Virtual Stop Station for Assembly Line Synchronization
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Solution Overview
Problem
Current assembly line systems face limitations in adaptability, particularly when complex assembly subprocesses require varying speeds, leading to inefficiencies and increased costs due to the need for stop stations and inaccurate encoder feedback, which also occupy valuable space and require additional workstations.
Innovation Solution
A 'virtual' stop station system utilizing a gantry carriage with independently moving robots and vision guidance, allowing for flexible integration within existing assembly lines without modifying the conveyor system, enabling robotic assembly independent of line speed and motion, thus eliminating the need for additional space and reducing labor and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a stop station is inserted into the moving assembly line to accommodate complex assembly subprocesses, then the adaptability for varying assembly speeds is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent replaces the mechanical stop station system with an encoder feedback control system. The encoder provides position feedback to the robot controller, which synchronizes robot operations with the moving assembly line speed electronically, eliminating the need for physical conveyor speed changes and stop stations.
Solution Approach 2:
The patent changes the control parameter from mechanical speed adjustment to electronic position feedback. The encoder converts physical position into electrical signals that the robot controller uses to synchronize operations, transforming a mechanical adaptation problem into an electronic control solution.
2Adaptability or versatility
If a stop station is inserted into the moving assembly line, then the adaptability for complex assembly subprocesses is improved, but the assembly line space requirements increase
Solution Approach 1:
The patent replaces the mechanical stop station infrastructure with a compact encoder feedback system. The encoder and robot controller work together to provide the necessary adaptability for complex assembly processes without requiring additional physical space or stopping the assembly line.
3Adaptability or versatility
If encoder feedback is used to synchronize robot with assembly line speed, then the adaptability is improved, but the measurement precision deteriorates due to chain backlash and wear
Solution Approach 1:
The patent introduces a pulley system as an intermediary mechanism that directly couples the encoder to the conveyor drive shaft. This eliminates the intermediate chain transmission that causes backlash and wear, providing accurate position feedback while maintaining synchronization capability.
4Adaptability or versatility
If encoder is coupled to assembly line conveyor drive at a distance from robotic station, then the adaptability is improved, but the cost increases due to cable length
Solution Approach 1:
The pulley system acts as a mechanical intermediary that transmits motion and position information from the conveyor drive to the encoder located at the robotic station. This eliminates the need for long electrical cables to connect distant components.
Data Source
AI summary
A virtual stop station is provided having a carriage straddling an assembly line operation. This provides an independently moving platform upon which one or more manufacturing robots are affixed. The carriage is coordinated with and tracked to the linear motion of the assembly line. A vision guidance system centers the workpiece, and lifting arms mounted on the moving carriage will locate the workpiece and lift the workpiece up off of the conveyor, while being coordinated with it. The workpiece and robots thus are now fixtured to the same frame, thus eliminating movement relative to one another creating a virtual stop station. Once subassembly is complete, the coordinated robotic gantry will disengage from the conveyor and return home. The instant abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.