DESC:FIELD OF THE INVENTION

The present disclosure relates generally to assembly lines, and particularly, the present disclosure relates to an assembly line designed for the efficient assembly of electrical switch plates.

BACKGROUND

The information in this section merely provides background information related to the present disclosure and may not constitute prior art(s) for the present disclosure.

Electrical switch plates are ubiquitous components in various electronic devices and household appliances. Traditionally, the assembly of these switch plates has been a labour-intensive and time-consuming process, often prone to errors and misalignments. Conventional assembly methods involve manual handling of base plates and cover plates, which can result in inconsistencies in fitment, leading to product defects and inefficiencies in the manufacturing process.

Additionally, as the demand for electronic devices and appliances continues to rise, there is a growing need for streamlined assembly processes that can handle large volumes of switch plates efficiently and with high precision. Manufacturers are increasingly seeking automated solutions to address these challenges and enhance the quality and speed of the assembly process.

Existing automated assembly systems, while providing some level of automation, often lack the synchronization and precision required for the intricate task of aligning cover plates with base plates. Misalignments during the assembly process can lead to product failures, increased production costs, and dissatisfied customers. Therefore, there is a pressing need for an innovative assembly system that not only automates the process but also ensures perfect alignment and fitment of the switch plates.

Furthermore, the modern manufacturing landscape demands not only efficiency but also adaptability and reliability in automated systems. Interruptions in the assembly process due to inaccuracy or misalignment may lead to significant downtime and financial losses for manufacturers.

Accordingly, there exists a need for an improved assembly line that addresses the limitations of conventional assemblies.

The drawbacks/difficulties/disadvantages/limitations of the conventional techniques explained in the background section are just for exemplary purposes and the disclosure would never limit its scope only such limitations. A person skilled in the art would understand that this disclosure and below mentioned description may also solve other problems or overcome the other drawbacks/disadvantages of the conventional arts which are not explicitly captured above.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention nor is intended for determining the scope of the invention.

In an aspect of the present disclosure, an assembly line for an electric switch plate is disclosed. The assembly line includes at least one conveying unit that is adapted for conveying a base plate and a cover plate associated with the electric switch plate. Further, the assembly line includes one or more manufacturing stations disposed along the conveying unit. Each of the one or more manufacturing stations is adapted to perform at least one operation on at least one of, the base plate and the cover plate. Furthermore, the assembly line includes at least one robotic device operatively connected to the conveying unit. The at least one robotic device is adapted to receive the base plate and the cover plate from the conveying unit. Furthermore, the at least one robotic device is adapted to assemble the base plate and the cover plate to manufacture the electric switch plate. The assembly line further includes a control unit that operably communicates with the at least one conveying unit, the at least one robotic device, and the one or more manufacturing stations. The control unit is configured to control operations of the at least one conveying unit, the at least one robotic device. Further, the control unit is configured to generate an instruction to initiate a subsequent operation upon completion of a current operation.

In another aspect of the present disclosure, a method for assembly of an electric switch plate using an assembly line is disclosed. The method includes conveying, via at least one conveying unit, a base plate and a cover plate associated with the electric switch plate. Further, the method includes performing, via one or more manufacturing stations disposed along the conveying unit, at least one operation on at least one of, the base plate and the cover plate. Furthermore, the method includes receiving, via at least one robotic device, the base plate and the cover plate from the at least one conveying unit. The method further includes picking, via the at least one robotic device, the base plate and the cover plate from the at least one conveying unit. Further, the method includes placing, via the at least one robotic device, the base plate and the cover plate on a fixture platform. Furthermore, the method includes applying, via the at least one robotic device, a predefined pressure on the cover plate against the base plate for assembling the base plate with the cover plate. In an embodiment, while manufacturing the electric switch plate, the method includes controlling, via a control unit, operations of the at least one conveying unit, the at least one robotic device, and the one or more manufacturing stations such that a subsequent operation is initiated upon completion of a current operation.

