Assembly Tool Localization for Correct Chassis Alignment
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Solution Overview
Problem
Current assembly line systems lack effective quality assurance for ensuring that operators use assembly tools correctly, leading to potential errors in the assembly of heavy-duty vehicles.
Innovation Solution
An assembly line arrangement featuring a movable trolley guided by roof-mounted rails, equipped with range detectors and an image capturing unit, which determines the position of the trolley and vehicle chassis to ensure accurate alignment and torque application of assembly tools, such as spindle tools, for correct usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional tracking methods (pre-recorded images, live camera feeds, position sensors) are used to monitor assembly line tools, then tool position can be tracked, but there is no quality check to ensure operators follow the correct assembly sequence
Solution Approach 1:
The patent replaces mechanical tracking systems with optical detection systems. Range detectors (optical sensors) mounted on the trolley and roof rails replace physical position sensors and camera-based tracking, providing automated measurement of distances and positions without requiring complex mechanical intervention or manual monitoring
Solution Approach 2:
The system implements automated feedback by continuously measuring the position of the trolley and vehicle chassis using range detectors, comparing the actual tool position with the predetermined assembly sequence, and providing quality assurance through automated verification rather than relying on operator compliance alone
2Adaptability or versatility
If the assembly line tool is mounted on a movable trolley guided by roof-mounted rails, then the tool can be repositioned along the assembly line, but the precise location of the tool relative to the vehicle chassis is difficult to determine
Solution Approach 1:
The patent introduces range detectors as intermediary measurement devices between the trolley and the vehicle chassis. These detectors serve as mediators that automatically measure and communicate position data, eliminating the need for direct physical alignment or manual measurement while maintaining high precision in determining tool location relative to the chassis
Solution Approach 2:
The system replaces manual alignment and physical measurement methods with optical range detectors that automatically calculate positions and distances, providing precise location data without requiring mechanical intervention or complex alignment procedures
3Productivity
If operators manually follow predetermined assembly sequences, then assembly can be performed, but there is no automated quality check to ensure correct procedure compliance
Solution Approach 1:
The system provides automated feedback by measuring the actual position of the assembly tool and comparing it with the predetermined assembly sequence requirements. This automated verification ensures that each assembly step is performed at the correct location and in the correct sequence, providing quality assurance without slowing down the assembly process
Solution Approach 2:
The system enables self-service quality assurance by automatically monitoring and verifying assembly procedure compliance without requiring additional manual inspection. The range detectors and control system work autonomously to ensure correct assembly, eliminating the need for separate quality check personnel while maintaining high assembly correctness
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 solution enhances the accuracy and quality of assembly by providing a simple and effective location method for assembly tools, ensuring correct usage and torque application, thereby improving the overall assembly process of heavy-duty vehicles.
Implementation Method 1
one or more first range detectors mounted on the roof-mounted rails and/or trolley in order to determine the position of the trolley
Implementation Method 2
the one or more first range detectors are laser range meters
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The disclosure relates to an assembly line arrangement (200) comprising an assembly line tool (208) attached to a movable trolley (212) guided by roof-mounted rails (214, 216). The arrangement further comprises one or more first range detectors (218, 222) mounted on the roof-mounted rails (214, 216) and/or trolley (212) in order to determine the position of the trolley in a plane defined by the roof-mounted rails, and one or more second range detectors (230a, 230b) mounted on the trolley (212) in order to determine the location of a chassis of a vehicle (102) on an assembly line (100). The disclosure also relates to a computer-implemented method (300a, 300b) for ensuring correct usage of an assembly line tool at a workstation of an assembly line, wherein the assembly line tool is attached to a movable trolley guided by roof-mounted rails.