Variable Jig Module for Automated Conveyance Assembly
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Solution Overview
Problem
The high manufacturing cost and difficulty in reusing or modifying jigs in assembly processes lead to significant losses in factories, especially when product standards change, requiring frequent jig replacements and disrupting production.
Innovation Solution
A conveyance apparatus with a variable jig module that adjusts its supporting base based on the shape of the workpieces, using a transport unit, sensing units, image processing, and a controller to manage the assembly process without the need for jig replacements, allowing for common jig usage across different products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fixed jigs are used for each product, then assembly precision is maintained, but manufacturing cost increases and productivity decreases due to frequent jig replacements
Solution Approach 1:
The patent implements a universal jig system where a single base jig can accommodate multiple different works through interchangeable fixing means. The fixing means includes multiple fixing positions with different fixing patterns, allowing the same jig to be used across various assembly processes for different products, thereby eliminating the need for frequent jig replacements and improving productivity
Solution Approach 2:
The jig system incorporates dynamic adaptability through selectable fixing patterns and adjustable fixing positions. The controller dynamically selects appropriate fixing patterns based on work identification, and the fixing means can be adjusted to different positions to match different work shapes and assembly requirements, enabling the jig to adapt to various products without physical replacement
2Adaptability or versatility
If product standards change, then market adaptability improves, but assembly precision deteriorates due to lack of jig modification capability
Solution Approach 1:
The system maintains assembly precision during product standard changes by dynamically selecting from multiple pre-configured fixing patterns. When a new product standard is introduced, the corresponding fixing pattern is selected by the controller based on work identification, ensuring that the fixing means is optimally positioned for the new product geometry without requiring jig modification
Solution Approach 2:
The fixing means can change its operational parameters including position, orientation, and fixing pattern based on the specific work being assembled. The system stores multiple fixing patterns with different parameters in the controller, and automatically adjusts the fixing means to the appropriate parameters when product standards change, maintaining assembly precision across different products
3Manufacturing precision
If multiple specialized jigs are manufactured for different works, then assembly precision is ensured, but manufacturing cost increases significantly
Solution Approach 1:
Instead of manufacturing multiple specialized jigs, the patent creates a single universal jig with multiple fixing positions and interchangeable fixing means. This universal jig can perform the assembly function for multiple different works, eliminating the need for expensive specialized jig manufacturing while maintaining assembly precision through proper fixing pattern selection
Solution Approach 2:
The jig system is segmented into a base jig structure and separate interchangeable fixing means. The fixing means can be independently selected and positioned according to the specific work requirements, allowing the same base jig to serve multiple functions without requiring multiple complete jig assemblies, thereby reducing manufacturing cost
4Adaptability or versatility
If jig replacement is performed when product standards change, then adaptability improves, but productivity decreases due to production stoppage
Solution Approach 1:
Multiple fixing patterns and positions are pre-configured in the controller before production begins. When a product standard change occurs, the controller automatically selects the pre-programmed fixing pattern corresponding to the new product, eliminating the need for time-consuming jig replacement operations and maintaining continuous production
Solution Approach 2:
The system dynamically switches between different fixing patterns based on real-time work identification without physical jig replacement. The controller receives work identification information and automatically adjusts the fixing means to the appropriate pattern, enabling rapid adaptation to product changes while maintaining continuous production flow
Data Source
AI summary
A conveyance apparatus including a variable jig and a driving method thereof. The conveyance apparatus includes a transport unit including a transfer belt extending from a loading position to an unloading position of works, the transport unit being a movement path for the works, a variable jig module disposed with respect to a position, where the works stop, in the movement path to support the works, the variable jig module being a variable jig that varies a supporting base, based on shapes of the works, a sensing unit disposed outside the transfer belt with respect to the variable jig module to measure a movement or position of the works, an image processing unit configured to perform image processing on the works transported through the transfer belt, and a controller electrically connected to the variable jig module to control an operation of the variable jig module.