Non-Electric Component Assembly With Digital Twin Path Planning
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Solution Overview
Problem
The manual assembly of non-electric components such as DIN-rails and wiring ducts onto switch or control cabinet back panels is inefficient, with high setup costs due to the need for custom production and lack of automation in the assembly process.
Innovation Solution
A method and assembly unit utilizing a hybrid, reactive, and deliberative machine architecture with machine motion generation for collision-free path planning and force feedback to automate the pick & place and connect operations, enabling the assembly of non-electric components onto a component-carrier with minimal setup costs by using a digital twin and machine workflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual assembly methods are used for non-electric components, then flexibility in handling custom-made components is maintained, but productivity and assembly efficiency deteriorate
Solution Approach 1:
The patent uses a digital twin (virtual model) of the component carrier and components to enable automated assembly. The digital model contains all necessary geometric and process information, allowing the robotic system to assemble custom-made non-electric components automatically without requiring manual intervention for each custom design.
Solution Approach 2:
The patent implements a hybrid machine architecture that combines reactive control (for real-time collision avoidance and adaptive motion) with deliberative control (for overall process coordination). This dynamic control system allows the automated assembly unit to adapt to custom component geometries while maintaining high productivity.
2Productivity
If automated assembly machines are introduced, then productivity and assembly efficiency improve, but device complexity and setup costs worsen
Solution Approach 1:
The patent creates a universal automated assembly system that can handle different custom-made non-electric components through the use of a digital twin. The same robotic assembly unit can assemble various components (DIN-rails, wiring ducts, etc.) by loading different digital models, eliminating the need for multiple specialized machines and reducing setup costs.
Solution Approach 2:
The patent replaces complex mechanical setup procedures with a digital model-based approach. Instead of physically reconfiguring machines for each custom component design, the system uses a digital twin to guide the robotic assembly process, significantly reducing setup time and complexity.
3Device complexity
If traditional assembly processes are used, then device complexity remains low, but manufacturing precision and assembly quality worsen
Solution Approach 1:
The digital twin provides a precise virtual representation of the component carrier and all non-electric components, including their exact geometries and assembly positions. This digital model guides the robotic assembly system to achieve high manufacturing precision while maintaining relatively simple physical hardware.
Solution Approach 2:
The patent implements a feedback mechanism where the digital twin is updated during the assembly process based on actual component positions and assembly status. This allows the system to compensate for tolerances and achieve high assembly quality through iterative correction while keeping the physical system relatively simple.
Data Source
AI summary
A pick & place operation picking a non-electric component and placing the picked component onto a component-carrier and a connect operation connecting the placed component with the component-carrier by implementing a connection technology 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”, and executing by machine motion generation including a collision-free motion or path planning of a machine within a machine workspace primary kinematic machine-movement-sequences enabling the pick & place operation and secondary kinematic machine-movement-sequences enabling the connect operation, and enabling the execution via the machine motion generation by initializing the “machine world model” according to a configuration file configuring the machine and the machine workspace and instantiating the “machine workflow” and updating the “machine world model” with a design of the component-carrier.