Assembly Vehicle Load Verification for Incomplete Build Detection
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Solution Overview
Problem
Existing manufacturing systems lack effective methods to verify proper assembly of products at each stage, leading to incomplete or improperly assembled final products.
Innovation Solution
A manufacturing system utilizing vehicles equipped with sensors and controllers to measure and compare actual forces on product interfaces with expected forces, providing notifications or control actions when discrepancies are detected, ensuring proper assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing systems are used without force verification, then the manufacturing process is simpler and faster, but the assembly quality and completeness cannot be ensured
Solution Approach 1:
The patent replaces traditional mechanical inspection methods with a sensor-based force measurement system. Force sensors coupled to the vehicle interface measure forces during assembly operations, and a controller compares measured forces against expected values to verify proper assembly, substituting physical inspection with automated force-based detection
Solution Approach 2:
The system implements feedback by continuously measuring forces during assembly, comparing them against expected force values stored in the controller, and providing real-time verification. When measured forces deviate from expected ranges, the system can trigger alerts or stop the assembly process, creating a closed-loop quality verification system
2Reliability
If force sensors and verification systems are added to vehicles, then assembly quality is improved, but the vehicle complexity and cost increase
Solution Approach 1:
The force sensors and verification system are designed to be universally applicable across different vehicle types and assembly operations. The controller can store and compare against multiple sets of expected force values for different products and assembly stages, making the system multi-functional rather than requiring dedicated verification systems for each vehicle configuration
Solution Approach 2:
The controller acts as an intermediary between the force sensors and the assembly verification process. It receives raw force data from sensors, compares it against stored expected values, and generates verification results, simplifying the overall system architecture by centralizing the verification logic in a dedicated control unit
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
Ensures proper assembly by detecting and addressing deviations in force measurements, minimizing errors and incomplete stations, thereby improving the quality of the final product.
Implementation Method 1
a sensor coupled to the interface and configured to provide sensor data indicating a measured force on the interface
Data Source
AI summary
A manufacturing system includes a vehicle configured to facilitate movement of a product throughout a manufacturing environment. The vehicle assembly includes a chassis, an interface coupled to the chassis and configured to support the product, and a sensor coupled to the interface. The sensor is operatively coupled to a controller, which is configured to receive sensor data, receive current stage of assembly of a product, determine an expected force based on the current stage of assembly, and compare the measured force and expected force. In response to a determination that the measured force differs from the expected force, the controller provides a notification to the user of the current status of the product.