Workpiece Carrier Device Coupling for Automated Substrate Handling
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Solution Overview
Problem
Manual handling of workpiece carriers in coating plants for substrates like turbine blades is time-consuming, unsafe, and prone to errors, leading to plant downtimes due to high temperatures and the need for individual substrate handling.
Innovation Solution
A method and system utilizing a robot to automate the changing of workpiece carrier devices through mechanical coupling and displacement, allowing for simultaneous and secure exchange of multiple substrates, reducing operator workload and minimizing handling errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling of workpiece carriers is used, then operators can directly handle substrates, but the process is time-consuming and leads to plant downtimes
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robot system. The robot gripper mechanically grasps the workpiece carrier device and performs automated displacement between supply zone and processing zone, eliminating manual operations and reducing plant downtime.
Solution Approach 2:
The workpiece carrier device is designed with self-contained features including integrated connecting arms with coupling interfaces and drive shafts that can be automatically engaged with the robot and production plant, enabling automated self-positioning and self-coupling without manual intervention.
2Reliability
If manual assembly and disassembly is performed, then substrates can be individually handled, but handling errors occur and safety issues arise due to high temperatures
Solution Approach 1:
The robot system with specialized gripper replaces manual mechanical handling. The gripper is designed to securely grasp the workpiece carrier device without direct contact with hot substrates, eliminating safety hazards from high temperature exposure and preventing handling errors through precise automated control.
Solution Approach 2:
The robot acts as an intermediary between the operator and the hot workpiece carrier device. It handles all operations in the high-temperature environment, protecting operators from thermal exposure while ensuring accurate and error-free handling through automated positioning and coupling operations.
3Ease of operation
If workpiece carrier device is manually changed, then individual substrates can be replaced, but the process is unergonomic and requires operator exposure to harsh conditions
Solution Approach 1:
The robot system completely replaces manual mechanical operations for workpiece carrier device handling. The robot performs gripping, lifting, pivoting, and displacement operations that would be unergonomic for human operators, particularly in high-temperature environments, thereby eliminating ergonomic risks.
Solution Approach 2:
The workpiece carrier device incorporates automated coupling interfaces and positioning features that enable self-alignment and self-connection with the robot and production plant, reducing the complexity of operation and making the system easier to operate without exposing personnel to harsh conditions.
4Productivity
If automated robot system is implemented, then substrate change speed increases, but device complexity increases due to coupling mechanisms
Solution Approach 1:
The coupling system is segmented into distinct functional components: robot gripper for grasping, connecting arms for positional connection, drive shafts for rotational connection, and locking mechanisms for securing. This segmentation allows each component to be optimized independently while maintaining overall system productivity.
Solution Approach 2:
The workpiece carrier device incorporates universal coupling interfaces that can be automatically engaged by the robot and connected to the production plant's drive system. These multi-functional interfaces handle both positional and rotational coupling, reducing the need for separate mechanisms and managing device complexity while maintaining high automated operation speed.
Data Source
AI summary
The disclosure relates to a method for changing a workpiece carrier device in a production plant for coating substrates. The method comprises the steps of:displacing a workpiece carrier device by means of a robot from a supply zone to a processing zone;releasably coupling the workpiece carrier device to the production plant via a coupling interface of the workpiece carrier device by further displacing the workpiece carrier device by means of the robot,wherein for releasably coupling the workpiece carrier device to the production plant, a connecting arm of the workpiece carrier device is coupled to a connection section of the production plant, thereby fixing the connecting arm in a fixed position relative to the connection section, andwherein for releasably coupling the workpiece carrier device to the production plant, a drive shaft of the workpiece carrier device is coupled to a driving shaft of the production plant, thereby connecting the drive shaft to the driving shaft in a rotatably drivable manner.