Automated Door Hinge Loading Device for Vehicle Assembly

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Solution Overview

Problem

The manual alignment and attachment of door hinges in vehicle manufacturing increase labor costs and lead to assembly variations, resulting in decreased productivity and quality issues, such as door deformation and external appearance degradation.

Innovation Solution

A door hinge loading device that automatically extracts and aligns front and rear door hinges from storage, using a clamping unit and moving unit to position them within the reach of an install robot, allowing for automated alignment and attachment, suitable for various vehicle models with different hinge sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If door hinges are manually aligned and attached by operators, then labor flexibility is maintained, but labor cost increases and assembly variation occurs

Engineering Contradiction:

Improveassembly precisionVSAvoidautomation level

Core Design Contradiction:

Manufacturing precisionVSExtent of automation

Solution Approach 1:

The door hinge storage device automatically extracts door hinges from storage and positions them on the attaching jig without operator intervention. The extracting mechanism self-performs the loading function, eliminating manual labor while ensuring consistent positioning and reducing assembly variation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations by operators are replaced with an automated extracting mechanism. The mechanism uses mechanical components such as extracting arms, positioning guides, and actuators to automatically remove door hinges from storage and place them on the attaching jig, substituting human labor with a controlled mechanical system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If door hinges are manually fastened by operators, then adaptability to different situations is maintained, but assembly variation increases and quality degrades

Engineering Contradiction:

Improveassembly qualityVSAvoidoperation complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system automatically performs the complete sequence of extracting, positioning, and fastening door hinges without operator intervention. The fastening mechanism self-adjusts and self-executes the bolting operation, ensuring consistent assembly quality and eliminating variations caused by manual operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Door hinges are pre-positioned and pre-aligned by the extracting mechanism before the fastening operation begins. The positioning guides and alignment features prepare the door hinges in advance, ensuring correct orientation and location prior to attachment, which improves assembly quality and reduces variation.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If door hinges are reattached in subsequent process for quality maintenance, then quality is improved, but productivity decreases

Engineering Contradiction:

Improveassembly qualityVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The extracting mechanism performs preliminary positioning and alignment of door hinges on the attaching jig before the fastening operation. This pre-positioning ensures correct placement and orientation, preventing assembly errors that would require reattachment in subsequent processes, thereby maintaining quality while improving productivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates positioning sensors and alignment detection mechanisms that provide feedback on door hinge placement accuracy. This feedback ensures correct positioning before fastening, preventing defective assemblies and eliminating the need for reattachment operations, thus maintaining both quality and productivity.

Inventive Principle:

Principle #23Feedback

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

This solution reduces labor costs, improves assembly quality by minimizing assembly variations, and enhances productivity by enabling efficient and precise alignment of door hinges before attachment to the vehicle body.

Implementation Method 1

a clamping unit that extracts the door hinges from the door hinge storage, and clamps the extracted door hinges while aligning bolts

Methodology Applied

Scientific EffectMechanical movement:

Implementation Method 2

a moving unit that is provided at a position corresponding to the clamping unit to be connected to the clamping unit, and selectively moves the clamping unit toward the door hinge storages

Methodology Applied

Scientific EffectMechanical displacement:

Data Source

PatentUS9359030B2Door hinge loading device for vehicle

Publication Date: 2016.06.07 HYUNDAI MOTOR CO LTD

AI summary

A door hinge loading device for a vehicle includes a door hinge storage that is attached to an attachment frame, where one or more door hinges are loaded on the door hinge storage, a clamping unit that extracts the door hinges from the door hinge storage, and clamps the extracted door hinges while aligning bolts, and a moving unit that is provided at a position corresponding to the clamping unit to be connected to the clamping unit, and selectively moves the clamping unit toward the door hinge storages.