Angled Motor Robot Tool for Sealing Plug Insertion
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Solution Overview
Problem
Existing methods for setting plugs in body components are ergonomically unfavorable, prone to human error, and inefficient, particularly in difficult-to-access areas, with existing robotic tools being non-HRC-compliant, energy-intensive, and limited in versatility.
Innovation Solution
A robotic tool with a compact design featuring a plug magazine and drive unit arranged at an angle, utilizing a flexible brush cable and elastic lip for secure plug placement, allowing for quick and precise insertion of multiple plugs without manual intervention, and enabling HRC-compliant operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a traditional robotic tool with vacuum head is used for plug insertion, then automation is achieved, but the tool requires compressed air supply and cannot operate in HRC mode
Solution Approach 1:
The patent replaces the traditional vacuum-based mechanical system with an electric drive unit. The insertion device is equipped with an electric motor that directly drives the plug insertion mechanism, eliminating the need for compressed air hoses and vacuum pumps. This substitution enables HRC compliance while maintaining automation.
Solution Approach 2:
The patent extracts and removes the compressed air supply system from the robotic tool. By eliminating the vacuum head and compressed air hoses, the tool becomes safer for collaborative operation and reduces energy consumption. The electric drive unit operates independently without requiring external air supply infrastructure.
2Device complexity
If the drive unit is arranged axially with the plug magazine, then the structure is simple, but the tool cannot reach hard-to-access areas
Solution Approach 1:
The patent repositions the drive unit from an axial arrangement to a radial arrangement relative to the plug magazine. The electric motor is mounted on the radial flange of the plug magazine, driving the insertion device through a radial transmission mechanism. This dimensional change reduces the axial length while maintaining structural simplicity.
Solution Approach 2:
The patent nests the drive unit components within the radial space of the plug magazine. The electric motor, transmission elements, and insertion mechanism are arranged in a compact nested configuration that fits within the radial envelope, minimizing axial protrusion while keeping the structure simple and maintainable.
3Adaptability or versatility
If plugs are inserted manually, then flexibility and adaptability are maintained, but ergonomic strain and human error increase
Solution Approach 1:
The patent designs the electric drive unit with a universal interface that can accommodate different plug types and insertion requirements. The radial drive mechanism can be configured for various insertion forces and speeds, maintaining adaptability while eliminating ergonomic strain through automated operation. The system can handle different plug diameters and insertion depths through programmable control.
4Manufacturing precision
If a robot tool with single-plug capacity is used, then precision is maintained, but productivity decreases due to constant reloading
Solution Approach 1:
The patent implements a magazine system that pre-lloads multiple plugs in the correct sequence and orientation. The electric drive unit retrieves plugs from the magazine and feeds them continuously to the insertion device, eliminating repeated reloading operations. This preliminary preparation of multiple plugs maintains precision while significantly improving productivity.
Solution Approach 2:
The patent enables continuous plug insertion operation through the integrated magazine and electric drive system. While one plug is being inserted, the next plug is already positioned and ready in the magazine, eliminating idle time. The electric motor provides continuous driving force without the interruptions required by traditional single-plug tools.
Data Source
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AI summary
The invention relates to a robot tool (1) for setting sealing plugs (2) in openings in a vehicle body component, comprising a setting device (3), in which a plug magazine (4) having a plurality of plugs (2) is accommodated, which can be set into the respective openings in direct succession by means of the setting device (3) without reloading. The invention further relates to a method for securely setting the plugs (2), wherein the plugs (2) can be pushed out of the plug magazine (4) accommodated in the setting device (3) in predefined steps by means of a drive unit (7), wherein the plug magazine (4) extends axially in a first direction and the drive unit (7) is arranged on the plug magazine (4) at an angle (α) of 90-150° to the first direction.