Brake Pedal Clevis Pin Assembly With Vision-Guided Robots
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Solution Overview
Problem
The manual assembly of a brake system, specifically the coupling of a clevis pin and snap pin to connect a pedal arm of a brake pedal to a clevis on a push rod, results in reduced productivity and inconsistent work quality due to time-consuming processes and limited workspace.
Innovation Solution
An apparatus and method utilizing robots equipped with grippers, vision sensors, and torque sensors to automate the assembly process, ensuring precise alignment and coupling of the clevis pin and snap pin through scanning, correcting, and rotating mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used to couple the clevis pin and snap pin, then the workspace requirements are reduced, but the productivity decreases and work quality becomes inconsistent
Solution Approach 1:
The assembly system is divided into multiple robotic arms, each responsible for specific components (pedal arm, clevis pin, snap pin). This segmentation allows parallel operation and reduces overall assembly time while maintaining manageable system complexity through modular design.
Solution Approach 2:
Manual mechanical assembly operations are replaced with automated robotic systems equipped with specialized grippers. The robotic arms perform positioning, insertion, and coupling operations that were previously done manually, significantly improving productivity and consistency.
2Manufacturing precision
If manual assembly is used to couple the clevis pin and snap pin, then the device complexity is reduced, but the work quality consistency deteriorates
Solution Approach 1:
Vision sensors are integrated into the robotic system to detect the positions and orientations of components in real-time. This feedback enables the robotic arms to adjust their movements dynamically, ensuring precise alignment and coupling of the clevis pin and snap pin, thereby improving assembly precision.
Solution Approach 2:
The vision sensors create digital representations (optical copies) of the physical components and their positions. This allows the control system to process spatial information and guide the robotic arms with high precision without requiring complex mechanical guidance mechanisms.
3Productivity
If automated assembly with robots is implemented, then the productivity increases, but the device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functional grippers that can handle different components (pedal arm, clevis pin, snap pin) using the same basic mechanism. This universality reduces operational complexity by eliminating the need for multiple specialized tools or frequent tool changes, while maintaining high productivity.
4Manufacturing precision
If vision sensors are used for scanning and alignment, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
Vision sensors serve as an intermediary between the physical components and the robotic control system. They capture optical information about component positions and orientations, converting physical spatial relationships into digital data that the control system can process, thereby achieving high alignment precision without direct mechanical measurement mechanisms.
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
Automates the assembly process, reducing work time, improving productivity and quality, and enabling data conversion of quality-related information for enhanced convenience.
Implementation Method 1
The second gripper may be an electromagnetic gripper configured to prevent the clevis pin from coming off
Data Source
AI summary
Proposed are an apparatus and a method for automatic assembly of a brake system, wherein the work of coupling a clevis pin (300) and a snap pin (400) to connect a pedal arm (110) of a brake pedal (100) to a clevis (220) provided on a push rod (210) of a brake (200) is automated, thereby contributing to work efficiency improvement and quality enhancement.