Tool Magazine Positioning to Minimize Automation Idle Time
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Solution Overview
Problem
Automation facilities face non-productive idle times due to inefficient handling and storage of machine tools in object storage magazines, leading to suboptimal process step transitions and increased handling times.
Innovation Solution
A system utilizing a probabilistic model to calculate optimal assignments of objects to magazine positions within an object storage magazine, based on observed object exchange times and the sequence of productive non-idle times, to minimize idle times and improve handling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If machine tools are stored in object storage magazine and pre-fetched by object handler, then machine tool availability is improved, but non-productive idle times increase due to handling and storage operations
Solution Approach 1:
The system performs pre-fetching of machine tools during productive periods when the current tool is still in use. The object handler retrieves the next required machine tool from the storage magazine and positions it in advance during the processing time of the current tool, so that the tool change can occur immediately when the current tool is finished, eliminating idle waiting time.
Solution Approach 2:
The optimization system calculates and enforces a continuous sequence of actions where the object handler is constantly engaged in productive operations. By carefully sequencing pre-fetch, store, and exchange operations, the system ensures that the object handler never remains idle and that machine tools are always available when needed, converting what would be idle time into productive handling operations.
2Productivity
If object handler performs pre-fetch and store operations, then machine tool switching efficiency is improved, but device complexity increases due to additional handling operations
Solution Approach 1:
The object handler is designed as a multi-functional device that performs multiple operations: pre-fetching machine tools from storage, temporarily storing them, exchanging tools between machine and storage, and post-storing finished tools. By consolidating these diverse functions into a single versatile handler, the system avoids the need for separate specialized devices for each operation, thereby managing complexity while maintaining high switching efficiency.
Solution Approach 2:
The system implements a nested structure where the object handler contains multiple slots for holding machine tools, and within the storage magazine, tools are organized in racks with multiple positions. This nesting allows the handler to manage multiple tools simultaneously and perform sequential operations without returning to the main storage, reducing the number of external interactions and simplifying the overall control logic.
3Adaptability or versatility
If machine tool exchange operations are performed frequently, then process adaptability is improved, but loss of time increases due to repeated handling operations
Solution Approach 1:
Before a machine tool exchange is needed, the system calculates the optimal sequence of operations and initiates pre-fetching of the required tool during the processing time of the current tool. This preliminary action ensures that when the exchange is needed, the new tool is already positioned and ready, minimizing the actual exchange time and allowing frequent tool changes without proportional increase in handling time.
Solution Approach 2:
The optimization system dynamically adjusts the handling sequence based on the specific process requirements, tool usage patterns, and current system state. By calculating optimal assignments in real-time and adapting the pre-fetch and store operations to match the actual production needs, the system minimizes handling time while maintaining the flexibility to respond to changing process requirements.
Data Source
AI summary
Provided is a system and method for minimizing non-productive idle times within an automation process executed by an automation facility, the system including a model memory which stores a probabilistic model of a distribution of object exchange times of objects used or consumed in the automation process; and an optimizer adapted to calculate optimal assignments of objects to magazine positions of an object storage magazine depending on the probabilistic model and depending on a sequence of productive non-idle times of objects used or consumed in process steps of the automation process.