DESC:
FIELD
The present disclosure relates to the field of transfer systems for transferring car body shells in an automobile manufacturing facility.
BACKGROUND
In a paint shop of an automobile manufacturing facility, a car body shell is required to undergo through various painting processes such as sealer application, primer application, primer oven, base coat and clear coat application, top coat oven, and then final inspection.
The car body shell enters into the paint shop on a skid and is moved around from station to station on conveyor systems such as transfer car, transfer car with turn table, process conveyor and buffer chain, and the like for painting processes. The speed of movement of the body shell is determined by the conveyor systems, which in turn determines the turnaround time of the paint shop. The time between receiving two consecutive car body shells at any particular station is called as the turnaround time or ‘Takt’ time.
Typically, the final painted body from the top coat oven is required to undergo a number of inspection checks at a polishing conveyor. The polishing conveyor is split into multiple conveyors so as to facilitate the following inspection operations:
1. Top side checking,
2. Right hand side checking,
3. Left hand side checking,
4. Back side checking,
5. Front side checking, and
6. Defects repairing and removing of fixture on body.
Generally, these checks are mandatory and require multiple conveyors, which lead to an increase in the required length of shop space.
Figures 1-4 illustrate schematic view of a conventional system 100 and a process thereof for transferring the car body shells between workstations of an automobile manufacturing facility. In Figure 1, a car body shell (not shown in figures) is received at a first workstation 102. The car body shell is thereafter conveyed to a transfer car 110 having a turntable 118 configured to rotate the car body shell. Figure 2 illustrates the transfer of the rotated car body shell to a second workstation 104. The car body shell is then processed on the second workstation 104, and is further transferred to a third workstation 106 from the other end of the second workstation 104 by means of another transfer car (not shown in figures). Further, the car body shell is again conveyed from the third workstation 106 to the transfer car 110 as shown in Figure 3. Figure 4 illustrates the transfer of the car body shell from the transfer car (110) third workstation 106 to a fourth workstation (108).
In order to complete one cycle, the transfer car 110 is required to commute from the first workstation 102 to the second workstation 104, then from the second workstation 104 to the third workstation 106, further from the third workstation 106 to the fourth workstation 108. An exemplary cycle takes 108 seconds to complete, whereas the typical ‘takt’ time is 99 seconds, exhibiting a delay or loss of 9 seconds per car body shell. This decreases the overall productivity of the automobile manufacturing facility.
Also, in most cases, there is a waiting time associated with processing of the car body shell at the first workstation 102 and the third workstation 106, which hinders continuous movement of the car body shell, thereby causing bottle necks.
Further, owing to the complex running operation of the transfer car 110, in convention system, at full speed, leads to frequent failure of the transfer car 110 due to wear and tear of wheels, shafts, and other mechanical components thereof.
Moreover, the iterative operation of transferring the car body shell between multiple conveyors within the ‘takt’ time draws excessive power which leads to additional cost of power.
There is, therefore, felt a need of a system for transferring car body shells in an efficient manner to overcome the drawbacks of the above conventional systems.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a system for transferring car body shells.
Another object of the present disclosure is to provide a system for transferring car body shells, which reduces the overall cycle time associated with the processing of a car body shell.
Still another object of the present disclosure is to provide a system for transferring car body shells, which consumes less power.
Yet another object of the present disclosure is to provide a system and method for transferring car body shells, which is economical.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a system for transferring car body shells between a plurality of workstations. The system comprises a first transfer unit, a second transfer unit, and a drive mechanism.
The first transfer unit is configured to transfer a car body shell between a first set of workstations of the plurality of workstations. The first transfer unit has a turntable that is configured to rotate and align the car body shell with respect to the at least one workstation of the first set of workstations.
The second transfer unit is coupled to the first transfer unit via a joining element of a pre-determined length. The second transfer unit is configured to transfer the car body shell between a second set of workstations of the plurality of workstations.
In an embodiment, the distance between a first workstation of the first set of workstations and a fourth workstation of the second set of workstations is equal to the distance between a second workstation of the first set of workstations and a third workstation of the second set of workstations. Further the distance is equal to the pre-determined length of the joining element.
