I am basically providing my Readers with my thoughts on removing Production labor from the actual Production line, circa 1999.
Work Station Mechanics
Lawrance George Lux
(First appearing as Appendix A, in Prognosis 2000, Xlibris Corporation, ISBN–0-7388-0660-9, Library of Congress No.99-091198, Copyright .Lawrance George Lux 1999, pps. 111-119)
The Work Station concept is relatively new, and will take the careful thought of innumerable engineer and design specialists, before a standard format will finally form. The intention here is to catalog some of the numerous functions which such a system will have to employ, and the equipment that must be present to fulfill these functions. Here is this author’s poor conceptional list:
1) The Work Station must be reach-oriented; so it will undoubtedly be half-moon with a half-moon inset to accommodate the seated operator.
2) A computer is integral to the system; so there will have to be a monitor, a keyboard, and a numeric keypad for calculations.
3) There must be, in addition, a work screen quartered, so that four views can be presented at one time. This screen must be distinct from the computer monitor, as a worker may have to refer to both during some operations.
A) There should be a push-in, rotating knob parallel to center each quarter of the view screen.
i) pushing the knob in will transfer the quarter into full view screen.
ii) rotating the know of each quarter view screen will allow for programable view of alternative operations, of one machine, or differing machines.
4) There must be three turn-wheels, whose purpose is setting each of the x,y, and z axises.
A) These wheels must have snap-gradients, so each click setting has definite value–computer set exact.
B)There must be four or five punch-in and lock buttons above the xyz wheels:
i) to choose between different value setting in one operation; or
ii) to choice between different settings for different machines.
C) Undoubtedly each joystick will require it’s own three snap-gradient wheels, and will probably be located to the upper outside of each slide close to the front, with gradient reading windows above each wheel.
D) These wheels will probably be place in a straight row always in specific order, x to the outside, y in the center, and z closest to the slide.
5) There must be a Column-row choice pad for choice of machine control, to be able to switch (Example: From Machine A& to machine B33).
A) there must be a number window above this choice pad showing the current machine in operation.
i) This window indicates the programmed clearance lockouts are in operation for the machine specified (Those lockouts must match the machine on which one is working, which will be physically marked on the view screen).
ii) a mismatch of numbers means a program malfunction.
6) There must be two rocker-arm joysticks.
A) They must slide forward or backward along at least a ten inch slide (Slide forward causes robonics extension; all the way back should be the clearance lock-out position)
B) They must rotate 180 degrees from vertical to horizontal (This will change the directional angle of the tool face)
C) Each joystick change can be rocked 20 degrees of vertical in any direction to assist in any alteration of the directional angle of the tool face.
D) Each joystick will have a side button which will change the tool face position to perpendicular.
E) Each joystick will have a trigger. The joystick cannot slide forward or backward or change directional angle unless the trigger is depressed. The trigger acts as an exact computer-controlled brake, locking the robonics arm into the last position indicated before release of the trigger.
F) Each joystick will have two red buttons on the top. The right will produce a clockwise rotation of the tool in operation. The left button will provide a counter-clockwise rotation of the tool in question.
i) These buttons should be at least one-half inch high–their degree of depression will determine the speed of rotation.
G) There must be a two-step thumb switch to the inside of each joysticks; this activate the clamp-on or clamp-off of robonics clamps.
7) There need be at least five lock-in buttons immediately in front of the joystick slides. These are programable tool choices for each robonics arm. The tool chosen should appear in red lettering at the top of the view screen.
8) There should be a row of five lock-in buttons parallel to the left of each joystick slide. These will determine which robonics arm will be used in multi-arm constructions.
9) There should be a line of lock-in buttons parallel to the right of each joystick slide; These buttons are to lock in varying amounts of torque used in lbs.
10) There is a big, red depression button centered between the center of the two joystick slides. This is machine operation button: It activates the machine in the view screen.
A) Machine will not operate if the clearance lockouts are violated, and a buzzer will sound.
11) Immediately in front of the red machine-operation button is a smaller black depression button; this brings to the computer screen the operating procedures for the machine shown, plus all specifics necessary for operation.
12) Immediately in front of the lock-in buttons to determine choice of tool, there must be a dial to adjust focus of view of the tool surface and machine of the joystick arm. Beside it must be a depress button, which starts an automated cleaning operation to clean the specific optics of the arm.
13) There must be a third screen plus keyboard on the Work Station; this is where you will program in part dimension tolerance before operation, and another set after operation. These will be given in x,y,z axises.
A) This screen and keyboard has multiple functions:
i) under measure measurement testing, a computer simulation will appear, and straight red lines will show the distance off dimension tolerance, with a red lettering to the inside of red line which gives the exact variance.
ii) This can be programed to accept dimension tolerance allowance.
B) This screen and keyboard also programs the correct positioning of robonic arm clamps in withdrawing the part from the import bin and placement in the machine, and the proper grip of the part for extraction from the machine and placement in the export bin.
i) This facility will cause two full screen red lines to appear in the center screen, these red lines will advance inward or outward with movement of the robonic arm. When the exact grip position has been reached, they will combine as a single red line in the center, which will disappear when the clamp has been applied; after a delay to show true position after clamp has been applied.
14) Each Work Station must have a two-hand wheel which inserts in the frame between the operator’s legs. This wheel can be pulled out for use up to ten inches. Mechanics of said wheel:
A) With this wheel, any vehicle can potentially be driven
B) The wheel will have a half-inch depression button above each grip which
i) the right grip button will be the accelerator
ii) the left grip button will be the brake
iii) the harder you depress the buttons, the greater the acceleration or the braking. Both are limited in degree by computer programing which will probably be defined by law.
C) Tilting the wheel towards the operator four degrees will activate a cruise control. Depression of the braking button will deactivate the cruise control.
15) The computer system of the Work Station must have functions keys to differentiate between operation on a specific machine:
B) Lubricant change
D) Part discard procedure
E) Optics repair
F) Die and Stops changing procedures
G) function programing procedure
The initial design of Work Station technology, and the pattern software for it, will be incredibly complex, and prohibitively expensive; yet, after it’s completion, it will be as easy to use as Windows applications are today. There are always the R%D costs which are the field of experts, what comes after is utility equipment of vast value, which ninety percent of the labor force will be able to use after training.
One of the rationales for standardization of Work Station Mechanics consists of avoidance of duplication of massive software development costs. The over-riding consideration is the avoidance of mis-training and over-ridden layered training which will always lead to mistakes on the part of labor; who develop the wrong reactions, then think to replace them. This requires a unified technology. Other directions will lead to unacceptable levels of defective parts in production. Intelligent inputs always expands satisfactory outputs. lgl..