Extended-reach Assist Device for Ergonomic Assembly

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Solution Overview

Problem

Ergonomic challenges arise for human operators performing assembly tasks that require bending and reaching, leading to increased stress and potential design adjustments for component placement, which may not be optimal.

Innovation Solution

An extended-reach assist device with an articulated base mechanism and a compliant end-effector that provides force augmentation and sensory feedback, allowing operators to perform tasks beyond their normal reach with reduced ergonomic strain, featuring passive and active degrees of freedom for gross and fine movements, and optional bracing for enhanced positioning accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the operator performs assembly tasks by bending over and reaching into work areas, then the operator can access components in hard-to-reach locations, but the operator experiences increased ergonomic stress and physical strain

Engineering Contradiction:

Improveergonomic performanceVSAvoidoperator strain

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an articulated base mechanism as an intermediary device between the operator and the assembly task. This mechanism includes multiple degrees of freedom that enable the operator to perform gross positioning movements without direct manual manipulation, thereby reducing ergonomic stress while maintaining access to hard-to-reach locations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system divides the assembly task into two distinct segments: gross motion handled by the articulated base mechanism and fine manipulation handled by the compliant end-effector. This segmentation allows each component to optimize for its specific function, reducing overall operator strain

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the operator manually manipulates components for assembly tasks, then precise positioning and manipulation can be achieved, but the operator must maintain awkward postures and apply forces at extended distances

Engineering Contradiction:

Improvecomponent positioning accuracyVSAvoidoperator accessibility

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces direct manual mechanical manipulation with a hybrid system combining articulated mechanics for gross motion and compliant mechanics for fine positioning. This substitution reduces the physical burden on the operator while maintaining precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If manufacturers adjust component placement to improve operator ergonomics, then operator strain is reduced, but component locations become suboptimal for assembly efficiency

Engineering Contradiction:

Improveergonomic stressorsVSAvoidassembly efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The articulated base mechanism provides dynamic positioning capability, allowing the end-effector to reach multiple locations without requiring fixed component placement optimized for ergonomics. This dynamic adaptability resolves the conflict between ergonomic component placement and assembly efficiency

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The articulated base mechanism serves multiple functions: it provides extended reach, supports the end-effector weight, enables gross positioning, and adapts to various component locations. This multi-functionality allows optimal component placement for assembly efficiency without compromising operator ergonomics

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10350766B2Extended-reach assist device for performing assembly tasks

Publication Date: 2019.07.16 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

An extended-reach assist device for an assembly task includes a base mechanism and a compliant end-effector. The articulated base mechanism provides one or more passive degrees of freedom. The end-effector is connected to the base mechanism, and has one or more active or passive degrees of freedom collectively configured to react to contact forces with the assist device when completing the dexterous assembly task. A weight of the end-effector is supported by the base mechanism. The end-effector may be optionally configured as a passive device configured to produce a remote center of compliance or as a robot mechanism. A mechanism may actively or passively augment a force applied by the operator. A sensor may detect a signature indicative of successful task completion, e.g., an acoustic, visual, or audio sensor.