The drive mechanism, of the system, is coupled to the first transfer unit. The drive mechanism includes a first set of drive wheels and at least one drive motor. The drive mechanism is configured to provide lateral movement to the system, thereby allowing the first transfer unit and the second transfer unit to transfer the car body shells between the plurality of workstations. The first set of drive wheels is connected to an operative bottom portion of the first transfer unit and at least one drive motor is coupled to at least one drive wheel of the first set of drive wheels to drive the at least one drive wheel, thereby driving the system.
The second transfer unit includes a second set of drive wheels. The second set of drive wheels are configured to move under the influence of the drive mechanism. In an embodiment, the second set of drive wheels are idler wheels.
Further, each of the first transfer unit and the second transfer unit includes a conveyor mechanism. The conveyor mechanism includes a conveyor belt, at least one pair of rollers, and a motor. At least one pair of rollers has a guided roller and a flat roller, wherein the guided roller and the flat roller are connected by means of a connecting member. Further, at least one pair of rollers is coupled with the motor which is configured to drive the at least one pair of rollers, thereby driving the conveyor belt.
In an embodiment, the connecting member includes a hollow shaft and a solid shaft. The solid shaft is disposed within the hollow shaft.
In another embodiment, the system includes a pair of locking plates associated with the connecting member, wherein each of the pair of locking plates is mounted on the conveyor mechanism diametrically opposite to each other. Further, each of the pair of locking plates has a slot configured thereon for receiving each end of the solid shaft respectively. In still another embodiment, each of the pair of locking plates includes a plurality of apertures configured thereon to facilitate mounting of the pair of locking plates on the conveyor mechanism by means of fasteners.
The system further includes a plurality of turntable drive wheels and a turntable drive motor. The plurality of turntable drive wheels is connected to an operative bottom portion of the turntable. The turntable drive motor is coupled to at least one turntable drive wheel of the plurality of turntable drive wheels, and is configured to drive the plurality of turntable drive wheels by means of the at least one turntable drive wheel, thereby rotating the turntable.
In an embodiment, the turntable is configured to rotate the car body shell by 180 degrees.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING
A system for transferring car body shells will now be described with the help of the accompanying drawing in which:
Figures 1 - 4 illustrate schematic views of a conventional system for transferring car body shells between workstations of an automobile manufacturing facility;
Figure 5A and Figure 5B illustrate schematic top views of a system for transferring the car body shells, of the present disclosure;
Figure 6A and Figure 6B illustrate schematic views of a connecting member used in the system of Figure 5B;
Figure 6C illustrates a schematic view of a locking plate that is connected to each operative end of a solid shaft of the connecting member of Figure 6C; and
Figures 7-8 illustrate schematic views of the system of Figure 5B depicting operative configuration.
LIST OF REFERENCE NUMERALS
100 - Conventional system
200 - System
102, 202 - First workstation
104, 204 - Second workstation
106, 206 - Third workstation
108, 208 - Fourth workstation
110 - Transfer car
112, 212 - Non-Drive wheel
114, 214 - Drive Wheel
212, 214 - First set of drive wheels
116, 216 - Drive Motor
212, 214, 216 - Drive mechanism
118, 218 - Turntable
210 - First transfer unit
210A - Second transfer unit
212A - Second set of drive wheels
220 - Joining element
221 - Connecting member
222 - Non drive wheel for Turntable
224 - Drive wheel for Turntable
222, 224 - Turntable drive wheels
226 - Turntable drive motor
228 - Motor
230 - Conveyor mechanism
232 - Hollow shaft
234 - Solid shaft
236 - Guided roller
238 - Flat roller
236, 238 - Pair of rollers
240 - Chain sprocket
242 - Circlip groove
250 - Locking plate
252 - Slot
254 - Apertures
DETAILED DESCRIPTION
In a paint shop of an automobile manufacturing facility, a car body shell is required to undergo various painting processes. The car body shell enters the paint shop on a skid, and is moved around from workstation to workstation on various transfer systems. The speed of movement, and therefore, the cycle time of the body shell is determined by the transfer system. The time between receiving two consecutive car body shells at any particular workstation is called as the cycle time or ‘Takt’ time.
Typically, the final painted body from a top coat oven has to undergo numerous inspection checks at a polishing workstation. Generally, these checks are mandatory and require multiple conveyors, which lead to a requirement of spacious and lengthy shop.
Figures 1-4 illustrate schematic view of a conventional system 100 and a process thereof for transferring the car body shells between various workstations of an automobile manufacturing facility. In order to complete one complete cycle the transfer car 110 having a turntable 118 is required to commute from a first workstation 102 to a second workstation 104, then from the second workstation 104 to a third workstation 106, and further from the third workstation 106 to a fourth workstation 108.
