Welding Work Cell Activity Detection for Accurate Arc-On Utilization
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Solution Overview
Problem
Current manufacturing facility management systems face challenges in efficiently tracking utilization metrics for welding equipment, such as arc on percentage and operator presence, due to manual processes and reliance on time-consuming access to time clock systems.
Innovation Solution
A system and method that detect operator activity in work cells to automatically calculate arc on time percentage and determine the number of employees working, using sensors and electronic messages to accumulate and analyze time periods, eliminating the need for user-defined work periods and reducing reliance on time clock data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tracking of welding power supply energized time is used, then equipment utilization measurement is obtained, but the process is time-consuming and prone to errors
Solution Approach 1:
The patent replaces manual mechanical tracking of equipment usage with an automated electronic sensor system. Sensors detect when the welding power supply is energized and automatically record the time periods, eliminating the need for manual data collection while maintaining measurement accuracy.
Solution Approach 2:
The system enables the welding equipment to self-report its usage status through integrated sensors that automatically detect and record when the power supply is energized. This self-service capability eliminates the need for external manual tracking and reduces errors associated with human operation.
2Loss of information
If time clock system data is accessed to determine operator presence, then number of employees working is obtained, but access is problematic and time-consuming
Solution Approach 1:
The patent introduces sensors as intermediary devices that directly detect operator presence in work cells. These sensors serve as a mediator between the operator and the data collection system, providing real-time presence information without requiring access to the time clock system.
Solution Approach 2:
The system extracts operator presence detection functionality from the time clock system by implementing independent sensors in work cells. This extraction allows presence data to be collected separately and more efficiently, eliminating the need to access the time clock system for this information.
3Reliability
If welding power supply is left on when not in use, then equipment availability is maintained, but utilization metrics become inaccurate
Solution Approach 1:
The patent implements a feedback mechanism where sensors continuously monitor the actual usage state of the welding power supply and compare it with the powered-on state. This feedback loop enables the system to distinguish between equipment being on but not in use versus actually being used, ensuring accurate utilization metrics while maintaining equipment availability.
Data Source
AI summary
A system for optimizing manufacturing utilization is disclosed. The system includes a manufacturing apparatus configured to transmit a first electronic message type indicating a time period when the manufacturing apparatus is in use, as well as a sensor disposed in a work cell associated with the manufacturing apparatus, the sensor configured to transmit a second electronic message type indicating a time period of operator activity within the work cell. The system further includes a computing device configured to receive the first and second electronic message types and accumulate one or more of each of the respective time periods of the first and second electronic message types. The computing device determines utilization of the manufacturing apparatus based on accumulated time periods corresponding to the first electronic message type as a percentage of accumulated time periods corresponding to the second electronic message type.