Method for the setup and/or the reconfiguration of an industrial plant, particularly for the manufacturing of motor vehicles or subassemblies thereof
11550302 · 2023-01-10
Assignee
Inventors
- Denny Monti (Turin, IT)
- Antonino Polimeni (Turin, IT)
- Marco Verger (Turin, IT)
- Diego Biancardi (Turin, IT)
Cpc classification
Y02P90/30
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G05B19/41815
PHYSICS
B23P21/00
PERFORMING OPERATIONS; TRANSPORTING
B23P21/004
PERFORMING OPERATIONS; TRANSPORTING
E04H5/02
FIXED CONSTRUCTIONS
B23Q37/007
PERFORMING OPERATIONS; TRANSPORTING
G05D1/0287
PHYSICS
International classification
G05B19/418
PHYSICS
G06Q10/06
PHYSICS
H01R13/00
ELECTRICITY
B23Q37/00
PERFORMING OPERATIONS; TRANSPORTING
B23P21/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Described herein is a method for setting up and/or reconfiguring an industrial plant, in particular for the manufacture of motor vehicles or sub-assemblies thereof. The method includes providing a plurality of mobile processing stations, each mobile processing station comprising a palletisable platform and at least one interface unit provided on the palletisable platform and configured for the coupling of the mobile processing station with one or more further adjacent mobile processing stations; arranging mobile processing stations according to a pre-set layout; and coupling at least one interface unit of each mobile processing station with the at least one interface unit of one or more further mobile processing adjacent stations thereto. Each interface unit includes at least one of the following: an electrical and/or electronic coupling device; a fluidic coupling device; and a mechanical coupling device.
Claims
1. A method for setting up and/or reconfiguring an industrial plant, comprising: providing a plurality of mobile processing stations, each mobile processing station of plurality of mobile processing stations comprising a palletisable platform and at least one interface unit provided on the palletisable platform and configured for coupling of that mobile processing station with one or more further adjacent mobile processing stations; arranging said plurality of mobile processing stations according to a predetermined layout; coupling the at least one interface unit of each mobile processing station with the at least one interface unit of one or more further mobile processing stations adjacent thereto, and prior to arranging the plurality of mobile processing stations according to the pre-set layout, shipping the plurality of mobile processing stations to one or more concerned destinations for the set up of the industrial plant, wherein each interface unit comprises at least one of the following: an electrical and/or electronic coupling device; a fluidic coupling device; and a mechanical coupling device.
2. The method according to claim 1, wherein each mobile processing station of the plurality of mobile processing stations and the one or more further mobile processing stations comprises at least one of the following: one or more processing machines; one or more magazines for workpieces or components; one or more tool magazines; and one or more electronic controllers.
3. The method according to claim 1, further including a reconfiguration step comprising: providing an additional mobile processing station in addition to the plurality of mobile processing stations and/or the one or more further mobile processing stations; displacing of one or more mobile processing stations of the plurality of mobile processing stations and/or the one or more further mobile processing stations so as to create a vacancy between two adjacent mobile processing stations of the plurality of mobile processing stations and/or the one or more further mobile processing stations; and inserting said additional mobile processing station into said vacancy.
4. The method second claim 3, wherein said displacing of one or more mobile processing stations comprises, prior to displacement, decoupling the at least one interface unit of each mobile processing station of the two adjacent mobile processing stations.
5. The method claim 1, further including a reconfiguration step comprising: identifying a mobile processing station of the plurality of mobile processing stations and/or the one or more further mobile processing stations to be eliminated; decoupling the at least one interface unit of the mobile processing station to be eliminated from the at least one interface unit of each mobile processing station adjacent the mobile processing station to be eliminated; and removing the mobile processing station to be eliminated.
6. The method according to claim 5, further including displacing one or more mobile processing stations of the plurality of mobile processing stations and/or the one or more further mobile processing stations so as to fill a vacancy created with removal of the mobile processing station to be eliminated.
7. The method according to claim 1, wherein said providing the plurality of mobile processing stations comprises providing the plurality of mobile processing stations on a basis of a local demand for goods to be produced by the industrial plant, specific to each of said concerned destinations involved.
8. The method according to claim 7, further comprising, subsequent to the setting up of the industrial plant, varying a production capacity thereof by increasing or eliminating groups of the plurality of mobile processing stations and/or the one or more further mobile processing stations in one or more of said concerned destinations involved.
9. The method according to claim 8, further including shipping the groups of the plurality of mobile stations eliminated in one of said concerned destinations to another of said concerned destinations where an increase in production capacity is required.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention will now be described with reference to the annexed drawings, which are provided purely by way of non-limiting example and in which:
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DETAILED DESCRIPTION OF THE INVENTION
(11) With reference to
(12) In the embodiment illustrated herein, the station 1 comprises two interface units 4A and 4B, but in the present description the interface unit is in general associated to the reference 4. Defined on the palletisable platform 2 is an operative volume 6, arranged within which is at least one of the following (c.f.