The waiting time associated with the processing of the car body shell on the first workstation 102 and the third workstation 106 hinders the continuous movement, causing bottle necks of the transfer car 110. Further, the complex running operation of the transfer car 110 results in frequent failure of the transfer car 110.
Moreover, the iterative operation of transferring the car body shell between multiple workstations within the ‘takt’ time draws excessive power, thereby leading to additional cost of power which is not desired.
The present disclosure envisages a system for transferring car body shells between a plurality of workstations that is configured to overcome the drawbacks of the conventional system.
A preferred embodiment of the system 200 for transferring car body shells, of the present disclosure, is now be described in detail with reference to the accompanying drawing. The present disclosure is now being described in detail with reference to Figure 5A through Figure 8. Referring to the aforementioned accompanying drawing, the system 200 comprises a first transfer unit 210, a second transfer unit 210A, and a drive mechanism (212, 214, 216). The system 200 is configured to transfer car body shells between a plurality of workstations (202, 204, 206, 208). In an embodiment, each of the plurality of workstations (202, 204, 206, 208) includes a conveyor.
The first transfer unit 210 is configured to transfer a car body shell between a first set of workstations (202, 204) of the plurality of workstations (202, 204, 206, 208). The first transfer unit 210 has a turntable 218 that is configured to rotate and align the car body shell with respect to the at least one workstation 204 of the first set of workstations (202, 204). In an embodiment, the first set of workstation includes a first workstation 202 and a second workstation 204. In another embodiment, the first workstation includes a top coat conveyor (not shown in figures). In still another embodiment, the second workstation 204 is a fuel lid fitment line.
The system 200 further includes a plurality of turntable drive wheels (222, 224) and a turntable drive motor 226. The plurality of turntable drive wheels is connected to an operative bottom portion of the turntable 218. The plurality of turntable drive wheels (222, 224) includes at least one turntable drive wheel 224 and a plurality of non-drive wheels 222. The turntable drive motor 226 is coupled to at least one turntable drive wheel 224. The turntable drive motor 226 is configured to drive the at least one turntable drive wheel 224, thereby rotating the turntable 218 by means of the at least one turntable drive wheel 224 and the plurality of non-drive wheels 222. In an embodiment, the turntable 218 is configured to rotate by 180 degrees, thereby rotating the car body shells.
The second transfer unit 210A is coupled to the first transfer unit 210 via a joining element 220 of a pre-determined length. The second transfer unit 210A is configured to transfer the car body shell between a second set of workstations (206, 208) of the plurality of workstations (202, 204, 206, 208). In an embodiment, the second set of workstation includes a third workstation 206 and a fourth workstation 208. In another embodiment, the third workstation 206 is a polishing line. In still another embodiment, the fourth workstation 208 is another polishing line.
In an embodiment, the distance between the first workstation 202 and the fourth workstation 208 is equal to the distance between the second workstation 204 and the third workstation 206, wherein said distance is equal to the pre-determined length of the joining element 220.
The drive mechanism (212, 214, 216), of the system 200, is coupled to the first transfer unit 210. The drive mechanism (212, 214, 216) includes a first set of drive wheels (212, 214) and at least one drive motor 216. The drive mechanism (212, 214, 216) is configured to provide lateral movement to the system 200, thereby allowing the first transfer unit 210 and the second transfer unit 210A to transfer the car body shells between the plurality of workstations (202, 204, 206, 208). The first set of drive wheels (212, 214) is connected to an operative bottom portion of the first transfer unit 210. At least one drive motor 216 is coupled to at least one drive wheel 214 of the first set of drive wheels (212, 214) to drive the at least one drive wheel 214, thereby driving the system 200.
Further, the second transfer unit 210A includes a second set of drive wheels 212A. The second set of drive wheels 212A are configured to move under the influence of the drive mechanism (212, 214, 216) mounted on the first transfer unit 210. In an embodiment, the second set of drive wheels are idler wheels.