The assembly line disclosed herein is adapted to ensure accurate and defect-free assembly of the electrical switch plates. Further, the adaptation of the control unit enables controlling operations associated with the manufacturing of the electrical switch plate such that the subsequent operation is initiated upon completion of the current operation, thereby automatically halting or terminating the operation in case of communication failure between consecutive operations.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates a block diagram depicting an assembly line for an electrical switch plate, in accordance with an embodiment of the present disclosure;

Figure 2 illustrates an exemplary image of the assembly line, in accordance with an embodiment of the present disclosure;

Figure 3a illustrates a cover plate of an electrical switch plate, in accordance with an embodiment of the present disclosure;

Figure 3b illustrates a base plate of the electrical switch plate, in accordance with an embodiment of the present disclosure;

Figure 3c illustrates the electrical switch plate, in accordance with an embodiment of the present disclosure;

Figure 4 illustrates a circuit diagram depicting a circuitry of a conveying unit in the assembly line, in accordance with an embodiment of the present disclosure; and

Figure 5 illustrates a circuit diagram representing a circuitry of a proximity sensor of an array of sensing units in the assembly line, in accordance with an embodiment of the present disclosure;

Figure 6 illustrates a flowchart depicting an exemplary method for the assembly of the electric switch plate using the assembly line, in accordance with an embodiment of the present disclosure; and

Figures 7 and 8 illustrate an exemplary process flow for the assembly of the electric switch plate using the assembly line, in accordance with an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the invention and are not intended to be restrictive thereof.

Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a nonexclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or subsystems or elements or structures or components proceeded by "comprises... a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

It should be understood at the outset that although illustrative implementations of the embodiments of the present disclosure are illustrated below, the present invention may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary design and implementation illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.

The term “some” as used herein is defined as “none, or one, or more than one, or all.” Accordingly, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would all fall under the definition of “some.” The term “some embodiments” may refer to one embodiment or to several embodiments or to all embodiments. Accordingly, the term “some embodiments” is defined as meaning one embodiment, or more than one embodiment, or all embodiments.”

The terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features and elements and do not limit, restrict, or reduce the spirit and scope of the claims or their equivalents.

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility, and non-obviousness.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

The present disclosure relates to an assembly line 100 for an electric switch plate 110, as depicted in Figures 1-2. Specifically, Figure 1 illustrates a block diagram depicting the assembly line 100 for the electric switch plate 110, in accordance with an embodiment of the present disclosure. Figure 2 illustrates an exemplary image of the assembly line 100, in accordance with an embodiment of the present disclosure. In an embodiment, the present disclosure may be explained in reference to the electric switch plate 110. However, this should not be construed as a limitation of the present disclosure. In another embodiment, the present disclosure may be used for other industrial products.

In an embodiment, the assembly line 100 may interchangeably be termed as a synchronized robotic assembly line 100 within the scope of the present disclosure. The assembly line 100 may help in assembling the electrical switch plate 110 by employing a seamless assembly process. At its core, the assembly line 100 may include but is not limited to, at least one conveying unit 104, at least one robotic device 106 with specialized End of Arm Tooling (EOAT) (not shown), a fixture platform (not shown), an array of sensing units 120, and a control unit 122.

The conveying unit 104 may be adapted for conveying or transporting one or more components associated with the electric switch plate 110. In an embodiment, the conveying unit 104 may be used for conveying a base plate 108 and a cover plate 102. In an embodiment, the base plate 108 and the cover plate 102 are illustrated in Figures 3a-3b. In an embodiment, the base plate 108 and the cover plate 102 may be assembled to manufacture the electrical switch plate 110 as illustrated in Figure 3c.

Figure 3a illustrates the cover plate 102 of the electrical switch plate 110, in accordance with an embodiment of the present disclosure. Figure 3b illustrates the base plate 108 of the electrical switch plate 110, in accordance with an embodiment of the present disclosure. Figure 3c illustrates the electrical switch plate 110, in accordance with an embodiment of the present disclosure.

Referring to Figures 1-2, the conveying unit 104 may interchangeably be termed as a conveying belt within the scope of the present disclosure. Figure 4 illustrates a circuit diagram 400 depicting a circuitry of the conveying unit 104 in the assembly line 100. In an embodiment, the conveying unit 104 may be equipped with a motor 30 that may be parallelly connected with a base plate manufacturing machine 112A and a cover plate manufacturing machine 112B with the help of relay 2 and relay 3 as illustrated in Figure 4. In an exemplary embodiment, the motor 30 may be a single-phase motor 30. In an embodiment, either of the relays 2 and 3 or both are turned ON to start the motor to enable rotation of the motor 30. This may enable movement of the conveying unit 104. In one embodiment, the output Y118 may be released when the at least one robotic device 106 may place the base plate 108 in the conveying unit 104. In another embodiment, the output P01 may be released when the at least one robotic device 106 may pick the cover plate 102 from the conveying unit 104.

