Type-variable production line with movable processing system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing production lines for motor vehicle body components face high resource expenditure and low utilization due to redundant equipment for different body types, and frequent type changes result in low production rates and equipment outlay.
Innovation Solution
A type-variable production line with type-specific processing stations equipped for consecutive joining operations, utilizing a single independent processing system that can be converted and moved between stations, along with a multi-axis robot and a single loading system, allowing for efficient processing of multiple body types with minimal equipment outlay and maintaining production cycle integrity during type changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple type-specific processing stations with complete tool sets are provided for different body types, then each body type can be processed with dedicated equipment, but production resources expenditure increases and equipment utilization decreases
Solution Approach 1:
A single processing station is designed to handle multiple body types through type-specific tool sets that can be exchanged. The station includes a positioning device with adjustable positioning elements and a fixing device with exchangeable fixing elements, allowing one station to perform the functions previously requiring multiple dedicated stations.
Solution Approach 2:
The processing station incorporates movable and adjustable components including positioning elements that can be moved to different positions, and fixing elements that can be exchanged. This dynamic configuration allows the station to adapt its structure and functionality based on the specific body type being processed.
2Device complexity
If a single processing station with type-independent basic equipment is provided, then production resources are reduced, but tool replacement time increases during body type changes
Solution Approach 1:
Tool sets for different body types are prepared in advance and can be quickly exchanged. The positioning elements and fixing elements are designed for rapid reconfiguration, with pre-positioned components that reduce the time required to switch between different body type configurations.
3Adaptability or versatility
If multiple type-specific processing stations are provided for each production step, then each body type has dedicated processing capability, but manufacturing equipment expenditure becomes very high
Solution Approach 1:
The processing station is designed as a universal unit that can process multiple body types through the exchange of tool sets. The station includes a positioning device with adjustable positioning elements and a fixing device with exchangeable fixing elements, allowing one station to replace multiple dedicated stations while maintaining dedicated processing capability for each body type.
4Device complexity
If a single processing system serves multiple processing stations, then equipment expenditure is reduced, but the system must be moved between stations during type changes
Solution Approach 1:
The processing system is designed to be movable between processing stations, with the positioning and fixing devices configured to accommodate this movement. The system can be relocated during type changes, and the station configurations are designed to minimize relocation time and maintain production continuity.
Data Source
AI summary
The type variable assembly line has processing stations, particularly geometry stations (3.1,3.2,3.3,3.4,3.5) for positioning, fixing and machining of the body components, where the stations are arranged along the assembly line. Multiple different type specific assembled processing stations are arranged adjacent to one another in the course of the assembly line and a common processing system (5) is assigned to the processing stations. The processing system is moved alternatively between the individual processing stations depending on the respective assembly type.