Virtual Parts Loading Control for Flexible Line Supply
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Solution Overview
Problem
Conventional parts delivery systems rely on manual operation of forklifts, leading to inefficiencies, safety hazards, and inaccurate inventory management due to human error, without the use of automatic warehouse facilities, which degrades production flexibility and productivity.
Innovation Solution
A parts delivery system utilizing an autonomous mobile robot (AMR) and automated guided vehicles (AGVs) to automatically load and discharge parts based on virtual space data, synchronized with a manufacturing execution system (MES), optimizing space utilization and scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual forklift operation is used for parts loading and discharging, then operational flexibility is maintained, but safety hazards increase and productivity decreases
Solution Approach 1:
The system enables automated self-service operation where the forklift autonomously performs parts loading and discharging operations without human operators. The control system automatically manages navigation, positioning, and operational execution, eliminating safety hazards associated with manual operation while maintaining continuous productivity.
Solution Approach 2:
The patent replaces manual mechanical operation with an automated control system that integrates navigation, positioning, and operational control. This substitution eliminates human involvement in hazardous operations while enhancing productivity through consistent, error-free automated execution.
2Extent of automation
If automatic warehouse facility is installed in parts loading site, then loading and discharging automation is achieved, but space occupancy increases and production flexibility decreases
Solution Approach 1:
The forklift system is designed to perform multiple functions including autonomous navigation, parts loading, discharging, and space utilization optimization. This multi-functionality allows the system to operate effectively in existing parts loading sites without requiring dedicated warehouse facilities, thereby maintaining production flexibility while achieving automation.
Solution Approach 2:
The system dynamically adapts to varying production requirements and spatial constraints by utilizing empty spaces in existing parts loading sites. The automated forklift can flexibly adjust its operational patterns and route planning to accommodate different production scenarios without fixed infrastructure.
3Device complexity
If manual parts loading and discharging is performed, then no automated infrastructure is needed, but information accuracy deteriorates and inventory management fails
Solution Approach 1:
The automated system incorporates feedback mechanisms where the control system continuously monitors and tracks parts loading and discharging operations. This real-time information tracking ensures accurate inventory management and prevents information loss, while the standardized automated process maintains manageable system complexity.
Data Source
AI summary
Disclosed are a parts delivery system and a method of operating the same. The parts delivery system includes a production line configured to receive parts and assemble a finished product, a parts loading site configured to have a space where the parts are loaded; a parts transportation unit configured to load the parts in the parts loading site or discharge the parts from the parts loading site to supply the parts to the production line, and a processor configured to provide virtual space data on the parts loading site, to establish a parts loading schedule and a parts discharging schedule on the virtual space data according to an assembly schedule of the finished product of the production line, and to control the parts transportation unit to load or discharge the parts in the actual parts loading site according to the parts loading schedule and the parts discharging schedule.