Production system
11623706 · 2023-04-11
Assignee
Inventors
Cpc classification
B65G2203/0283
PERFORMING OPERATIONS; TRANSPORTING
B65G1/0492
PERFORMING OPERATIONS; TRANSPORTING
B62D65/18
PERFORMING OPERATIONS; TRANSPORTING
B66F9/0755
PERFORMING OPERATIONS; TRANSPORTING
B66F9/19
PERFORMING OPERATIONS; TRANSPORTING
International classification
B62D65/18
PERFORMING OPERATIONS; TRANSPORTING
B66F9/075
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Production system for series production of in particular motor vehicles, includes a container storage area storing containers containing components for production, production shelves, remote from container storage area, from which workers remove components from containers. Transport for transporting containers from container storage area to production shelves. Transport has automated guided vehicle (AGV) on which transport shelf is situated and designed so containers are automatically delivered from transport shelf to production shelves in a conveying direction (delivery direction). Handling device situated on AGV, has a base body and a handling unit situated on base body. Handling unit removes containers from transport shelf in conveying direction and delivering containers to production shelf. Relative to base body, handling unit is linearly adjustable along first linear adjustment axis in conveying direction, along a second linear adjustment axis transverse to conveying direction, height-adjustable along a third adjustment axis, and rotatable about vertical fourth adjustment axis.
Claims
1. A production system for the series production of motor vehicles, comprising: a) a container storage area for storing containers that contain components intended for the production, b) a plurality of production shelves, remote from the container storage area, from which components may be removed from a container of the containers by workers, and c) a transport means for transporting containers from the container storage area to the plurality of production shelves, d) the transport means has at least one automated guided vehicle (AGV) on which a transport shelf is situated and which is designed in such a way that the containers are or may be automatically delivered from the transport shelf to the plurality of production shelves in a conveying direction (delivery direction), e) a handling device is situated on the at least one AGV, the handling device having a base body and a handling unit, situated on the base body, and the handling unit is designed for removing the containers from the transport shelf in a conveying direction and delivering the containers to the plurality of production shelves, and f) a control apparatus is provided, and g) wherein relative to the base body the handling unit is linearly adjustable along a first linear adjustment axis in the conveying direction, and is linearly adjustable along a second linear adjustment axis transverse to the conveying direction, and is height-adjustable along a third adjustment axis, and is connected to the base body so as to be rotatable about an essentially vertical fourth adjustment axis, and electric motor drives that are independently controllable by the control apparatus are associated with the first, second, third, and fourth adjustment axes.
2. The production system according to claim 1, wherein: a) the handling unit has at least one fork-like supporting element for supporting a container of the containers to be handled.
3. The production system according to claim 2, wherein: a) at least one supporting element has a conveying means for conveying a container of the containers to be handled in the conveying direction and opposite the conveying direction.
4. The production system according to claim 3, wherein: a) the conveying means has at least one conveyor belt that extends in the conveying direction.
5. The production Production system according to claim 3, wherein: a) the conveying means has at least two spaced-apart conveyor belts situated in parallel.
6. The production system according to claim 5, wherein: a) the at least two conveyor belts are independently controllable by a control apparatus.
7. The production system according to claim 6, wherein: a) for conveying a container of the containers situated on the conveyor belts in the conveying direction, the control apparatus controls the conveyor belts in such a way that they run in the same direction.
8. The production system according to claim 6, wherein: a) for changing the rotational position of a container of the containers situated on the conveyor belts in the conveying direction, the control apparatus controls at least two conveyor belts in such a way that they run in opposite directions.
9. The production system according to 1, wherein: a) a sensor means for determining the position of the handling unit relative to a shelf, is provided, the sensor means being in data transmission connection with the control apparatus in such a way that the control apparatus controls the drives associated with the adjustment axes as a function of the position, determined by the sensor means, of the handling unit relative to the shelf in order to remove a container of the containers from the shelf or deliver a container of the containers to the shelf.
