Automated Assembly of Non-Electric Components on Switch Cabinets
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Solution Overview
Problem
The assembly of non-electric components onto a component-carrier, such as DIN-rails and wiring ducts onto a back panel of a switch or control cabinet, is largely manual, leading to inefficiencies and high setup costs per assembly.
Innovation Solution
A method and assembly unit that automate the assembly process using a hybrid, reactive, and deliberative machine architecture. This involves pick & place operations and connection technologies, with machine motion generation ensuring collision-free paths and intentional contacts for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual assembly methods are used for non-electric components, then flexibility for custom-made switch cabinets is maintained, but productivity and efficiency deteriorate
Solution Approach 1:
The system dynamically adapts its assembly process based on digital models of custom switch cabinet designs. The machine architecture can adjust its motion sequences and assembly parameters in real-time to accommodate different customer specifications while maintaining automated high-speed assembly operations
Solution Approach 2:
The system changes operational parameters such as motion paths, assembly forces, and sequence of operations based on the specific digital model being assembled. This allows the same automated system to handle diverse custom designs by modifying control parameters rather than physical hardware
2Productivity
If automated assembly machines are introduced, then productivity improves, but device complexity and setup costs increase
Solution Approach 1:
The automated assembly system is designed as a universal platform capable of assembling different types of non-electric components (DIN-rails, wiring ducts, cable trays) on various component-carriers. By using a hybrid machine architecture with reusable digital models, the system achieves multi-functionality without requiring separate specialized machines for each assembly type
Solution Approach 2:
The system uses digital models as virtual copies of the physical switch cabinet designs. These digital twins allow the automated system to plan and execute assembly operations without physical prototypes or extensive setup, reducing the complexity of transitioning between different custom designs
3Ease of manufacture
If traditional riveting processes are used, then manufacturing simplicity is maintained, but assembly time and loss of time increase
Solution Approach 1:
The system performs preliminary planning of assembly sequences using digital models before physical assembly begins. Motion sequences are pre-calculated to optimize the riveting process, allowing multiple components to be positioned and assembled in the most efficient order, reducing overall assembly time while maintaining the simplicity of the riveting operation itself
Data Source
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AI summary
In order to assemble non-electric components onto a component-carrier, by which assembling the non-electric components is automated, it is proposed 1) to carry out -- - a pick & place operation (PPOP) picking a non-electric component (CP, CPA, CPB, CPC) and placing the picked component onto a component-carrier (CPC, BP, SC) and - a connect operation (COP) connecting the placed component with the component-carrier by implementing a connection technology (CT) -- on a hybrid, at least reactive and deliberative machine architecture based on a "machine world model" as a digital twin to formulate correct machine-behavioral sets being used during machine run-time as well as an "machine workflow" - a piece of machine work to carry out the operations is passed in series of machine stages from initiation to completion, 2) to execute by machine motion generation including a collision-free motion or path planning of a machine (MA) within a machine workspace (MAWS) - primary kinematic machine-movement-sequences (MAMSk1) enabling the pick & place operation and - secondary kinematic machine-movement-sequences (MAMSk2) enabling the connect operation, and 3) to enable or ensure the execution via the machine motion generation by - initializing (ilz) the "machine world model" according to a configuration file (CFGF) configuring the machine and the machine workspace and - instantiating (itt) the "machine workflow" and updating (upd) the "machine world model" with a design of the component-carrier.