Clamping Frame-less Joining via Robotic Positioning
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Solution Overview
Problem
Existing methods for joining components in automotive and other industries face challenges such as geometric inaccuracies, elastic deformation, and wear of positioning elements due to the use of clamping frames, which lead to reduced accuracy and increased risk of composite cracking.
Innovation Solution
A method and device utilizing a holding robot and a positioning robot operating in a master-slave mode, where components are clamped only by contact with each other, eliminating the need for a clamping frame, and using marking points for precise positioning with sensors to determine the relative position, thereby reducing mechanical stresses and wear on positioning means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a clamping frame is used to clamp components tightly together for joining, then the components are held securely in position, but the components deform elastically due to geometric inaccuracies and tolerances, causing spring-back behavior and reduced positioning accuracy
Solution Approach 1:
The patent removes the clamping frame from the joining system entirely. Instead of using a rigid clamping frame to hold components, the invention uses robots to hold and position components freely in space, allowing components to be joined without the harmful clamping forces that cause elastic deformation and spring-back
Solution Approach 2:
The patent replaces the mechanical clamping frame system with a robotic positioning system. Robots use sensors to detect marking points on components and precisely position them relative to each other through master-slave coordination, eliminating the need for mechanical clamping and its associated deformation problems
2Ease of manufacture
If a clamping frame with positioning elements is used to join components, then the components can be clamped and joined, but the positioning elements wear down due to friction when components are picked up, reducing positioning accuracy
Solution Approach 1:
The patent removes the physical positioning elements (such as positioning pins) from the clamping frame. Instead of using fixed positioning elements that wear down, the invention uses robots with sensors to detect marking points on components and dynamically calculate and adjust positions, eliminating wear-related accuracy degradation
Solution Approach 2:
The patent implements a feedback mechanism where sensors detect the actual positions of marking points on components, the system calculates the required adjustments, and the robots adjust their positioning accordingly. This closed-loop control compensates for geometric inaccuracies and tolerances without requiring physical contact or wear-prone positioning elements
3Productivity
If a stationary clamping frame is used in a geometry station for joining body shells, then components can be joined in sync with the production cycle, but the clamping process causes elastic deformation and spring-back behavior
Solution Approach 1:
The patent transitions from a stationary clamping frame to a dynamic robotic system. The robots can move freely in space and adjust their positions dynamically during the joining process, allowing components to be positioned and joined without the constraints and deformations caused by a fixed clamping frame
Solution Approach 2:
The patent removes the stationary clamping frame from the production line and replaces it with mobile robots that can perform joining operations without physical clamping, eliminating the source of elastic deformation while maintaining production cycle synchronization
Data Source
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AI summary
A method for joining components, wherein a) a holding device (1; 31) holds a first component (10), b) a positioning robot (2; 2, 5) positions a second component (20) relative to the first component (10) in a joining position and presses it against the first component (10) in the joining position, c) the components (10, 20) are clamped against each other in the joining position by means of the positioning robot (2; 2, 5) through contact only between the components (10, 20), d) and the components (10, 20) are joined in the joining position determined relative to each other only by component contact, wherein contours inherently present on the components (10, 20) are metrologically recorded in order to position the components (10, 20) relative to each other in the joining position, or f1) the first component (10) at a marking point with a first mark (11; 12; 13;14) and the second component (20) is provided with a second mark (21; 22; 23; 24) at a marking point, which is preferably shaped congruently to the marking point of the first component (10), f2) the marks (11, 21; 12, 22; 13, 23; 14, 24) are detected by means of a sensor (8) when positioning the components (10, 20), f3) the position that the first mark (11; 12; 13; 14) occupies relative to the second mark (21; 22; 23; 24) is determined, f4) the robot(s) (1; 1, 2; 2, 5) position the components (10, 20) depending on the determined relative position of the marks (11, 21; 12, 22; 13, 23; 14, 24) in the joining position, wherein f5) the marking points are brought into contact f6) and the position that the first mark (11; 12; 13; 14) occupies relative to the second mark (21; 22; 23; 24) is sensorially detected and determined in the contact of the marking points.;