Dual-Robot Hinge Installation With Universal Vision Alignment
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Solution Overview
Problem
Existing door hinge installation systems for vehicles face challenges due to varying hinge mounting locations and orientations on different vehicle models and pillars, requiring multiple vision systems which increase costs and complexity.
Innovation Solution
A collaborative dual robot hinge mounting system is introduced, featuring a first robot with cameras to detect hinge mounting hole locations and orientations, and a second robot to position the hinges relative to the Body-in-White (BIW), with bolt runners to drive bolts through the hinges and into the BIW.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple vision systems are used to detect hinge mounting locations for different vehicle models and pillars, then positioning accuracy is maintained, but system complexity and cost increase
Solution Approach 1:
A single vision system is designed to perform multiple functions by detecting hinge mounting locations and orientations across different vehicle models and pillar types (A-pillar, B-pillar, C-pillar). The system uses one or more cameras positioned to capture images of various mounting locations, processing circuitry that identifies coordinates and orientations for different pillars, and controls that direct robots accordingly. This universal system replaces multiple dedicated vision systems while maintaining the ability to accurately detect and accommodate variations in hinge mounting requirements across different vehicle configurations.
2Reliability
If multiple vision systems are used for different vehicle models, then detection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements a universal vision system that can reliably detect hinge mounting locations for multiple vehicle models and pillar types using a single integrated setup. The system includes cameras positioned to capture images of various mounting locations, processing circuitry that identifies coordinates and orientations for different pillars (A, B, and C pillars), and controls that direct robots to appropriate mounting locations. This eliminates the need to manufacture and maintain multiple separate vision systems for different vehicle models, thereby reducing manufacturing costs while maintaining detection reliability through the system's ability to adapt to various vehicle configurations.
3Device complexity
If a single multi-purpose vision system is used, then system cost and complexity are reduced, but positioning precision for varying hinge locations must be maintained
Solution Approach 1:
The vision system incorporates dynamic positioning capabilities with cameras that can be positioned at various locations and angles to capture images of different hinge mounting locations on A-pillars, B-pillars, and C-pillars. The processing circuitry dynamically calculates coordinates and orientations based on the captured images, and the control system adjusts robot positioning accordingly. This dynamic adaptability allows a single vision system to maintain precise positioning for varying hinge locations across different vehicle models and pillar types without requiring multiple fixed vision systems.
4Ease of manufacture
If vehicle-specific vision systems are eliminated, then cost is reduced, but the system must handle varying hinge mounting locations and orientations
Solution Approach 1:
The patent implements a universal vision system that handles varying hinge mounting locations and orientations across different vehicle models and pillar types through integrated image capture, coordinate detection, and robot control. The system uses cameras positioned to capture images of various mounting locations, processing circuitry that identifies coordinates and orientations for different pillars, and controls that direct robots to appropriate mounting locations. This universal design eliminates the need for vehicle-specific vision systems while maintaining full adaptability to different hinge configurations through its ability to detect and respond to variations in mounting requirements.
Data Source
AI summary
A collaborative dual robot hinge mounting system includes: a first robot including an end effector that moves a pair of bolts in position to be run through a pair of hinges and into a BIW, where the end effector includes a first bolt runner and a second bolt runner; and first and second cameras that detect locations or orientations of hinge mounting holes on the BIW for the pair of hinges. A control module sends to a second robot the locations or orientations of the hinge mounting holes to signal the second robot to position the pair of hinges relative to the BIW and, in response to detecting the pair of hinges being placed relative to the BIW, drives the pair of bolts via the first bolt runner and the second bolt runner through the pair of hinges and into the hinge mounting holes in the BIW.