The conveying unit 104 helps in transporting the base plate 108 and the cover plate 102 to/from one or more manufacturing stations 112, 114, 116, 118 adapted to perform different operations thereon. In one example, the plurality of stations 112, 114, 116, 118 may include manufacturing stations 112, a cutting station 114, a polishing station 116, an assembly station 118, etc. The conveying unit 104 synchronizes the movement of the base plate 108 and the cover plate 102, ensuring their arrival at the plurality of stations 112, 114, 116, 118 may be synchronized. This synchronized movement is crucial, laying the foundation for subsequent steps in the assembly line 100. In one embodiment, the operations may include but are not limited to manufacturing operations, cutting operations, polishing operations, and assembling operations. In an embodiment, the operations may include sub-operations associated with the manufacturing operations, cutting operations, polishing operations, and assembling operations.

In an embodiment, the base plate manufacturing machine 112A and the cover plate manufacturing machine 112B may be adapted to manufacture the base plate 108 and the cover plate 102 respectively. The base plates 108 and cover plates 102 so manufactured may then be transferred to the cutting station 114 by the conveying unit 104. The cutting station 114 may be adapted to cut off any extra material on the base plate 108 or the cover plate 102. The base plate 108 and the cover plate 102 may then be transferred to the polishing stations. In one example, the polishing stations 116 may include the base plate polishing station and cover plate polishing station which may be adapted to polish the base plate 108 and the cover plate 102 respectively. It is to be understood that the plurality of stations 112, 114, 116, 118 mentioned herein are only for exemplary purposes, and do not limit the scope of type of stations.

Again, referring to Figures 1-2, the assembly line 100 may include the at least one robotic device 106 that may be operatively connected to the conveying unit 104. In an embodiment, a single robotic device 106 may be used in the present disclosure. It is to be understood that the number of the robotic device 106 mentioned herein is only for exemplary purposes, and does not limit the scope of numbers of the robotic device 106. In another embodiment, the assembly line 100 may include more than one robotic device 106.

In an embodiment, the robotic device 106 may include at least one robotic arm that may be equipped with the EOAT. In an exemplary embodiment, the robotic device 106 may be mounted on the assembly station 118. In an embodiment, the robotic arm via the EOAT may be adapted to pick the base plate 108 from the conveying unit 104 and place the base plate 108 on the fixture platform. In an exemplary embodiment, the base plate 108 of the electrical switch plate 110 may include switches thereon and may be adapted to be fixed onto a surface. Further, the robotic arm may be adapted to pick up the cover plate 102 from the conveying unit 104 and place the cover plate 102 above the base plate 108 such that the cover plate 102 aligns with the base plate 108. Further, the EOAT of the robotic arm may be equipped with at least one cushioning pad to apply a predefined pressure on the cover plate 102 against the base plate 108 to assemble the cover plate 102 with the base plate 108. More specifically, the cover plate 102 is fixed onto the base plate 108 to make the electrical switch plate 110 aesthetically appealing. In one embodiment, at least one cushioning pad may be made up of a soft material to gently press the cover plate 102 onto the base plate 108, ensuring a snug fit through vacuum assistance.

Referring to the fixture platform, the fixture platform may be adapted to securely hold the blasé plate 108. More specifically, the fixture platform may include a plurality of micro-adjustable clamps ensuring secure positioning of the base plate 108. The adaptability of the plurality of micro-adjustable clamps allows for minute adjustments accommodating diverse designs of the base plate 108 and the cover plate 102 with ease. Such adaptability ensures that each base plate 108 is held in place with unerring precision, thereby ensuring a uniform and consistent assembly process of the base plate 108 and the cover plate 102.

Referring to Figure 1, the assembly line 100 may further include an array of sensing units 120. In an embodiment, the array of sensing units 120 may herein refer to proximity sensors within the scope of the present disclosure.

Figure 5 illustrates a circuit diagram 500 representing a circuitry of a proximity sensor from the array of sensing units 120 in the assembly line 100. In an embodiment, the at least one robotic device 106 may be adapted to power the proximity sensor (S1). In an embodiment, whenever a predefined number of the base plate 108 may be detected, by the proximity sensor (S1), on the conveying unit 104, the at least one robotic device 106 may stop to pick up and place the base plate 108 in the conveying unit 104. In an embodiment, whenever the cover plate 102 may be detected on the conveying unit 104 by the proximity sensor (S1), the at least one robotic device 106 may pick up the cover plate 102 from the conveying unit 104 and place the cover plate 102 over the base plate 108 for assembling.

