Ultra-flexible production manufacturing

• US 8,798,787 B2
• Filed: 12/09/2013
• Issued: 08/05/2014
• Est. Priority Date: 08/09/2012
• Status: Active Grant

• Current Assignee: ABB Schweiz AG (ABB Limited)
• Original Assignee: ABB Research Ltd. (ABB Ltd.)
• Inventors: Fuhlbrigge, Thomas A., Newkirk, Jeremy, Martinez, Carlos, Zhang, George Q., Rossano, Gregory F., Staab, Harald, Boca, Remus, Choi, Sangeun, Kock, Soenke, Eakins, William John
• Primary Examiner(s): CUMBESS, YOLANDA RENEE
• Application Number:
  US14/069,465
• Publication Number:
  US 20140121828A1
• Time in Patent Office: 239 Days
• Field of Search: None
• US Class Current: 700/228
• CPC Class Codes: B25J 5/00 Manipulators mounted on wheels or on carriages B25J1/00 takes precedence; programme-controlled manipulators B25J9/00 ; vehicle aspects B60, B62, e.g. remote-controlled steering for motor vehicles B62D1/24; control of position of vehicles G05D1/00
• CPC Class Codes: G05B 19/41895 using automatic guided vehicles [AGV] control of position or course of AGV's G05D1/00
• CPC Class Codes: G05B 2219/31003 Supervise route, reserve route and allocate route to vehicle, avoid collision
• CPC Class Codes: G05B 2219/31013 Second AGV with wafers already underway before processing first finished
• CPC Class Codes: G05B 2219/32388 Autonomous flexible system, cells and agv autonomous
• CPC Class Codes: G05D 1/0297 by controlling means in a control room
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/60 Electric or hybrid propulsion means for production processes
• CPC Class Codes: Y10S 901/01 Mobile robot

Abstract

A manufacturing system has one or more work cells that each performs one or more manufacturing processes. The system also has one or more mobile transport units (“MTUs”) that deliver transportable containers containing workpieces to and from said work cells. The MTUs deliver the containers to the work cells in a manner such that the workpieces are localized in the work cells. The manufacturing system also has a computer system that has status information for each of the one or more MTUs and uses the status information to control each of the one or more MTUs to deliver the transportable containers to and from the one or more work cells.

Claims

1. A system of manufacturing comprising:

one or more work cells, where each of said cells performs one or more manufacturing processes on an associated one of one or more workpieces;

one or more mobile transport units (“

MTUs”

) to deliver transportable containers containing said workpieces to and from said work cells, said one or more mobile transport units delivering said containers to said work cells independent of a fixed in place path between said one or more work cells and in a manner such that said workpieces are localized in said work cells; and

a computer system having therein status information for each of said one or more MTUs and using said status information to control each of said one or more MTUs to deliver said transportable containers to and from said one or more work cells;

wherein when a determination is made that work performed at one of said one or more work cells on said associated workpiece is in error, said computer system commands said associated one of said one or more MTUs to deliver said transportable container with said workpiece on which said work in error was performed to one of a rework station or a disposal area.

2. The system of claim 1 wherein there is a known process flow that is used by said computer system to perform MTU selection.

3. The system of claim 2 wherein said computing system performs production scheduling and workpiece routing.

4. The system of claim 1 wherein at least one of said one or more work cells comprises machinery capable of performing said one or more manufacturing processes.

5. The system of claim 4 wherein at least one of said one or more work cells comprises one or more industrial robot arms.

6. The system of claim 5 wherein one or more of said one or more industrial robot arms comprises a tool changer that allows said tool adapted to perform said specific task to be changed for another tool adapted to perform another specific task when each of said one or more robots have to perform said another specific task.

7. The system of claim 1 wherein said computer system has therein a road network and traffic rules for controlling movement of each of said one or more MTUs.

8. The system of claim 7 wherein said road network defines lanes or paths for said MTUs to follow and said traffic rules define one way directions for lanes or paths when necessary and which of said one or more MTUs has the right of way in the event of a possible collision.

9. The system of claim 1 wherein at least one of said one or more work cells locates said transportable containers within said at least one of said one or more work cells.

10. The system of claim 1 wherein each of said one or more work cells that is performing work on said workpieces in said transportable container delivered to said work performing work cell requests at a predetermined time based on how much time is left to complete said work that one of said one or more MTUs on demand be sent to said requesting work cell.

11. The system of claim 1 wherein said manufacturing processes performed by each of said one or more work cells and the flow of MTUs are controlled in accordance with an associated production schedule.

12. The system of claim 11 wherein said flow of MTUs can change when a process event has occurred.

13. The system of claim 1 wherein said one or more manufacturing processes at said one or more work cells can be changed so that said work cell performs a different one of said one or more manufacturing processes.

14. The system of claim 13 wherein said computer system transmits information to said work cell about said different one of said one or more manufacturing processes to be performed.

15. The system of claim 1 wherein more than one distinct process flows are performed simultaneously, and one or more of said work cells are used in more than one of the distinct process flows.

16. The system of claim 1 wherein one or more of said work cells are added to add one or more of said processes to the process flow or are removed to remove one or more of said processes from the process flow by changing the traffic flow of said MTUs.

17. The system of claim 1 wherein one or more other work cells are added to a set of said one or more work cells to thereby increase the number of work cells in said set of said one or more work cells.

18. The system of claim 1 wherein two or more of said one or more work cells perform the same one or more processes.

19. The system of claim 1 wherein there are one or more buffer stations for holding said transportable containers until said work cell is prepared to receive said transportable container and the one or more buffer stations'"'"' locations are dynamically allocated.

20. The system of claim 1 wherein one or more of said one or more work cells comprises one or more container stations for receiving said transportable containers delivered to work cell.

21. The system of claim 20 wherein one or more of said container stations are at predetermined locations within said work cell.

22. The system of claim 20 wherein one or more of said container stations are docking stations for localizing said transportable containers in said work cell.

23. The system of claim 1 wherein more than one of said MTUs can be used for transport of more than one type of said transportable containers.

24. The system of claim 1 wherein said one or more manufacturing processes performed by each of said work cells are performed in a flow that can be dynamically changed.

25. The system of claim 24 wherein said flow for said one or more manufacturing processes is changed only by software.

26. The system of claim 24 wherein said flow for said one or more manufacturing processes is changed due to events relating to said manufacturing processes.

27. The system of claim 24 wherein said flow for said one or more manufacturing processes is changed to add or remove one or more of said work cells.

28. The system of claim 1 wherein when said error in a workpiece is corrected at said rework station and said computer system commands said associated one of said one or more MTUs to deliver said transportable containers with said corrected workpiece to one of:

a location for receiving completed workpieces or when it is determined that one or;

to a work cell that can perform said one or more further processes when it is determined that one or more further processes to be performed on said workpieces more further processes are still to be performed on said workpiece to a work cell that can perform said one or more further processes.