Collaborative Robot Windscreen Assembly
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Solution Overview
Problem
Current methods for assembling and mounting motor-vehicle component parts in automotive manufacturing lines are complex, expensive, and inefficient, with operators performing numerous movements and facing safety risks due to the separation of operating areas and reliance on multiple manipulator devices.
Innovation Solution
A collaborative robot system that operates in an unprotected space alongside the operator, capable of picking up windscreen glasses from racks, supporting them for manual assembly, applying adhesive, and mounting them on vehicle structures, reducing operator movements and enhancing safety by eliminating the need for separate manipulator devices and tilting tables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tilting table and separate manipulator device are used to handle glass, then the glass can be securely held and positioned, but the device complexity and cost increase significantly
Solution Approach 1:
The patent combines the glass handling function into the robot's end effector (gripper) rather than using a separate manipulator device. The robot arm with specialized gripper directly picks up glass from the rack and positions it for assembly, eliminating the need for complex tilting tables and separate manipulators while maintaining reliable glass handling throughout the process
Solution Approach 2:
The robot system performs multiple functions: it picks up glass from the rack, positions it for manual assembly, applies adhesive, and mounts the finished assembly to the vehicle. This multi-functional approach replaces the need for specialized dedicated devices for each operation, reducing overall system complexity while maintaining operational reliability
2Object-affected harmful factors
If the operator works in a protected area separated from the robot, then operator safety is ensured, but the operator must make numerous movements to access components and the assembly process becomes inefficient
Solution Approach 1:
The patent introduces a collaborative robot as an intermediary that handles dangerous tasks (glass handling, adhesive application) while the operator performs precision tasks (accessory assembly) in the same space. The robot's presence enables the operator to work close to components without direct exposure to hazards, and the coordinated interaction between robot and operator streamlines the assembly process, reducing unnecessary movements
Solution Approach 2:
The assembly process is segmented into distinct functional zones: glass picking, accessory assembly, adhesive application, and mounting. The robot and operator operate in complementary zones within the same physical space, allowing efficient workflow without requiring physical separation barriers that would limit access and increase movement requirements
3Ease of manufacture
If multiple separate devices are used for glass picking, supporting, and mounting, then each function can be optimized, but the overall process complexity and cost increase
Solution Approach 1:
The robot system is designed to perform multiple functions: picking glass from the rack using a specialized gripper, supporting the glass during assembly, applying adhesive, and mounting the finished assembly to the vehicle. This multi-functional robot replaces multiple separate dedicated devices, reducing system complexity while maintaining optimized performance for each function through programmable control and interchangeable end effectors
Solution Approach 2:
The system uses a dynamic, programmable robot that can adapt its movements and actions based on the specific assembly task. The robot's programmable control allows it to optimize each operation (glass picking, positioning, adhesive application, mounting) without requiring fixed, dedicated mechanical structures for each function, reducing overall system complexity while maintaining functional optimization
Data Source
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AI summary
A method for assembling a group of motor-vehicle component parts and for mounting the group in a motor-vehicle assembling line, comprises a first assembling phase for assembling the group (P) and a second subsequent phase, wherein a robot (R) mounts the assembled group (P) onto a motor-vehicle structure along the motor-vehicle assembling line (1). The robot (R) is a collaborative robot, i.e. a robot equipped with safety devices configured in such a way that the robot can operate in an unprotected space, close to an operator (3). The robot (R) is used to perform a pick-up operation of a group main component (P) from a rack (8), to support the picked-up main component (P) in one or more positions suitable to perform an optical detection of the quality of the main component (P), to hold the picked-up main component (P) in a position suitable for manual assembly of a plurality of accessory parts on the main component (P) by the aforesaid operator (3), and for mounting the group (P) thus assembled onto a motor-vehicle structure, along the assembling line (1).