In an example, the array of sensing units 120 may be disposed along the assembly line 100, specifically along the conveying unit 104 to maintain synchronization during various operations at the plurality of stations 112, 114, 116, 118. The array of sensing units 120 ensures accurate positioning of the base plate 108 and the cover plate 102 and prevents misalignments during assembly thereof. Further, the array of sensing units 120 may be configured to detect the operation of the least one conveying unit 104, the at least one robotic device 106, and the one or more manufacturing stations 112, 114, 116, 118.

Preferably, the array of sensing units 120 positioned across the plurality of manufacturing stations 112, 114, 116, 118 further helps in elevating precision in the assembly line 100. The array of proximity sensors operates with utmost sensitivity, monitoring the positioning and movements of the base plate 108, the cover plate 102, and other components, if any, with accuracy. At the slightest deviation, the array of proximity sensors may trigger instant corrective actions. These actions, executed swiftly and precisely, ensure that every base plate 108 and cover plate 102 may be accurately aligned before the final assembly step. In one embodiment, the proximity sensors may be adapted at the fixture platform and/or the EOAT to ensure the alignment of the base plate 108 and the cover plate 102 which is explained in the below paragraphs.

Referring to Figure 1, the control unit 122 may operably communicate with the conveying unit 104, the robotic device 106, and the one or more manufacturing stations 112, 114, 116, 118. In an embodiment, the control unit 122 may be in communication with the array of sensing units 120 to receive data from the array of sensing units 120. The data indicates information associated with the positioning and the movement of the base plate 108 and the cover plate 102. Further, the data may be indicative of the operation performed by the at least one conveying unit 104, the at least one robotic device 106, and the one or more manufacturing stations 112, 114, 116, 118. Further, the control unit 122 may be configured to determine the current operation based on the received data.

In an embodiment, the control unit 112 may be configured to analyze data and based on the analyzed data, the control unit 122 may be configured to generate instructions based on the received data. In an embodiment, the generated instructions are indicative of commands for controlling the operations. Further, the control unit 122 may be configured to transmit instructions to the conveying unit 104, and/or the robotic device 106, and/or the one or more manufacturing stations 112, 114, 116, 118 to control operations in the assembly line 100. This may synchronize the movement of the base plate 108 and the cover plate 102 in such a manner that base plate 108 and the cover plate 102 are conveyed at the same time for the assembly at the assembly station 118.

More specifically, the control unit 122 may be configured to generate an instruction to initiate a subsequent operation upon completion of a current operation. In an embodiment, the current operation is indicative of an ongoing operation performed by at least one robotic device 106, the one or more manufacturing stations 112, 114, 116, 118, and the at least one conveying unit 104 on the at least one of, the base plate 108 and the cover plate 102.

In an exemplary scenario, in a case during the cut-off of any extra material from the base plate 108 and the cover plate 102. For instance, a cutting operation in the base plate 108 is delayed due to some error in a cutting machine. Therefore, the movement of the cover plate 102 may also halt and continue once the cutting operation is performed on the base plate 108.

In an embodiment, the control unit 122 may be configured to control the traversing of the base plate 108 and the cover plate 102 to the one or more manufacturing stations 112, 114, 116, 118 with accuracy. The control unit 122 may further be configured to indicate a degree of misalignment of the base plate 108 and the cover plate 102 at the assembly station 118. The control unit 122 may be configured to dynamically learn the variables involved in the assembly process. By dividing the operations into synchronized cycles, the control unit 122 continuously analyzes data from the array of sensing units 120 and other feedback mechanisms employed in the assembly line 100. In an embodiment, during the assembling operation, the control unit 122 may further be configured to make real-time adjustments, recalibrate the robotic arm’s movements, fine-tune vacuum levels of the vacuum assistance unit, and adjust the positions of the fixture platform. Such real-time adaptability of the control unit 122 ensures that base plate 108 and the cover plate 102 may be assembled with precision, irrespective of variations in component dimensions or material properties.

In an embodiment, the control unit 122 may include but is not limited to, a processor, a memory, a module(s), and data. The module(s) and the memory may be coupled to the processor. The processor may be a single processing unit or a number of units, all of which could include multiple computing units. The processor may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the processor is adapted to fetch and execute computer-readable instructions and data stored in the memory.

