AI Vision Wheel Mounting for Moving Vehicle Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automating the wheel mounting process in vehicle assembly is challenging due to inconsistent wheel and hub arrangements, requiring manual adjustments for precise alignment, which hinders efficient and automated production.
Innovation Solution
A system utilizing machine vision components and AI software to identify mounting points on partially assembled vehicles in motion, enabling fixtureless wheel mounting through synchronized robot operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual wheel mounting with visual adjustment is used, then alignment precision is improved, but productivity is worsened
Solution Approach 1:
The patent replaces manual visual alignment with an automated vision system using cameras and AI software to detect hub and wheel features, calculate mounting offsets, and guide robotic positioning. This substitution maintains alignment precision while enabling automated high-speed wheel mounting without manual intervention.
Solution Approach 2:
The system performs preliminary detection and calculation of mounting offsets before the actual wheel mounting operation. The vision system captures images of hubs and wheels, calculates precise positioning offsets using multi-iterative best fit weighted vector analysis, and prepares mounting instructions in advance, enabling accurate and efficient automated mounting.
2Productivity
If automated wheel mounting is implemented, then productivity is improved, but manufacturing precision is worsened due to alignment issues
Solution Approach 1:
The patent replaces manual visual alignment with an automated vision system using cameras and AI software to detect hub and wheel features, calculate mounting offsets, and guide robotic positioning. This substitution maintains alignment precision while enabling automated high-speed wheel mounting without manual intervention.
Solution Approach 2:
The system uses machine vision to continuously detect the actual positions of hubs and wheels, compares them with target positions, and dynamically adjusts mounting offsets based on real-time feedback. This closed-loop control ensures precise alignment even with variations in component presentation during automated mounting.
3Ease of operation
If fixtureless mounting is used, then ease of operation is improved, but device complexity is worsened due to need for vision systems
Solution Approach 1:
The vision system and control software serve multiple functions: detecting hub and wheel features, calculating mounting offsets, guiding robotic positioning, and verifying mounting accuracy. This multi-functionality justifies the added complexity by eliminating the need for fixtures and manual operations across the entire wheel mounting process.
Solution Approach 2:
The system enables self-aligned wheel mounting where the vision system automatically detects component positions and the robot autonomously positions and mounts wheels without human intervention or physical fixtures. The process is self-sufficient, requiring only the vision system and controller to handle all alignment and positioning tasks.
Data Source
AI summary
Systems and methods for mounting wheels to partially assembled vehicles in motion using machine vision systems and artificial intelligence software are provided. Lug nut handling robots pick and place lug nuts at wheels for the vehicles. Wheel handling robots pick up the wheels and lug nuts, travel through the work area alongside the conveying subassembly at matched speed and position, and synchronously place the wheels at the vehicle under the command of a controller based on data received from sensors and machine vision systems regarding speed and position of the vehicle in the work area, wheel rim hole positions, and wheel hub position. This data is processed by an artificial intelligence model to calculate offsets between the measured rim hole positions and reference rim hole positions as well as the measured wheel hub position and reference wheel hub position to achieve the synchronous placement.