Electronic Alignment for Precision Assembly
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Solution Overview
Problem
The assembly of parts with tight tolerance fitting is challenging and expensive due to the need for precision assembly tools and trained human capabilities, and existing industrial robots often fail to accurately position parts due to uncertainties in manufacturing consistency and vision system precision.
Innovation Solution
Incorporating electronic elements, such as capacitive or conductive coupling, onto parts during additive manufacturing to facilitate precise alignment and assembly by providing measurable outputs for positioning, allowing for less expensive and scalable assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision assembly tools and trained human capabilities are used, then assembly quality is improved, but cost and complexity increase
Solution Approach 1:
The part itself provides alignment guidance through integrated electronic elements (fiducial markers, conductive features) that enable automated detection and positioning, eliminating the need for complex external precision tools and trained operators
Solution Approach 2:
Electronic sensing and detection systems replace mechanical precision measurement tools, using electrical coupling and signal processing to achieve accurate alignment without complex mechanical gauges or specialized equipment
2Manufacturing precision
If force-torque sensors are added to robot arms, then assembly precision is improved, but cost increases
Solution Approach 1:
Electronic elements on the parts serve as intermediaries that mediate the positioning process, providing detectable signals that guide alignment without requiring expensive force-torque sensors on the robot arm
Solution Approach 2:
The physical alignment information is copied into electronic form through fiducial markers and conductive patterns, allowing the robot to detect position through electrical signals rather than mechanical force sensing
3Extent of automation
If vision systems are used to locate parts, then automation is improved, but positioning accuracy deteriorates due to vision system errors
Solution Approach 1:
Optical vision systems are replaced with electrical detection methods that use conductive coupling and electronic signaling to determine part positions, providing higher precision than optical methods
Solution Approach 2:
The detection parameter is changed from optical (light reflection, color) to electrical (conductivity, capacitance), which provides more precise and reliable positioning information for automated assembly
4Device complexity
If simple positional control robots are used, then cost is reduced, but assembly capability deteriorates due to inability to handle tolerance variations
Solution Approach 1:
Electronic elements provide real-time feedback signals during the assembly process, allowing simple robots to detect and compensate for position variations and tolerance deviations through electrical coupling measurements
Solution Approach 2:
Alignment information is pre-encoded into the part geometry through electronic elements during manufacturing, allowing the robot to read and follow predetermined alignment paths without complex decision-making capabilities
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 approach reduces assembly errors and costs by enabling high-quality assembly operations with less expensive capabilities, both human and machine, while ensuring accurate alignment and assembly of parts through integrated electronic guidance.
Implementation Method 1
The electrical coupling may comprise one of: conductive coupling, capacitive coupling and inductive coupling
Implementation Method 2
The electrical coupling may comprise one of: conductive coupling, capacitive coupling and inductive coupling
Implementation Method 3
The electrical coupling may comprise one of: conductive coupling, capacitive coupling and inductive coupling
Data Source
AI summary
A first object for assembly with a second object, the first object comprising: a body having a first mating portion; and a first electronic element fabricated on the body; wherein the first electronic element is provided to establish an electrical coupling with a second electronic element fabricated on one of: the body and the second object, wherein a second mating portion is provided on the second object, and wherein the electrical coupling is configured to provide a measurable output for positioning the first mating portion at a desired position relative to the second mating portion according to an analysis of the measurable output against a predetermined reference output.