The memory may include any non-transitory computer-readable medium known in the art including, for example, volatile memory, such as static random-access memory (SRAM) and dynamic random-access memory (DRAM), and/or non-volatile memory, such as read-only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes.

The module(s), amongst other things, include routines, programs, objects, components, data structures, etc., which perform particular tasks or implement data types. The module(s) may also be implemented as, signal processor(s), state machine(s), logic circuitries, and/or any other device or component that manipulates signals based on operational instructions.

Further, the module(s) may be implemented in hardware, instructions executed by at least one processing unit, for e.g., the processor, or by a combination thereof. The processing unit may comprise a computer, a processor, a state machine, a logic array, and/or any other suitable devices capable of processing instructions. The processing unit may be a general-purpose processor which executes instructions to cause the general-purpose processor to perform operations or, the processing unit may be dedicated to performing the required functions. In some example embodiments, the module(s) may be machine-readable instructions (software, such as web application, mobile application, program, etc.) which, when executed by a processor/processing unit, perform any of the described functionalities.

In another aspect of the present disclosure, a method 600 for assembly of the electric switch plate 110 is disclosed which is discussed in conjunction with Figure 6.

Figure 6 illustrates a flowchart depicting an exemplary method 600 for the assembly of the electric switch plate 110 using the assembly line 100, in accordance with an embodiment of the present disclosure. At step 602, the method 600 may involve conveying, via the conveying unit 104, the base plate 108 and the cover plate 102 associated with the electrical switch plate 110.

At step 606, the method 600 may include performing, via the one or more manufacturing stations 112, 114, 116, 118 disposed along the conveying unit 104, the operations on the base plate 108 and the cover plate 102. At step 606, the method 600 may include receiving, via the robotic device 106, the base plate 108 and the cover plate 102 from the conveying unit 104.

At step 608, the method 600 may include picking, via the at least one robotic device 106, the base plate 108 and the cover plate 102 from the at least one conveying unit 104. Further, at step 610, the method 600 may include placing, via the at least one robotic device 106, the base plate 108 and the cover plate 102 on the fixture platform. Furthermore, at step 612, the method 600 may include applying, via the at least one robotic device 106, the predefined pressure on the cover plate 102 against the base plate 108 for assembling the base plate 108 with the cover plate 102. In an embodiment, while manufacturing the electric switch plate 110, the method 600 may include controlling, via the control unit 122, the operations of the conveying unit 104, the at least one robotic device 106, and the one or more manufacturing stations 112, 114, 116, 118 such that the subsequent operation is initiated upon completion of the current operation.

In one embodiment, the present disclosure may be explained with reference to exemplary embodiments depicted in Figures 7 and 8. Figures 7 and 8 illustrate an exemplary process flow for the assembly of the electric switch plate 110 using the assembly line 100. At step 702, the robotic device 106 may pick the base plate 108 from a base plate manufacturing machine. Further, at step 704, the robotic device 106 may check a presence of the base plate 108 in the conveying unit 104. Furthermore, at step 706, the robotic device 106 may pick the base plate 108 from the conveying unit 104 after detecting the presence of the base plate 108 in the conveying unit 104. At step 708, the robotic device 106 may place the first base plate 108 into the conveying unit 104 at a desired position if no base plate 108 is detected at step 704. Thereafter, at step 710, the conveying unit 104 may start rotating for a first predefined time of T1 seconds. Further, the robotic device 106 may place a second base plate 108 from the base plate manufacturing machine. Furthermore, the conveying unit 104 may start rotating for a second predefined time of T2 seconds.

Further, at step 802, it may be checked whether the base plate 108 is present in the fixture platform. Thereafter, at step 804, the robotic device 106 may pick a first cover plate 102 and a second cover plate 102 from the conveying unit 104. Further, at step 806, the robotic device 106 may place the first cover plate 102 in a desired position and press using the at least one cushioning pad. Furthermore, at step 808, the robotic device 106 may place the second cover plate 102 in a desired position and press using the at least one cushioning pad, and simultaneously, both electrical switch plates 110 are picked up and placed in another conveying unit 104 at step 810.