Further, each of the first transfer unit 210 and the second transfer unit 210A includes a conveyor mechanism 230. The conveyor mechanism 230 includes a conveyor belt (not shown in figures), at least one pair of rollers (236, 238), and a motor 228. Each pair of the roller (236, 238) includes a guided roller 236 and a flat roller 238 wherein the guided roller 236 and the flat roller 238 are connected with each other by means of a connecting member 221. The connecting member 221 includes a hollow shaft 232 and a solid shaft 234. The solid shaft 234 is disposed within the hollow shaft 232. The guided roller 236 and the flat roller 238 is coupled to the motor 228 which is configured to drive the guided roller 236 and the flat roller 238, thereby driving the conveyor belt. In an embodiment, at least one pair of rollers (236, 238) is coupled with the motor 228 by means of a chain and sprocket assembly 240. The sprocket allows a passage for the chain thereon to facilitate the rolling/movement of the conveyor belt.
Further, the system 200 also includes at least one pair of locking plates 250 mounted on the conveyor mechanism 230 diametrically opposite to each other. Each pair of the locking plate 250 is associated with the connecting member 221. In an embodiment, the count of pairs of locking plate 250 is equal to the count of connecting member 221. Further, each locking plate 250, of the pair of locking plate 250, has a slot 252 configured thereon for receiving an end of the solid shaft 234 respectively. In still another embodiment, each locking plate 250 of the pair of locking plate 250 has a plurality of apertures 254 configured thereon to facilitate mounting of the at least one pair of locking plates 250 on the conveyor mechanism 230 by means of fasteners (not shown in figures).
As seen in Figure 6B and 6C, the solid shaft 234 is inserted into the hollow shaft 232 and a bearing (not exclusively labelled) is fitted thereon. A circlip groove 242 is configured on the solid shaft 234. Subsequent to the fitment of the bearing, a locking circlip (not shown in the figures) is fitted into the circlip groove 242. In an embodiment, the solid shaft 234 is tapered and has flat portion at both the end to facilitate locking of each ends of the solid shaft 234 into each of the pair of locking plate 250 (as shown in Figure 6C). Thus, the solid shaft 234 serves the dual purpose of holding the hollow shaft 232 and acting as a tension bar for the conveyor mechanism 230, thereby increasing its strength.
In an operative configuration, as illustrated in Figure 7 and Figure 8, initially the car body shell is transferred, from the first workstation 202, to the first transfer unit 210 having the turntable 218. The system 200 is then moved towards the second workstation 204 such that the first transfer unit 202 is aligned with the second workstation 204 and the second transfer unit 210A is aligned with the third workstation 206. The car body shell is aligned in a reverse direction and needs to be in a forward direction as per process requirements. The car body shell is thus turned by the turntable 218 of the first transfer unit 210, through 180°. The car body shell mounted on the first transfer unit 210 is transferred to the second workstation 204. At the same instance, another car body shell (not shown in figures) mounted on the third workstation 206 is transferred to the second transfer unit 210A. The car body shell received from the third workstation 206 is transferred from the other end of the second workstation 104 by means of another system (not shown in figures). Now, two car body shells are mounted on each of the first transfer unit 210 and the second transfer unit 210A of the system 200. Further, the system 200 is moved towards the fourth workstation 208 such that the first workstation is aligned with the first transfer unit 210 and the fourth workstation is aligned with the second transfer unit 210A. At this stage, the car body shell mounted on the second transfer unit 210A is transferred to the fourth workstation 208 while at the same instance the first transfer unit 202 receives another car body shell from the first workstation 202. Further, the system 200 is again moved towards the second workstation and the cycle continues.
The technical advancement of the system 200, of the present disclosure, is that the first transfer unit 210 with the turntable 218 operates only for first set of workstations (202, 204) instead of each of the plurality of workstations (202, 204, 206, 208) compared to the conventional system with a single transfer unit. The first transfer unit 210, of the system 200, moves from the first workstation 202 to the second workstation 204 and then from the second workstation 204 back to the first workstation 202. Similarly, the second transfer unit 210A, of the system 200, moves from the third workstation 206 to the fourth workstation 208 and then from the third workstation 206 back to the fourth workstation 208. The system 200 will not move from the second workstation 204 to the third workstation 206, then from the third workstation 206 to the fourth workstation 208 resulting in time saving.
In an exemplary embodiment, the system 200 of the present disclosure reduces the cycle time by 45 seconds and the first transfer unit 210 with the turntable 218 along with the second transfer unit 210A completes the cycle within the prescribed ‘takt’ time. The second transfer unit 210A further enhances the capacity of the first transfer unit 210 to move car body shells between stations by 40%.
