Vehicle Body Turntable Assembly for Failure-Resilient Production
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Solution Overview
Problem
Existing vehicle body production systems face interruptions due to facility failures, leading to increased costs and inefficiencies, as they require additional buffer facilities to prevent process interruptions, which incur excessive investment costs.
Innovation Solution
A vehicle body production system utilizing multiple turntables and robots to adapt production to vehicle types and quantities, allowing flexible production methods that reduce facility maintenance and management costs, and enable continuous production without line interruptions by rerouting panels to operational turntables during failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If buffer facilities are added between production processes to prevent interruptions, then production continuity is improved, but facility investment costs increase excessively
Solution Approach 1:
The system dynamically switches between normal production mode and failure response mode. When a facility failure occurs, the control unit automatically redirects panels from the failed turntable to operational turntables, enabling dynamic adaptation to maintain production continuity without requiring permanent buffer facilities
Solution Approach 2:
The system changes operational parameters by redirecting panel flow paths based on facility status. Instead of maintaining fixed buffer facilities, the system dynamically alters production parameters (panel routing, turntable assignment) to achieve continuity, reducing facility investment while maintaining reliability
2Adaptability or versatility
If multiple turntables are installed to enable flexible multiple-vehicle production, then adaptability is improved, but facility maintenance and management costs increase
Solution Approach 1:
Multiple turntables are designed with universal functionality to produce different vehicle types. The control unit manages panel allocation across turntables based on production requirements, allowing each turntable to serve multiple purposes and reducing overall maintenance complexity through standardized design
Solution Approach 2:
The system uses standardized turntable designs that can be replicated across multiple units. This copying approach allows flexible production of different vehicle types while maintaining uniform maintenance procedures and reducing management costs through consistency
3Reliability
If a bogie-changing device is used to handle facility failures, then production continuity is improved, but facility complexity increases
Solution Approach 1:
The patent removes the bogie-changing device from the system entirely. Instead of using a complex mechanical device to handle failures, the system extracts this function and replaces it with a control unit that manages panel redistribution to operational turntables, achieving the same continuity goal with reduced complexity
Data Source
AI summary
A vehicle body production system includes a plurality of turntables including a plurality of jigs disposed therein and configured to weld and assemble a panel, a supply robot configured to grip the panel and supply the panel to the turntable, an assembly robot provided beside the turntable and configured to weld and assemble the panel supplied to the turntable, a take-out robot configured to take out the welded and assembled panel, and a control unit configured to control the supply robot to grip a plurality of panels and supply the plurality of panels to the turntable depending on a vehicle type, to control the assembly robot to sequentially weld and assemble the supplied panels while rotating the turntable depending on the vehicle type, and to control the take-out robot to take out the welded and assembled panels.