After that, at step 812, another conveying unit 104 may be rotated for a third predefined time of T3 seconds. At step 814, the robotic device 106 may check the presence of the first base plate 108 in the conveying unit 104. Furthermore, at step 816, the robotic device 106 may pick the base plate 108 from the conveying unit 104 after detecting the presence of the base plate 108 and place it in the fixture platform. At step 818, the robotic device 106 may place the base plate 108 into the conveying unit 104 if no base plate 108 is detected at step 814. At step 818, the robotic device 106 may pick the first base plate 108 from the conveying unit 104 and place it in the fixture platform. At step 820, the conveying unit 104 may start rotating for a fourth predefined time of T4 seconds. Thereafter, at step 822, the robotic device 106 may check the presence of the second base plate 108 in the conveying unit 104. Furthermore, at step 824, the robotic device 106 may pick the second base plate from the conveying unit 104 after detecting the presence of the base plate 108 and place it in the fixture platform. At step 826, the robotic device 106 may place the base plate 108 into the conveying unit 104 if no base plate 108 is detected at step 824.

The synchronized movements of the base plate 108 and the cover plate 102 minimize downtime ensuring a continuous and efficient assembly process. The configuration of the control unit 122 allows the handling of diverse designs of base plates 108 and cover plates 102 with ease. Real-time monitoring and adaptive control mechanisms of the control unit 122 help in eliminating errors, thereby ensuring a defect-free final electric switch plate. Further, by minimizing defects and optimizing efficiency, the assembly line 100 significantly reduces manufacturing costs in the long run.

Further, the control unit 112 helps in controlling the operations performed for manufacturing the electrical switch plate 110 such that the subsequent operation is initiated only after the completion of the current operation, thereby automatically halting or terminating the process in case of communication failure between consecutive operations.