Thus, the present disclosure provides a low cost, operationally efficient, automated system 200 for transferring the car body shells. The system 200 further increases the productivity and decreases the operating cost drastically.
TECHNICAL ADVANCEMENTS AND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a system of transferring car body shells that:
? reduces the cycle time of processing car body shells between workstations;
? enhances the capacity of an automobile manufacturing facility;
? reduces movement of transfer unit between stations, thereby minimizing the chances of breakdown of machinery;
? reduces speed of transfer unit resulting in lesser wear and tear of wheels, shafts, and other mechanical components;
? requires less power to operate;
? increases overall productivity and efficiency of the manufacturing facility; and
? reduced operator fatigue.
The disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully revealed the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:
1. A system (200) for transferring car body shells between a plurality of workstations (202, 204, 206, 208), said system (200) comprising:
a first transfer unit (210) configured to transfer a car body shell between a first set of workstations (202, 204) of said plurality of workstations (202, 204, 206, 208), said first transfer unit (210) having a turntable (218) configured to rotate and align said car body shell with respect to said at least one workstation (204) of said first set of workstations (202, 204);
a second transfer unit (210A) coupled to said first transfer unit (210) via a joining element (220) having a pre-determined length, said second transfer unit (210A) configured to transfer said car body shell between a second set of workstations (206, 208) of said plurality of workstations (202, 204, 206, 208); and
a drive mechanism (212, 214, 216) coupled to said first transfer unit (210), said drive mechanism (212, 214, 216) configured to provide lateral movement to said system (200), thereby allowing said first transfer unit (210) and said second transfer unit (210A) to transfer said car body shells between said plurality of workstations (202, 204, 206, 208).
2. The system (200) as claimed in claim 1, wherein said drive mechanism (212, 214, 216) includes:
a first set of drive wheels (212, 214) connected to an operative bottom portion of said first transfer unit (210); and
at least one drive motor (216) coupled to at least one wheel (214) of said first set of drive wheels (212, 214), and configured to drive said at least one wheel (214), thereby driving said system (200).
3. The system as claimed in claim 1, wherein said second transfer unit (210A) includes a second set of drive wheels (212A) configured to move under the influence of said drive mechanism (212, 214, 216).
4. The system (200) as claimed in claim 3, wherein said second set of drive wheels (212A) are idler wheels.
5. The system (200) as claimed in claim 1, wherein each of said first transfer unit (210) and said second transfer unit (210A) includes a conveyor mechanism (230), said conveyor mechanism (230) having:
• a conveyor belt;
• at least one pair of rollers (236, 238) having a guided roller (236) and a flat roller (238), wherein said guided roller (236) and said flat roller (238) are connected with each other by means of a connecting member (221); and
• a motor (228) coupled with said at least one pair of rollers (236, 238), said motor (228) configured to drive said at least one pair of rollers (236, 238), thereby driving said conveyor belt.
6. The system (200) as claimed in claim 5, wherein said connecting member (221) comprises:
a hollow shaft (232); and
a solid shaft (234) disposed within said hollow shaft (232).
7. The system as claimed in claim 6, which includes at least one pair of locking plates (250) mounted on said conveyor mechanism (230) diametrically opposite to each other, wherein each locking plate (250) of said at least one pair of locking plates (250) has a slot (252) configured thereon for receiving an end of said solid shaft (234) respectively.
8. The system (200) as claimed in claim 7, wherein each locking plate (250) of said pair of locking plates (250) has a plurality of apertures (254) configured thereon to facilitate mounting of said at least one pair of locking plates (250) on said conveyor mechanism (230) by means of fasteners.
9. The system (200) as claimed in claim 1, which includes:
• a plurality of turntable drive wheels (222, 224) connected to an operative bottom portion of said turntable (218); and
• a turntable drive motor (226) coupled to at least one turntable drive wheel (224) of said plurality of turntable drive wheels (222, 224), said turntable drive motor (226) configured to drive said at least one turntable drive wheel (224), thereby rotating said turntable (218).
10. The system (200) as claimed in claim 1, wherein the distance between a first workstation (202) of said first set of workstation (202, 204) and a fourth workstation (208) of said second set of workstation (206, 208) is equal to the distance between a second workstation 204 of said first set of workstation (202, 204) and a third workstation 206 of said second set of workstation (206, 208), wherein said distance is equal to said pre-determined length of said joining element (220).