Degate Robot End-of-Arm Tooling for Downward Punching

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing degating machines are inefficient due to the need for multiple steps and manual interventions to correct errors, which are time-consuming and labor-intensive, as they often rely on upward strokes that allow excess metal to fall back and cause jams, requiring manual separation.

Innovation Solution

An automatic degating system featuring a robotic arm with a punch assembly and gripping device, utilizing a plurality of cutting pucks and a fixture for precise positioning, which removes excess metal in a controlled manner, reducing manual intervention and improving efficiency by staggering the impact of cutting pucks to distribute the load and reduce shock.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an upward stroke is used to dislodge excess metal, then the excess metal can be removed from the component, but gravity causes the removed metal to fall back onto or into the component or onto the machine, causing jams or requiring manual intervention

Engineering Contradiction:

Improveprocess reliabilityVSAvoidexcess metal falling back and causing jams

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent inverts the conventional upward punching stroke to a downward punching stroke. The punch assembly moves downward to dislodge excess metal, and the excess metal is directed into a waste recovery system below, preventing it from falling back onto the component or machine. This inversion resolves the harmful effect of metal falling back and causing jams.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent utilizes gravity, which previously caused harm by making removed metal fall back onto the component, by directing the downward motion to benefit the process. The excess metal is guided into a waste recovery system, converting the harmful gravitational effect into a beneficial automatic waste collection mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If multiple degating steps and manual interventions are used to correct errors, then the degating process can be completed, but the process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvedegating process completionVSAvoiddegating cycle time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The robotic arm with the punch assembly performs the degating process automatically without requiring manual intervention. The system is self-sufficient in completing the degating operation, positioning the punch, executing the cutting stroke, and removing excess metal autonomously, thereby eliminating time-consuming manual corrections.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical operations with an automated robotic system. The robotic arm, controlled by a programmable logic controller, substitutes human operators in performing degating steps, reducing labor intensity and cycle time while maintaining process reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If a robotic arm with punch assembly and gripping device is used, then manual intervention is reduced and efficiency is improved, but the system complexity increases

Engineering Contradiction:

Improvedegating efficiencyVSAvoidautomated system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines the punch assembly and gripping device into a single integrated end-of-arm tooling unit mounted on the robotic arm. This merging of functions into one unified system reduces the number of separate components and simplifies the overall system architecture while maintaining high productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The robotic arm with the integrated end-of-arm tooling performs multiple functions: positioning, punching, gripping, and transferring the workpiece. This multi-functional design eliminates the need for separate machines for each operation, reducing system complexity while improving productivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11453052B2Degate robot end-of-arm tool and methods of use

Publication Date: 2022.09.27 HONDA MOTOR CO LTD

AI summary

A method and an automatic degate system includes a fixture configured to receive a workpiece, a registration device configured to position the workpiece in a predetermined orientation and position, and a robotic arm. The robotic arm is configured to move in at least a gripping direction. The robotic arm includes a gripping device configured to engage the workpiece at predetermined locations after being moved in the gripping direction. The robotic arm also includes a support bracket, a plurality of elongate rods each having a predetermined length and extending orthogonally from the support bracket, and a respective cutting puck coupled to a distal end of each of the plurality of elongate rods. The cutting pucks configured to remove a biscuit of excess material from the workpiece while being moved in the gripping direction.