10. The production system according to claim 9, wherein: a) the sensor means has at least one optical sensor.
11. The production system according to claim 2, wherein: a) the supporting element is designed in such a way that it is movable beneath the base of a container of the containers in order to handle a container of the containers that is accommodated in a shelf.
Description
(1) The invention is explained in greater detail below with reference to the appended drawings, in which one embodiment of a production system according to the invention is schematically illustrated, sometimes in the form of a sketch. All features that are described, illustrated in the drawings, and claimed in the patent claims, alone or in any arbitrary combination, constitute the subject matter of the invention, regardless of their recapitulation in the claims or their back-reference, and regardless of their description or illustration in the drawings.
(2) In the drawings:
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(21) The drawings in part are highly schematic in the form of sketches, and the detail is reduced considerably to the level essential for understanding the invention.
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(23) In the series production of motor vehicles, so-called A, B, and C parts are used, the C parts being bulk material with no particular value. In particular C parts are delivered in material containers, also referred to below as containers for short. The production system 2 has a container storage area 6 for storing containers that contain components intended for the production. Production shelves are situated on both sides of the assembly line 4, remote from the container storage area 6, from which containers containing components may be removed by workers. Only one production shelf by way of example is provided with reference numeral 8 in
(24) One important logistical task is to ensure that in the production system 2, a sufficient number of containers containing components necessary for the production are always available on the production shelves 8. One logistical subtask is to transport containers, filled with components, from the container storage area 6 to the production shelves 8, and to deliver them to the containers corresponding to the individual picking shelves 8, depending on the need for components. For transporting containers from the container storage area 6 to the production shelves 8, a transport means is provided, which according to the invention has at least one automated guided vehicle (AGV) within the scope of an automated guided system (AGS). A single AGV is indicated strictly symbolically in
(25) According to the invention, at least one AGV 10 is configured and designed in such a way that containers are or maybe automatically delivered to the production shelves 8.
(26) The AGV 8 is controlled via radio by a central apparatus, for example a central control computer, by means of which all logistical operations within the production system are coordinated, in the illustrated embodiment the radio connection being established via a WLAN.
(27) The AGV 10 is controllable in the container storage area 6 into a loading position, shown in
(28) To report a need for components to one of the production shelves 8, a sensor means is provided at at least one production shelf 8 which senses whether a container is present at a predetermined location on the production shelf. The sensor means may have an optical sensor or at least one electromechanically operating sensor, for example, as known from DE 20 2007 012926 U1, for example, the contents of which are hereby incorporated in full into the present patent application.
(29) An operating path is formed on each of the production shelves 8, and in particular may be designed as a roller conveyor and as an inclined plane, and runs on the container in which the components necessary for the series production are accommodated. Containers that are situated on the same operating path, and thus in the same production shelf, are generally the same components.
(30) With regard to one embodiment of an electromechanically operating sensor of the sensor means, reference is made once again to DE 20 2007 012926 U1, in which it is shown and described that a probe of an electromechanically operating sensor protrudes into the operating path in order to sense whether a material container is present at that time at the location where the sensor is situated. However, it is also possible for a worker to place an empty material container on a deposition surface provided for this purpose, and for a determination to be made via an appropriate sensor means whether a material container is present at that time on this deposition surface, and accordingly, there is a need for a supplementary delivery of components.
(31) According to the invention, the sensor means may generate a requirement notification signal when no container is present at the predetermined location, for example on the production shelf. The requirement notification signal is transmitted via radio to the central apparatus for material demand planning. A plurality of signals that indicate a need for different components at different locations in the production process thus pass to the central apparatus.
