Automated Assembly Station Force Monitoring
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Solution Overview
Problem
Automated assembly processes in industries like automotive face challenges in detecting defects such as misalignment and defective sub-components, which can lead to improper assembly and are difficult to identify using traditional quality assurance methods.
Innovation Solution
An automated assembly station equipped with a mobile platform and a 6-axis robot featuring a moveable arm with a load cell and gripper, which measures and records insertion and pulling forces to ensure secure assembly, triggering alarms if forces exceed or fail to meet predetermined thresholds, thereby detecting potential defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional observation or quality assurance measures are used, then the assembly process is simple, but defects such as misalignment and defective sub-components are difficult to detect
Solution Approach 1:
The system incorporates force sensors that provide real-time feedback on insertion forces during assembly. When the measured insertion force exceeds a predetermined threshold, the system automatically triggers an alarm or stops the assembly process, enabling immediate detection and response to potential defects without requiring complex post-assembly inspection equipment
Solution Approach 2:
The patent replaces traditional mechanical observation and quality assurance methods with automated force measurement and electronic monitoring systems. The force sensors and control systems automatically detect assembly defects through force threshold comparisons, substituting manual inspection with automated electronic detection
2Productivity
If automated assembly processes are used, then assembly speed is rapid, but defects arise from alignment and defective sub-components
Solution Approach 1:
The automated assembly system integrates force sensors that continuously monitor insertion forces during the assembly process. When forces exceed predetermined thresholds, the system provides immediate feedback through alarms or automatic shutdown, enabling rapid detection of alignment issues or defective components without sacrificing assembly speed
Solution Approach 2:
The system establishes predetermined force thresholds before assembly begins, based on expected proper assembly parameters. This preliminary setup enables the system to automatically detect deviations from proper assembly conditions during high-speed operation, maintaining both speed and quality
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
The solution enables reliable assembly by monitoring insertion and pulling forces, ensuring that workpieces are properly secured and reducing the likelihood of defects, thereby enhancing the quality of assembled components.
Implementation Method 1
The load cell is operable to measure an amount of insertion force used to insert the second workpiece into the locked position
Implementation Method 2
the robot is configured to, after insertion of the second workpiece into the locked position, use the moveable arm and gripper to apply a pulling force on the second workpiece to test whether the second workpiece is secure
Implementation Method 3
the insertion of the second workpiece into the locked position on the mating part of the first workpiece includes engaging a spring lock by moving the second workpiece onto the first workpiece and overcoming a spring force of the spring lock
Data Source
AI summary
An automated assembly station includes a mobile platform for holding a first workpiece, a robot having a moveable arm, and a controller. The moveable arm includes a load cell and a gripper that is adapted to grasp a second workpiece. The robot is operable to use the moveable arm and gripper to insert the second workpiece into a locked position on a mating part of the first workpiece. The load cell is operable to measure an amount of insertion force used to insert the second workpiece into the locked position. The controller is configured to record the insertion force and trigger an alarm in response to the insertion force exceeding a predesignated threshold insertion force.