Transfer-Storage Layout for Compact Automated Machining Lines
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Solution Overview
Problem
Compact-design machine tools face challenges in automation due to limited space, requiring innovative solutions for efficient and precise handling and transfer of workpieces while maintaining operator access and integration with existing manufacturing systems.
Innovation Solution
A manufacturing system with a handling cell adjacent to the machine tool, featuring a handling unit for automated workpiece and tool changes, and a combined transfer and storage device for efficient workpiece handling and storage, allowing partial or fully automated operation without occupying the machine tool's working space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a compact-design machine tool is used to machine small components, then the machining precision and efficiency are improved, but the space for automation equipment and workpiece handling becomes insufficient
Solution Approach 1:
The patent transitions from horizontal workspace to vertical stacking arrangement, utilizing the third dimension (height) to accommodate multiple machine tools and automation equipment. Machine tools are arranged vertically with robotic cells positioned between them, effectively converting limited horizontal space into usable vertical space for both machining and automation operations.
Solution Approach 2:
The patent implements a nested configuration where robotic cells are positioned within the vertical space between stacked machine tools. The robotic cells are integrated into the available gaps, allowing automation equipment to operate within the footprint of the machine tool arrangement without requiring additional horizontal space.
2Productivity
If automation equipment is added to enable automated workpiece handling, then productivity is improved, but the device complexity increases
Solution Approach 1:
The robotic cells are designed with multi-functionality, capable of performing both workpiece handling and tool changing operations. This universal design reduces the need for separate specialized equipment, thereby improving productivity while limiting the increase in system complexity.
Solution Approach 2:
The patent combines multiple functions into integrated units: robotic cells that handle both workpieces and tools, and control systems that manage multiple machine tools through centralized architecture. This merging approach streamlines the automation system, enhancing productivity without proportionally increasing complexity.
3Area of stationary object
If multiple machine tools are arranged in a stacked configuration, then space utilization is improved, but the difficulty of integration and coordination increases
Solution Approach 1:
The manufacturing system is segmented into modular stacked units, each comprising a machine tool and associated robotic cell. This segmentation allows for standardized integration patterns and simplified coordination, as each module can be independently configured and then systematically connected through consistent interfaces and control protocols.
Solution Approach 2:
The patent introduces centralized control systems and standardized communication interfaces as intermediaries between the stacked machine tools and robotic cells. These intermediary elements facilitate coordinated operation by managing data exchange and synchronization, thereby reducing the complexity of direct point-to-point integration between multiple devices.
4Productivity
If the working space of the machine tool is reduced to accommodate compact design, then the manufacturing efficiency is improved, but the ease of operation and maintenance deteriorates
Solution Approach 1:
The patent addresses operator access challenges by utilizing vertical arrangement to provide multiple access levels. Operators can approach machine tools from different vertical positions, and control interfaces are positioned at ergonomically appropriate heights, maintaining ease of operation despite reduced individual working spaces.
Solution Approach 2:
The system incorporates automated robotic cells as intermediaries that handle routine operations, reducing the need for operators to physically access tight working spaces. This allows compact machine tool design while maintaining operational ease through automation-assisted workflows and remote monitoring capabilities.
Data Source
AI summary
A combined transfer and storage device for machining includes a storage level, a transfer device, at least one machining interface, and a feeding interface. The storage level has two or more storages that are spaced apart from one another in a longitudinal direction and storage spaces for workpiece carriers, which are arranged one above the other for holding blanks or machined workpieces. The transfer device extends in the longitudinal direction. The machining interface is used for directly or mediately coupling with a machine tool. The feeding interface is accessible for a driverless transport vehicle. The transfer device accomplishes a workpiece transfer between the feeding interface, the storage level and the at least one machining interface. A manufacturing line is provided with a combined transfer and storage device and with at least one manufacturing system having at least one machine tool and a handling cell.