(32) A route of the AGV 10 is symbolized by a dashed line 12 in
(33) According to the invention, a transport trip of the AGV 10 may be initiated, for example, as a function of at least one requirement notification signal of the sensor means provided on the production shelves 8. The logistical task of transporting material in containers in a timely manner to the production shelves in such a way that there are always a sufficient number of the necessary components available here, but at the same time, designing transport trips of the AGV to be as economical as possible, for example by approaching different production shelves 8 during a transport trip and at that location delivering containers containing different materials, is achieved by appropriate control in the central apparatus.
(34) However, it is also possible according to the invention to initiate a transport trip of the AGV 10 as a function of at least one requirement control signal of the central apparatus for material demand planning. For example, the material demand at the individual locations in the production process, and thus at the individual production shelves 8, may be estimated based on the advancement in the production process, wherein components are delivered in appropriate containers to the individual production shelves 8, based on the estimate, in accordance with a safety reserve if necessary.
(35) According to the invention, a requirement control may be triggered by a logistician occasionally checking the individual production shelves as to whether a sufficient number of components are still available. A material demand may be communicated to the central apparatus via a suitable technical means, for example via material demand cards which are provided on the individual production shelves, and which for indicating a material demand may be removed and transmitted to the central apparatus.
(36) According to the invention, in a production system the above-described types of requirement notification may also be combined with one another, and optionally also with other methods for requirement notification, at the central apparatus.
(37) The AGV 10 is loaded with filled containers in the loading area, wherein the loading area, for example and in particular, may be formed in the container storage area.
(38) In the loading area, filled containers are scanned before loading the AGV 10; a scanning means for scanning the containers is provided in the loading area for this purpose. In the illustrated embodiment, the scanning means has a scanner for optoelectronically readable characters, in particular a barcode. However, the filled containers may also be scanned in some other way for detection prior to loading of the AGV. For example, the scanning means may have at least one camera.
(39) Thus, for example, within the scope of the method according to the invention a barcode may be affixed to each container. The barcode may be permanently affixed to the container when the same parts are always transported in this container. However, it is also possible to transport different components in the same container during different transport trips of the AGV. An individual barcode is then affixed to each container in accordance with its contents. The particular container is detected by scanning and may be loaded onto the AGV 10.
(40) The design of one embodiment of an AGV according to the invention is explained in greater detail below with reference to
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(42) After the AGV 10 has been loaded, the central apparatus controls it in such a way that the AGV 10 travels from the loading position to a delivery position, specified by the central apparatus, for delivery of loaded, filled containers to at least one production shelf 8.
(43) In the illustrated embodiment, the delivery means is designed as a passive delivery means and is controlled by the central apparatus.
(44) The delivery means on the AGV 10 has at least one delivery chute on which containers may be situated one behind the other at at least two positions. It is apparent from
(45) As is apparent from
(46) As is also apparent from
(47) According to the invention, at least one blocking element is associated with each delivery chute 14, the blocking element being movable from a blocking position, in which the delivery chute 14 is blocked from delivery of containers, and a delivery position, in which the delivery chute is enabled for delivery of containers.
(48) One embodiment of such a blocking element is illustrated in
(49) In the present embodiment, the blocking element is designed as a locking bar 22 that is pivotable about a pivot axis 24 by means of an electromotive rotary drive. In the blocking position illustrated in
(50) If the delivery chute 14 is “type-sorted,” i.e., loaded solely with containers that contain the same components, according to the invention it is sufficient for a single blocking element 22, situated at the front end of the delivery chute 14 in the delivery direction, i.e., at the left end of the delivery chute 14 in
(51) To also allow loading that is not “type-sorted,” in which the containers situated in the delivery chute 14 contain different components, in the illustrated embodiment a separation means is assigned for individually delivering containers from the delivery chute 14. The separation means is designed in that a blocking element is associated with each of the individual positions 18, 18′, 18″ of the delivery chute 14, as illustrated in
(52) The loading of an AGV 10 is completed as follows:
(53) For loading, the AGV 10 is controlled into a loading position in which it is situated, for example, in front of the container storage area 6. A logistician removes containers from the container storage area 6 that are to be loaded onto the AGV 10. The barcode provided on each container is initially scanned. To facilitate the loading, a display means is provided in the loading area for displaying a position on the AGV 10 that is provided for the particular container.
