Dual-Gripper Workpiece Alignment During Transport for Precise Joining
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Solution Overview
Problem
Existing methods for aligning workpieces to form joints in the automotive industry fail to meet precision requirements for Leading Edge Offset (LEO) and Tailing Edge Offset (TEO), necessitating a more precise alignment process without the need for an additional alignment station or transport system.
Innovation Solution
A method where a common multi-axis robot with two grippers performs both transverse and longitudinal alignment of workpieces during transport from the preparation station to the processing station, using mechanical stops and sensors for precise positioning, allowing for parallel alignment and correction of offsets without additional handling or transport steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate alignment station and additional transport system are introduced to improve workpiece alignment precision, then manufacturing precision improves, but device complexity and production costs increase
Solution Approach 1:
The patent combines the alignment function with the existing transport manipulator by equipping it with sensors (laser scanners, cameras) and control systems. The manipulator simultaneously performs transport and alignment tasks, eliminating the need for a separate alignment station and reducing overall system complexity while maintaining high alignment precision for tailor-made blanks
Solution Approach 2:
The transport manipulator is transformed into a multi-functional device that performs both material transport and precise alignment operations. By integrating sensing capabilities and intelligent control, the same manipulator structure serves multiple purposes: transporting workpieces from the preparation station and aligning them with precision before welding, thereby avoiding additional dedicated alignment equipment
2Manufacturing precision
If a separate alignment station is added to improve alignment precision, then manufacturing precision improves, but production time and cycle duration increase
Solution Approach 1:
The alignment operation is merged into the transport process itself. The manipulator with integrated sensors performs alignment during the transport phase, eliminating the need for a separate alignment station and its associated time consumption. This integration allows alignment to occur concurrently with material handling, reducing total production cycle time
Solution Approach 2:
The alignment is performed preliminarily during the transport phase before the workpieces reach the welding position. By completing alignment operations during transport rather than as a separate subsequent step, the system ensures precise positioning is achieved in advance, eliminating additional time-consuming alignment operations at the welding station
3Manufacturing precision
If multiple separate manipulators are used for different operations (transport and alignment), then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple manipulators into a single multi-functional manipulator system. By equipping one manipulator with integrated sensing capabilities (laser scanners, cameras) and intelligent control, the system achieves precise alignment without requiring separate dedicated manipulators for transport and alignment operations, thereby reducing mechanical complexity while maintaining high precision
Solution Approach 2:
A single manipulator is designed to perform multiple functions: transporting workpieces from the preparation station, positioning them with high precision through sensor-guided control, and preparing them for welding. This universal manipulator replaces what would traditionally require multiple specialized manipulators, simplifying the overall system architecture while achieving the required alignment precision
Data Source
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AI summary
The invention relates to a method for orienting two workpieces (102, 103) to form a joining connection, wherein in a longitudinal orientation step the first workpiece (103) is oriented relative to the second workpiece (103) along at least one of the workpiece edges by means of a linear movement of at least one of the grippers (13, 14) relative to the other gripper (13, 14), and wherein the longitudinal orientation step is carried out during transportation of the workpieces (102, 103) from the provisioning station (3) to the processing station (4). The invention also relates to a manipulator (2) that comprises a first gripper (13) and a second gripper (14).