(13) Each interface unit comprises at least one of the following: an electrical and/or electronic coupling device; a fluidic coupling device; and a mechanical coupling device. Preferably, each palletisable platform 2 comprises interface units equipped with all three of the aforementioned devices, which are used (or deactivated) according to the need. Preferably, the function of mechanical coupling is implemented in combination with an electrical/electronic and/or fluidic coupling device, thus providing a sort of universal connector for the stations 1. Illustrated by way of example in the diagram of
(14) The structure with main line, as will be seen hereinafter, is useful in the case where the station 1 is to be used as mere connection element between adjacent stations, for example when one of the systems on board is not required, or none of them is required, to supply any unit of the station.
(15) By means of the interface units 4 it is possible to integrate in the palletisable platform all the supply lines of the station, and it is possible in this way to convey the electrical or fluidic supply between stations 1 of the plant without any need for extensive fixed networks or systems being installed in the building that houses the plant. Not only this, but the interface units 4 also enable mechanical coupling of the palletisable platforms 2 so as to ensure mutual positioning of the stations 1 in the case where this were to be required.
(16) Alternatively, the interface unit 4 can enable coupling to fixed positioning structures arranged on the floor in the case where the stations 1 were to be arranged according to a layout that does not envisage strict adjacency.
(17) An example of interface unit is illustrated in the diagrams of
(18) Provided at the head H—in the complete configuration—are the mechanical interface M, the electrical/electronic interface E, and the fluidic interfaces F (
(19) It should moreover be borne in mind that, according to the needs, it is possible to have a larger number of interface units 4 in the version with a head H on each side of the platform 2: in this case, it is possible to distribute the interfaces H, F, M in a uniform way on the heads or else concentrate some interfaces on one head and provide the remaining ones on another head.
(20) It is moreover possible to have just one interface unit 4 in the version with a head H for each side, for example in the case where it is desired to relegate to a simpler interface unit once again set on the same side (for example, a simple mechanical coupler) the function of mechanical interface between adjacent platforms 2.
(21) As may be seen in
(22) With reference to
(23) A first step consists in providing a plurality of mobile processing stations 1 according to the needs of the production cycle; by way of non-limiting example, in the case of a plant for manufacturing motor vehicles, the mobile stations 1 may comprise body-in-white (welding) stations, painting stations, body-in-white stations, and stations for assembly of vehicle sub-assemblies.
(24) A second step consists in arranging the mobile processing stations according to a pre-set layout, where this layout is dictated by the specific sequence of operations that is envisaged for the production cycle. Again, in the case of motor vehicles, the sequence of operations—except for certain operations that require a given sequence (e.g., welding of the body prior to painting)—may depend upon the model of vehicle produced. As illustrated in
(25) A third step consists in coupling the at least one interface unit 4 of each mobile processing station 1 with at least one interface unit 4 of one or more further mobile processing stations 1 adjacent thereto in such a way as to provide, according to the needs, the electrical, and/or fluidic, and/or mechanical coupling of the processing stations 1 of the plant by means of the interface units 4. It should be borne in mind, as has been mentioned, that in certain cases a mobile processing station 1 that does not directly require, for example, supply of fluid, may in any case be fluidically coupled to the adjacent stations in so far as, according to the position that it occupies in the pre-set layout of the stations 1, it is convenient for it to function as stretch of fluidic connection between the stations adjacent thereto, which may possibly require supply of fluid or may once again function as mere connection elements. In this sense, provision of a main-line scheme for the electrical and/or fluidic systems enables easy implementation of this possibility, without recourse to external bypass lines.
(26) Moreover, some stations 1 can be purposely equipped with interface units 4 not designed for coupling to other stations 1. In particular, these interface units may be designed for temporary connection to an auxiliary mobile station, for example transported by means of an AGV (Automated Guided Vehicle), which interacts with some equipment on board the station 1 for given operations. For instance, when the station 1 is provided with an industrial robot R (for example, a welding robot, a handling robot, a painting robot, etc.) in the case of high-power welding, the needs for cooling the welding jaws may prove excessive for the capacity of the system on board the platform 2. In this case, the auxiliary station may consist of a mobile chiller unit, which is temporarily coupled to the platform 2 that carries the robot R to contribute to cooling of the jaws. An implementation of this arrangement is illustrated in
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(30) After this, the second station 1 is positioned alongside the template D (once again using forklift truck or other manipulator) (part III).
(31) The template D is then removed, and the station SS is inserted in position between the two stations 1 (part IV). The units AC, GF, AS, QE are then operatively and mechanically connected to the stations 1 by means of the interface units 4.