(54) In the illustrated embodiment, the display means has a touchscreen on which the AGV 10 is symbolically depicted. After the barcode of a container is scanned, the particular position in the particular delivery chute of the AGV 10 where the container is to be positioned is displayed on the touchscreen. The logistician then places the container at the displayed position and confirms the partial loading operation, thus performed, on the touchscreen.
(55) A further container may then be scanned and loaded onto the AGV 10. This partial loading operation is repeated until all containers to be transported by the AGV 10 in the pending transport trip have been loaded onto the AGV 10 or all positions of the AGV 10 are occupied with containers.
(56) The distribution of containers on an AGV 10 or a plurality of AGVs is controlled by the central apparatus.
(57) The containers to be loaded onto the AGV 10 may also be identified in some other way than a barcode or other types of optoelectronically readable characters. For example, the containers may be scanned using a camera, or the individual containers may be provided with a transponder, for example an RFID transponder. A locating means for automatically identifying and/or locating containers on the AGV 10 may be provided to check the arrangement of the containers on the AGV 10. In one embodiment in which the individual containers are provided with an RFID transponder, this locating means may have a reading apparatus for the transponder situated on the particular container. The correct loading of the AGV 10 with containers may be checked in this way.
(58) After loading is completed, the central apparatus controls the AGV 10 in such a way that the AGV travels from the loading position to a delivery position, specified by the central apparatus, for delivery of loaded, filled containers to at least one production shelf 8.
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(60) To automatically deliver the container 20, for example, from the delivery chute 14 of the AGV 10 to the storage chute 28 of the production shelf 8, the AGV is positioned by the central apparatus, optionally with the assistance of a controller provided on the AGV 10, in front of the production shelf 8 in such a way that the delivery chute 14 of the AGV 10 is in flush alignment with the storage chute 28 of the production shelf 8.
(61) In this delivery position, the locking bar associated with the position 18 in the delivery chute 14 is controlled from the blocking position illustrated in
(62) A sensor means may be provided to check that one or more containers have actually been delivered to the production shelf 8 in the desired manner.
(63) In the illustrated embodiment, the AGV 10 is designed for accommodating empty containers on the production shelves 8. As is apparent from
(64) As is apparent from
(65) The delivery of empty containers from the delivery chute 42 of the production shelf 8 to the receiving chute 38 of the AGV 10 may take place simultaneously with the delivery of containers from the AGV 10 to the production shelf 8, or before or after same.
(66) In the sense of an automatic delivery of the empty containers to the AGV 10, a blocking element, for example, may be associated with the delivery chute 42 of the production shelf 8, as described with regard to the AGV 10 with reference to
(67) For an automatic delivery of empty containers from the AGV 10 to the container storage area 6, for example, the blocking elements associated with the operating paths 40, 40′ of the receiving chute 38 may then be controlled in their delivery position.
(68) The receiving chute 38 of the AGV is vertically adapted to the delivery chute 42 of the production shelf 8 in such a way that the front end of the delivery chute 42 in the flow direction is at the same height as in the rear direction of the receiving chute 38 in the flow direction when the AGV 10 is situated in front of the production shelf 8.
(69) After filled containers from the AGV 10 are delivered to the production shelf 8 and empty containers are received by the AGV 10, the transport trip of the AGV may be continued with control by the central apparatus. For this purpose, the AGV 10 may either approach further production shelves to deliver filled containers and/or receive empty containers, or may return to the container storage area 6.
(70) In the container storage area, the AGV 10 may once again receive filled containers in preparation for a further transport trip. A receiving means for automatically or semiautomatically receiving empty containers by an AGV 10 may be provided in an empty container transfer area, which may be formed in the container storage area 6, for example. However, it is also possible according to the invention for empty containers that an AGV 10 has brought from a transport trip to be manually unloaded by logisticians in the container storage area.
