Variable Barrier Reach Instrument for Worker Measurement
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Solution Overview
Problem
In the manufacturing industry, particularly in automobile assembly, there is a need to accurately and systematically measure the reach of assembly line workers at varying barrier heights to optimize task assignment and design tasks that match employee capabilities.
Innovation Solution
A system and apparatus that includes a variable barrier reach instrument with adjustable heights, a sensing and recording device, and a software program to simulate, measure, and record a subject's ability to perform barrier reaches, generating an interpolated arc of their reach capabilities at different barrier heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a physical barrier is used to simulate actual work conditions, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The patent uses a physical barrier that replicates the actual work environment conditions without requiring the complete complex assembly structure. The barrier is a simplified copy that captures the essential reaching constraint characteristics, allowing accurate measurement without the full complexity of actual automotive assembly equipment.
Solution Approach 2:
The physical barrier serves as an intermediary element between the worker and the measurement system. It translates complex work condition constraints into a simplified reaching task that can be systematically measured, mediating between real-world complexity and measurement capability.
2Measurement precision
If multiple barrier heights are tested to capture varying reach capabilities, then measurement completeness is improved, but testing time increases
Solution Approach 1:
The barrier height is made adjustable and variable, allowing the testing system to dynamically adapt to different measurement requirements. This enables comprehensive assessment of reach capabilities across multiple heights without requiring separate fixed structures for each measurement condition.
Solution Approach 2:
The system varies the barrier height parameter systematically to capture different aspects of reach capability. By changing this single parameter across multiple test conditions, the system achieves comprehensive measurement coverage efficiently.
3Productivity
If automated sensing and recording devices are used to capture reach data, then productivity is improved, but device complexity increases
Solution Approach 1:
The sensing and recording device is designed to perform multiple functions: detecting barrier contact, tracking reach distance, recording data points, and generating interpolated arcs. This multi-functionality increases productivity without proportionally increasing complexity, as a single integrated system handles all measurement tasks.
Solution Approach 2:
The automated sensing device provides real-time feedback on reach performance by continuously monitoring and recording data points. This feedback mechanism enables immediate assessment of reach capabilities, improving productivity through automated decision-making support.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables systematic measurement and recording of reach performance, allowing for optimal task assignment and task design matching, improving efficiency and safety by ensuring workers are assigned tasks that suit their abilities.
Implementation Method 1
a linear encoder attached to a second end of the cable and configured to sense and record an amount of cable that is withdrawn from the linear encoder at various times
Implementation Method 2
a rotary encoder slidably engaging the cable along a length thereof and configured to sense and record the angular displacement of the bar and cable at various times
Data Source
AI summary
A method and apparatus for simulating, measuring and recording a subject's ability to perform a varying range of barrier reaches is provided. The apparatus includes a variable barrier reach instrument for simulating an actual barrier that the subject may lean against in performing a work task The variable barrier reach instrument may include a physical barrier having a substantially horizontal upper surface at a height above a base point. A sensing and recording device may be positioned proximate to the variable barrier reach instrument for sensing and recording a plurality of barrier reach data points as the subject bends forward against the physical barrier. A computer and an associated software program are also provided into which the recorded data points are entered. An algorithm may be contained within the software program that generates an interpolated arc reflecting the subject's reach at the physical barrier height from the recorded data points. Storage means associated with the computer are further provided for storing the interpolated arc and recorded data points.