(32) It should moreover be noted that, even though
(33) Thanks to the method according to the invention, it is hence possible to set under way a production cycle without any need for carrying out civil works and/or installing complex fixed networks and systems. In addition, the plant can be set up in any industrial building, without any particular structural requirements of any sort, given that the systems equipment is already provided on board the stations 1, and recourse to overhead lines is not envisaged. The industrial building that is to house the stations 1 becomes—in the limit—a mere “container” of a modular industrial plant obtained by combining the stations 1.
(34) For instance, in the case where there arises the need to set up industrial plants that operate on a small scale in a range of production sites in order to replicate one and the same type of production on a small scale over a more extensive territory and/or in order to produce parts of a single product at a local level, it is possible to define, at the central company level, the work cycle that each production plant is to carry out, and subsequently ship the required mobile processing stations to each site using the means of transport normally used for logistics of goods travelling via container.
(35) The fact that the platforms 2 are palletisable enables these to be transported by means of merchant vessels, rail vehicles, and articulated lorries, all of which being means of transport that are extremely well tested and are capable, in combination, of achieving a good degree of capillarity in distribution of the stations 1.
(36) Thanks to the method and to the stations 1 according to the invention, not only is fast setting-up of an industrial plant possible, but an equally fast reconfiguration thereof is also possible.
(37) In particular, in the case where an additional mobile processing station is provided, the existing constraints in location of the stations in known plants are no longer present; i.e., it is not necessary for the station to be inserted in pre-set points of the plant corresponding to the areas where the vacant stations are arranged.
(38) Provision of vacant stations remains a design constraint necessary for allowing the possibility of recombining the layout of the stations 1, but in no way will the additional stations necessarily have to be placed where the pre-existing vacant stations are present.
(39) In particular, in the case of reconfiguration by addition of a station 1 (
(40) The sequence referred to above applies, of course, on the condition that there exists a vacant station 1V upstream of the stations 1 occupying the first position up to the third position. In the case where the vacant station were located downstream of the station 1 originally in the sixth position, then the operation referred to above would involve the stations 1 that originally occupied the fourth position up to the sixth position, which would be shifted forwards by one position so as to create the required vacancy.
(41) Once the additional mobile processing station has been located in the vacancy thus created, the activity of the plant can be resumed as soon as coupling between the interface units of the new station and the interface units of the adjacent stations has been restored according to the need.
(42) It should moreover be noted that the same method, with the appropriate modifications, can be applied also in the case of reconfiguration by subtraction of processing stations.
(43) In this case (
(44) In the limit, by decoupling all the interface units of all the stations it is possible to re-arrange the entire lot of mobile processing stations 1 of the plant according to a new pre-set layout, dictated, for example, by a sudden demand for production of a new model of motor vehicle.
(45) The method according to the invention moreover underlies the logic of distribution and/or setting-up of industrial plants illustrated schematically in
(46) With reference to
(47) With reference to
(48) The situation illustrated in
(49) Of course, it is also possible to implement in the individual plants IP the methods of reconfiguration by addition or subtraction illustrated in
(50) The situation represented in
(51) By way of example,
(52) Again, the specific structure of the homologous modules in the individual plants may be the same or may differ as regards slight details, according, for example, to the characteristics of the industrial building that houses the plant in the individual country and/or to specific normative needs.
(53) Setting-up of the plants IP1, IP2, IP3 is carried out by implementing the method according to the invention, starting from shipping in loco of the necessary ensembles of stations 1. Of course, it is also possible to implement within the individual plants IP1, IP2, IP3 the methods of reconfiguration by addition and subtraction illustrated in
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(55) A first possibility consists in shipping new ensembles of stations 1 to the countries listed in points a), b), c) above, and in simultaneous dismantling/reduction of capacity in the countries indicated in point d), all carried out adopting the method according to the invention. However, this option is likely to introduce into the reference territory an excess of stations 1, the logistics (and—at this point—accumulation) of which should be managed separately, thus coming to erode the benefits deriving from the method according to the invention.
(56) The most interesting possibility made available by the method according to the invention is outlined, instead, in the specific graphic representation of
(57) In the situation illustrated here, the plant at capacity IP3 installed in the Russian Federation is cut down to the capacity IP1 (references (IP3), IP1 in
(58) As regards Spain, the plant originally at capacity IP1 present in Italy is completely dismantled (reference (IP1) in
(59) In this way, it becomes possible to re-modulate with extreme rapidity and ease the volumes of production in the countries involves, thus rendering the method free from all the constraints proper to plants of a known type.
(60) Of course, the details of construction and the embodiments may vary widely with respect to what has been described and illustrated herein, without thereby departing from the present invention, as defined by the annexed claims.