(71) According to the invention, it is also possible to provide, in addition to the AGV 10, at least one “empty container AGV” whose primary task is to pick up empty containers from the production shelves 8. The control of one or more AGVs is generally known to those skilled in the art, and therefore is not explained in greater detail here. In particular, the AGVs used may travel on different routes, wherein bypass loops, for example, may be provided.
(72) In order for the central apparatus, for example, to be always informed of the position of an AGV 10, according to the invention a means for position determination and/or display of at least one AGV may be provided. The exact location of an AGV may thus be determined at any time. This is particularly advantageous when a malfunction occurs.
(73) All of the above-described control operations for controlling the AGV 10 and its components as well as further automatic or semiautomatic components of the production system may be carried out by the central apparatus. However, according to the invention it is also possible for at least a portion of the control operations, in particular of the AGV 10, to be carried out by a controller provided on the AGV 10. The invention thus provides a production system and an AGV 10 by means of which the delivery of material in a production system for the series production in particular of motor vehicles may be largely automated.
(74) One alternative embodiment of an AGV designed according to the invention is explained in greater detail below with reference to
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(77) According to the invention, the handling unit 56 is adjustable relative to the base body 54 along adjustment axes, symbolized by arrows in
(78) In particular, the handling unit 56 is linearly adjustable relative to the base body 54 along a first linear adjustment axis in a conveying direction (arrow 58), and along a second linear adjustment axis transverse to the conveying direction (arrow 60). In addition, the handling unit 56 is height-adjustable relative to the base body 54 along a third linear adjustment axis (arrow 62), and is also connected to the base body 54 so as to be rotatable about an essentially vertical fourth adjustment axis (arrow 64).
(79) The linear adjustment axes 58, 60, and 62 are implemented by linear guides, and the rotational axis 64 is implemented by a rotary guide.
(80) Electric motor drives in the illustrated embodiment which are independently controllable by a control apparatus are associated with the adjustment axes 58 through 64, and during operation of the production system are supplied with power via a battery that is present on the AGV 50.
(81) The handling unit 56 has a fork-like supporting element 66 for supporting a container to be handled. The supporting element 66 is situated on a carriage 68 and is adjustable relative to same along the first adjustment axis 58. The carriage 68 is adjustable relative to the base body 54 along the second adjustment axis 60, and is rotatable relative to the base body 54 about the rotational axis 64. In addition, the carriage 68 is height-adjustable along the third adjustment axis 62, along a column 70 of the base body 54 along the third adjustment axis 62.
(82) In the illustrated embodiment, the supporting element 66 has a conveying means for conveying a container to be handled in the conveying direction and opposite the conveying direction, in the illustrated embodiment 4 this conveying means having conveyor belts 72, 74, 76, 78 that extend on the supporting element 66 in the conveying direction and are spaced apart from one another transverse to the conveying direction, and that are independently controllable by a control apparatus.
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(85) With reference to
(86) As symbolized by an arrow 86 in
(87) As symbolized by an arrow 88 in
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(89) After the conveyor belts 72, 74 have conveyed the container 82 in the conveying direction toward the column 70, as indicated by an arrow 90 in
(90) If a misalignment occurs during removal of the container 82, so that the side surfaces of the container 82 are not in parallel with the conveyor belts 72, 74, this misalignment may be corrected by controlling the conveyor belts 72, 74 to briefly run in opposite directions.
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(92) By appropriate control of the conveyor belts 72 through 78, the rotational position of the container 82 is subsequently changed by rotating it by 90 degrees, as indicated by an arrow 94 in
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(94) As is apparent from
(95) Due to the multiaxial adjustability of the handling unit 56, with regard to the removal of containers from the transport shelf and the delivery of the containers to a production shelf the invention provides significantly increased flexibility compared to the prior art.