Rotatable Wiring Module Production Plant with Manual-Mechanical Work Coordination
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Solution Overview
Problem
There is a need for a production plant that efficiently combines manual and mechanical work to manufacture wiring modules, as the mechanization of wire harness assembly has advanced, requiring a system that can skillfully integrate both types of work processes.
Innovation Solution
A wiring module production plant with a rotatable support having multiple stages and stations, allowing for manual and mechanical work to be performed sequentially, where the rotatable support is controlled to rotate only when both manual and mechanical work stations have completed their tasks, ensuring efficient processing and preventing rotation during active work.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotatable support rotates continuously to transport objects through multiple stations, then productivity is improved, but safety deteriorates due to risk of rotation during active work
Solution Approach 1:
The system uses sensors to detect worker presence and work completion status, providing feedback signals that control the rotation regulator. When a worker is detected or work is incomplete, the feedback prevents rotation; when work is complete, the feedback enables rotation, thus resolving the contradiction between continuous production and work safety
Solution Approach 2:
The rotation regulator dynamically adjusts the rotation state of the rotatable support based on real-time work status. The system transitions between static (during work) and dynamic (during transport) states, allowing both high productivity during transport and high safety during manual operations
2Productivity
If the production plant uses fully automated mechanical work stations, then productivity is improved, but adaptability deteriorates for tasks requiring manual dexterity
Solution Approach 1:
The production plant is segmented into multiple work stations with different functional characteristics. Some stations are equipped for automated mechanical work while others are designed for manual operations, allowing the system to leverage both automation efficiency and human adaptability for different task requirements
Solution Approach 2:
The rotatable support structure serves multiple functions: it transports objects between stations, positions objects for both automated and manual work, and coordinates the sequence of operations. This multi-functional design enables the system to accommodate diverse work types while maintaining high throughput
3Productivity
If the rotatable support rotates at high speed to increase throughput, then productivity is improved, but measurement precision deteriorates for detecting work completion status
Solution Approach 1:
The system performs preliminary detection of work completion status using sensors before initiating rotation. This ensures that the rotation only occurs when work is truly complete, maintaining detection accuracy while enabling high-speed operation during the actual rotation and transport phases
Data Source
AI summary
A wiring module production plant includes a rotatable support supported so as to be capable of rotating and having N stages (where N is an integer equal to or greater than two) on which an object (such as a base wiring module and a bracket) involved in production of the wiring module can be arranged, the stages being provided corresponding to each of N positions having N-fold rotational symmetry. N stations are provided so as to respectively correspond to each of the N positions having N-fold rotational symmetry centered around a rotation axis of the rotatable support. The N stations include a manual work station which allows manual work to be performed on the object, and a mechanical work station which allows mechanical work to be performed on the object.