segmented into main pallets (for robot handling) and sub-pallets (for workpiece mounting). The robot only needs to handle the lightweight main pallets, while sub-pallets remain on the workpieces. This segmentation reduces the weight and size of the conveyed objects, improving conveyance efficiency without requiring larger robots.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sub-pallets are extracted from the main pallets and placed directly on the workpieces. This allows the robot to handle only the essential main pallets for positioning and support, while the sub-pallets with workpieces are conveyed separately or remain stationary during machining, reducing the overall system complexity and robot requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If multiple types of hands are mounted on the robot to handle various workpiece shapes and weights, then the robot can adapt to different workpieces, but it requires preparing multiple hands and multiple hand operating programs

Engineering Contradiction:

Improveworkpiece handling capabilityVSAvoidnumber of hands and programs

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The main pallets are designed with universal features that can accommodate different sub-pallet configurations and workpiece arrangements. The robot uses a single standardized hand to handle all main pallets, while the sub-pallets on the workpieces provide the necessary adaptability for different workpiece shapes and weights. This multi-functionality approach eliminates the need for multiple specialized hands and programs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If large main pallets are used to accommodate various workpieces, then the pallets can handle different workpiece sizes, but the weight conveyed by the robot becomes larger even for small workpieces

Engineering Contradiction:

Improveworkpiece accommodation capabilityVSAvoidpallet weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The pallet system is divided into main pallets and sub-pallets. Main pallets are kept lightweight and serve only as support structures, while sub-pallets are mounted directly on the workpieces and provide the necessary size variations. This segmentation allows small workpieces to be handled on lightweight main pallets without the excess weight of large standardized pallets.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If workpieces are directly mounted on main pallets, then the setup process is straightforward, but the efficiency of setup work is poor

Engineering Contradiction:

Improvesetup process simplicityVSAvoidsetup efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Sub-pallets are prepared in advance with workpieces mounted on them before being placed on the main pallets. This preliminary action allows workpiece positioning and clamping to be performed separately and efficiently, then the pre-prepared sub-pallets are quickly transferred to the main pallets for conveyance, improving overall setup efficiency while maintaining process simplicity.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP2062687B1Machining facility using sub-pallet

Publication Date: 2012.10.31 MAKINO MILLING MASCH CO LTD

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AI summary

Provided is a flexible machining facility using a sub-pallet, which can quickly satisfy the increasing or decreasing of units or other required specifications. It The machining facility includes a machine tool (1) having a pallet changer (47) for changing main pallets (39), a plurality of sub-pallets (3) for a workpiece to be mounted thereon, a setup station (5) for carrying the sub-pallet (3) and mounting and dismounting a workpiece on and from the sub-pallet (3), a sub-pallet stocker (7) for carrying the sub-pallet (3) thereon, and a sub-pallet conveyor system (9) for conveying the sub-pallet (3) and configured to include sub-pallet carrying parts of the machine tool (1), setup station (5), and sub-pallet stocker (7) in a workable area thereof. The sub-pallet (3) can be used to convey and machine a workpiece.