Through synchronized movements, soft material handling, vacuum assistance, and real-time monitoring, the assembly line 100 ensures the perfect alignment and fitment of base plates and cover plates, setting new standards for efficiency, accuracy, and reliability in switch plate manufacturing. Moreover, the assembly line 100 reduces the overall time of manufacturing the electrical switch plate 110, thereby reducing manufacturing costs. In addition, the assembly line 100 is a synchronized robotic assembly that eliminates need for human intervention, thereby reducing overall inventory and manufacturing costs.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
,CLAIMS:1. An assembly line (100) for an electric switch plate (110), the assembly line (100) comprising:
at least one conveying unit (104) adapted for conveying a base plate (108) and a cover plate (102) associated with the electric switch plate (110);
one or more manufacturing stations (112, 114, 116, 118) disposed along the conveying unit (104), each of the one or more manufacturing stations (112, 114, 116, 118) is adapted to perform at least one operation on at least one of, the base plate (108) and the cover plate (102); and
at least one robotic device (106) operatively connected to the conveying unit (104), the at least one robotic device (106) adapted to:
receive the base plate (108) and the cover plate (102) from the conveying unit (104), and
assemble the base plate (108) and the cover plate (102) to manufacture the electric switch plate (110); and
wherein the assembly line (100) comprises:
a control unit (122) operably communicates with the at least one conveying unit (104), the at least one robotic device (106), and the one or more manufacturing stations (112, 114, 116, 118), the control unit (122) configured to control operations of the at least one conveying unit (104), the at least one robotic device (106), and the one or more manufacturing stations (112, 114, 116, 118), wherein the control unit (122) is configured to generate an instruction to initiate a subsequent operation upon completion of a current operation.
2. The assembly as claimed in claim 1, wherein the current operation is indicative of an ongoing operation performed by at least one robotic device (106), the one or more manufacturing stations (112, 114, 116, 118), and the at least one conveying unit (104) on the at least one of, the base plate (108) and the cover plate (102).
3. The assembly line (100) as claimed in claim 1, wherein the operations comprise at least one of, manufacturing operations, cutting operations, polishing operations, and assembling operations.
4. The assembly line (100) as claimed in claim 1 comprising an array of sensing units (120) disposed along the at least one conveying unit (104), wherein the array of sensing units (120) is configured to:
detect movement of the base plate (108) and the cover plate (102); and
detect operation of the at least one conveying unit (104), the at least one robotic device (106), and the one or more manufacturing stations (112, 114, 116, 118).
5. The assembly line (100) as claimed in claim 1, wherein the at least one robotic device (106) comprises:
at least one robotic arm having an End of Arm Tooling (EOAT) adapted to:
pick the base plate (108) from the at least one conveying unit (104) and place the base plate (108) on a fixture platform;
pick the cover plate (102) from the at least one conveying unit (104) and place the cover plate (102) above the base plate (108) such that the cover plate (102) aligns with the base plate (108); and
apply a predefined pressure on the cover plate (102) against the base plate (108) to assemble the base plate (108) with the cover plate (102).
6. The assembly line (100) as claimed in claim 1, wherein the End of Arm Tooling (EOAT) comprises at least one cushioning pad adapted to apply the predefined pressure on the cover plate (102) against the base plate (108) to assemble the base plate (108) with the cover plate (102).
7. The assembly line (100) as claimed in claim 4, wherein the array of sensing units (120) comprises proximity sensors configured at the fixture platform and the EOAT to ensure the alignment of the cover plate (102) with the base plate (108).
8. The assembly line (100) as claimed in claim 1, wherein the control unit (122) may be in communication with the array of sensing units (120), the control unit (122) is adapted to:
receive data from the array of sensing units (120), wherein the data is indicative of the movement associated with the base plate (108) and the cover plate (102), and the operation performed by the at least one conveying unit (104), the at least one robotic device (106), and the one or more manufacturing stations (112, 114, 116, 118),
wherein the control unit (122) is configured to determine the current operation based on the received data;
generate instructions based on the received data, wherein the instructions are indicative of commands for controlling the operations; and
transmit instructions to the at least one conveying unit (104), the one or more manufacturing stations (112, 114, 116, 118), and the at least one robotic device (106) to control operations of the assembly line (100), and synchronizing the movement of the base plate (108) and the cover plate (102) in such a manner that the base plate (108) and the cover plate (102) are conveyed at a same time for the assembly.
9. A method (600) for assembly of an electric switch plate (110) using an assembly line (100), the method (600) comprising:
conveying, via at least one conveying unit (104), a base plate (108) and a cover plate (102) associated with the electric switch plate (110);
performing, via one or more manufacturing stations (112, 114, 116, 118) disposed along the conveying unit (104), at least one operation on at least one of, the base plate (108) and the cover plate (102);
receiving, via at least one robotic device (106), the base plate (108) and the cover plate (102) from the at least one conveying unit (104); and
picking, via the at least one robotic device (106), the base plate (108) and the cover plate (102) from the at least one conveying unit (104);
placing, via the at least one robotic device (106), the base plate (108) and the cover plate (102) on a fixture platform; and
applying, via the at least one robotic device (106), a predefined pressure on the cover plate (102) against the base plate (108) for assembling the base plate (108) with the cover plate (102);
wherein while manufacturing the electric switch plate (110), the method (600) comprises:
controlling, via a control unit (122), operations of the at least one conveying unit (104), the at least one robotic device (106), and the one or more manufacturing stations (112, 114, 116, 118), such that a subsequent operation is initiated upon completion of a current operation.
10. The method (600) as claimed in claim 9, wherein the current operation is indicative of an ongoing operation performed by the at least one of, the robotic device (106), the one or more manufacturing stations (112, 114, 116, 118), and the at least one conveying unit (104) on the at least one of, the base plate (108) and the cover plate (102).
11. The method (600) as claimed in claim 9, wherein the operations comprise at least one of, manufacturing operations, cutting operations, polishing operations, and assembling operations.
12. The method (600) as claimed in claim 9, wherein applying, via at least one cushioning pad of the at least one robotic device (106), a predefined pressure on the cover plate (102) against the base plate (108) for assembling the base plate (108) with the cover plate (102).
13. The method (600) as claimed in claim 9 comprising detecting, via an array of sensing units (120), movement of the base plate (108) and the cover plate (102), and operation performed by the at least one conveying unit (104), the at least one robotic device (106), and the one or more manufacturing stations (112, 114, 116, 118).
14. The method (600) as claimed in claim 9, comprising:
receiving, via the control unit (122), sensing data from the array of sensing units (120), wherein the data is indicative of the movement associated with the base plate (108) and the cover plate (102), and the operation performed by the at least one conveying unit (104), the at least one robotic device (106), and the one or more manufacturing stations (112, 114, 116, 118),
wherein the method (600) comprises determining the current operation based on the received data;
generating instructions based on the received data, wherein the instructions are indicative of commands for controlling the operations; and
transmitting, via the control unit (122), instructions to the at least one conveying unit (104), the one or more manufacturing stations (112, 114, 116, 118), and the at least one robotic device (106) to control operations of the assembly line (100), and synchronizing the movement of the base plate (108) and the cover plate (102) in such a manner that the base plate (108) and the cover plate (102) are conveyed at a same time for the assembly.