AGV-Guided Assembly Line Position Tracking for Moving Vehicle Bodies
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Solution Overview
Problem
Automotive final assembly lines face challenges in robot automation due to irregular motion and vibrations of vehicle bodies on conveyor systems, leading to positioning errors and inaccuracies, which existing solutions struggle to fully address without stopping the conveyor.
Innovation Solution
Implementing a method that uses real-time vision systems to monitor the position of Automated Guided Vehicles (AGVs) and target areas, enabling visual servoing and compliant behavior processes to synchronize the movement of industrial robots with the AGV, allowing accurate and efficient assembly operations without stopping the conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a robot is controlled to track the movement of a conveyor using encoders and optical sensors, then the robot can synchronize its position with the conveyor, but positioning errors due to conveyor vibrations and limited encoder resolution are not appropriately addressed
Solution Approach 1:
The patent replaces the mechanical encoder-based positioning system with a vision-based measurement system. A laser scanner or camera captures the actual position of the part on the conveyor, substituting optical measurement for mechanical encoding. This eliminates the limitations of encoder resolution and provides more accurate real-time position data to compensate for vibrations and positioning errors.
Solution Approach 2:
The patent implements a feedback loop where the vision system continuously measures the actual position of the part, compares it with the desired position, and adjusts the robot's positioning accordingly. This closed-loop control allows the system to compensate for dynamic vibrations and positioning errors in real-time, improving both measurement precision and assembly reliability.
2Manufacturing precision
If the conveyor is stopped to determine the coordinates of points on the vehicle body, then positioning errors can be compensated, but productivity is reduced due to conveyor interruptions
Solution Approach 1:
The patent enables continuous conveyor operation by implementing real-time vision-based measurement and robot control. Instead of stopping the conveyor to measure part positions, the system continuously tracks the moving part's coordinates using a laser scanner or camera and adjusts the robot's position dynamically. This maintains continuous material flow while achieving accurate positioning for assembly operations.
Solution Approach 2:
The patent transitions from a static measurement approach (requiring conveyor stops) to a dynamic measurement approach. The vision system and robot controller operate in real-time while the conveyor is moving, allowing the system to adapt to the part's motion and continuously update positioning data without interrupting production flow.
3Productivity
If robots are used for automated assembly operations on moving parts, then productivity increases, but positioning errors and inaccuracies arise due to irregular motion and vibrations
Solution Approach 1:
The patent replaces mechanical position tracking methods with optical vision-based measurement. A laser scanner or camera mounted on the robot or conveyor continuously measures the actual position and orientation of the part, providing accurate real-time data that compensates for vibrations and irregular motion, enabling high-precision automated assembly on moving parts.
Solution Approach 2:
The patent implements real-time feedback control where vision system measurements of the part's actual position are continuously fed back to the robot controller. This allows dynamic adjustment of the robot's end effector position to maintain precise alignment with the part's target features, compensating for motion irregularities and vibrations during automated assembly operations.
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 enhances the accuracy and speed of assembly operations by compensating for various sources of error, including conveyor vibrations and limited encoder resolution, while reducing the risk of collisions and enabling complex operations like mounting the cockpit in a vehicle.
Implementation Method 1
arranging a first real time vision system to monitor the position of the AGV
Data Source
AI summary
A method for assembling parts in an assembly line, such as an automotive final assembly line, is disclosed. The method includes advancing a part along the assembly line with an Automated Guided Vehicle (AGV), arranging a first real time vision system to monitor the position of the AGV in at least two directions, and providing the readings of the first real time vision system to a controller arranged to control an assembly unit of the assembly line to perform an automated operation on the part that is advanced or supported by the AGV. An assembly line is also disclosed.