3D-Printed Metrology Features for Fixtureless Assembly Alignment
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Solution Overview
Problem
Conventional measurement devices and assembly processes face challenges in achieving precision and efficiency in automated assembly, particularly in confined spaces with intricate shapes and high precision requirements, where traditional subtractive manufacturing methods for metrology features are costly and time-consuming.
Innovation Solution
The use of 3-D printed metrology features that allow for contact-free measurements using a laser detector or other light sources, enabling a measurement device to detect feature locations and determine component position and orientation without physical contact, thereby reducing complexity and clutter in the assembly cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional subtractive manufacturing is used to create metrology features, then measurement precision can be achieved, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent changes the manufacturing parameter from subtractive machining to additive 3-D printing, allowing metrology features to be created directly during the printing process. This enables precise geometric features to be manufactured without the high costs and long lead times associated with traditional subtractive methods, while maintaining the required measurement precision
Solution Approach 2:
The patent combines the manufacturing of the component and its metrology features into a single 3-D printing process. Instead of creating metrology features separately through machining or assembly, they are integrated into the component manufacturing itself, reducing overall manufacturing complexity and cost
2Difficulty of detecting and measuring
If conventional measurement devices are used in automated assembly, then measurement capability is provided, but device complexity and assembly cell clutter increase
Solution Approach 1:
The patent replaces complex mechanical contact-based measurement devices with optical laser detection systems. The laser detector can non-contactly measure the 3-D printed metrology features, eliminating the need for physical contact probes and reducing mechanical complexity in the measurement system
Solution Approach 2:
The 3-D printed metrology features serve multiple functions: they provide measurement references for laser detection, maintain structural integrity of the component, and can be designed to accommodate various measurement angles and positions. This multi-functionality reduces the need for specialized measurement equipment
3Extent of automation
If multiple robots are used for automated assembly, then assembly automation increases, but task coordination and space constraints become more challenging
Solution Approach 1:
The patent introduces 3-D printed metrology features as intermediary reference elements that facilitate coordination between multiple robots. These features provide a common reference framework that allows different robots to understand and coordinate their positions and tasks, simplifying the overall system coordination complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables a partially or fully fixtureless assembly process, improving the accuracy and efficiency of assembly by allowing multiple tasks to be performed concurrently or in rapid sequence, while reducing the risk of task interference and enhancing the overall manufacturing flexibility.
Implementation Method 1
contact-free measurements using a laser detector or other light sources, enabling a measurement device to detect feature locations
Data Source
AI summary
Aspects for implementing 3-D printed metrology feature geometries and detection are disclosed. The apparatus may a measurement device for a 3-D printed component. The component may include a plurality of printed-in metrology features arranged at different feature locations on a surface of the component. The measurement device can be configured to detect the feature locations of the printed-in metrology features and to determine a position or an orientation of the component based on the detected feature locations. In various embodiments, the metrology feature may be a protruding or recessed spherical portion, with the corresponding feature location at the center of the sphere.