Adaptive Cabin Rail Assembly for Precise Heavy Module Installation
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Solution Overview
Problem
The installation of heavy modules in vehicle cabins is challenging due to space limitations and weight handling issues, requiring specialized equipment and expertise, which can lead to safety hazards and costly mistakes if not done properly.
Innovation Solution
An adaptive rail system with a movable jig and rail interface is integrated into the cabin, allowing for precise placement and repositioning of modules within the cabin, facilitated by a wheel-based jig carrier, motorized linear actuator, or mobile robot unit, and adjustable in length, height, and width to accommodate conic sections, enabling safe handling and installation of heavy modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heavy modules are manually handled during installation, then installation can be performed without specialized equipment, but safety hazards increase and handling becomes difficult
Solution Approach 1:
The patent introduces a robotic manipulator as an intermediary device between the human operator and the heavy module. The manipulator, controlled by a remote control unit, handles the module during installation, eliminating direct manual handling while maintaining operational control. This resolves the contradiction by providing safe handling through automation while preserving ease of operation through remote control.
Solution Approach 2:
The patent replaces manual mechanical handling with an automated robotic manipulator system. The manipulator uses mechanical arms and grippers to hold and position modules, substituting human physical effort and manual techniques with automated mechanical systems. This improves safety by removing humans from direct contact with heavy modules while maintaining installation capability.
2Reliability
If specialized equipment is used to handle heavy modules safely, then installation safety improves, but device complexity increases
Solution Approach 1:
The robotic manipulator is designed with multi-functionality to handle various types of modules (AV equipment, kitchen equipment, entertainment systems) with different weights and dimensions. The same manipulator system can perform multiple installation tasks throughout the vehicle assembly process, reducing the need for multiple specialized devices and thereby reducing overall device complexity while maintaining safety.
Solution Approach 2:
The manipulator system incorporates self-adjusting features where the gripper force and positioning can be automatically adjusted based on the detected module characteristics. The system can autonomously navigate to installation positions and coordinate with other assembly robots, reducing the need for complex manual control mechanisms and simplifying the overall equipment complexity while maintaining safe handling.
3Manufacturing precision
If modules are precisely placed in limited cabin space, then installation accuracy improves, but maneuverability of heavy modules deteriorates
Solution Approach 1:
The robotic manipulator replaces manual handling operations, providing precise control over module placement in the limited cabin space. The manipulator's controlled motion and positioning systems can achieve accurate placement (within millimeters) while the remote control system maintains operational ease by allowing operators to control the complex movements without direct physical manipulation.
Solution Approach 2:
The system incorporates sensors and vision systems that provide real-time feedback on module position and orientation during manipulation. This feedback enables precise placement by continuously monitoring and adjusting the manipulator's movements, while the automated feedback loop reduces the operational complexity for the human operator who only needs to provide high-level guidance through the remote control interface.
Data Source
AI summary
A vehicle with a cabin comprising an adaptive rail system. The cabin includes a connection area adapted to hold the adaptive rail system. The adaptive rail system includes a rail interface, configured to be attachable to the connection area, at least one installation rail, configured to be attachable to the rail interface, and a jig. The jig is connected to the at least one installation rail in a moveable manner, such that a module attached to the jig is movable inside the cabin.