Fixtureless Assembly Sequencing for Flexible Robotic Cells
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Solution Overview
Problem
Conventional automobile manufacturing relies heavily on expensive and inflexible fixtures for robotic assembly, leading to high capital investment and limited design flexibility, necessitating long model update cycles and reduced consumer choice.
Innovation Solution
A method and system for fixtureless assembly using robotic systems that generate and optimize assembly sequences based on part and robotic cell configurations, eliminating the need for fixtures by controlling robots to join structures without them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixtures are used for robotic assembly, then assembly precision and stability are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent removes fixtures entirely from the robotic assembly system, extracting the constraint mechanism and replacing it with robot-controlled positioning and assembly operations. This eliminates the need for expensive fixtures while maintaining assembly precision through software-controlled robot movements and real-time monitoring.
Solution Approach 2:
The patent replaces the mechanical fixture system with a software-controlled robotic system. Instead of using physical fixtures to hold and position parts, the system uses robot arms with sensors and control algorithms to achieve precise positioning and assembly, substituting mechanical constraints with intelligent control.
2Stability of the object's composition
If fixtures are used for robotic assembly, then assembly stability is improved, but system flexibility and adaptability deteriorate
Solution Approach 1:
The patent introduces dynamic adaptability by replacing static fixtures with programmable robot systems. The robot assembly system can dynamically adjust its operations through software control, allowing it to adapt to different part designs, assembly sequences, and configurations without physical reconfiguration, thereby maintaining stability through controlled processes while gaining flexibility.
Solution Approach 2:
The patent enables flexibility by allowing changes in assembly parameters through software rather than physical fixture modifications. The robotic system can change assembly sequences, positioning parameters, and operation modes programmatically, enabling rapid adaptation to different vehicle models and design requirements while maintaining assembly stability through controlled parameter management.
3Manufacturing precision
If multiple specialized fixtures are used for different parts, then assembly precision is maintained, but device complexity and capital investment increase
Solution Approach 1:
The patent implements a universal robotic assembly system that can handle multiple different parts and assembly operations with a single integrated system. The robot arms, sensors, and control software work together to perform various assembly tasks that would traditionally require multiple specialized fixtures, reducing device complexity while maintaining precision through programmable control.
Solution Approach 2:
The patent uses digital models and virtual assembly simulations to plan and optimize assembly sequences before physical execution. The system creates virtual representations of parts and assembly processes, allowing precision to be achieved through digital planning and simulation rather than relying on multiple physical fixtures for each part type.
Data Source
AI summary
Having a flexible robotic system layout that allows for the assembly of any structure creates a challenge in finding an optimal sequence of assembly. In some examples, the optimal sequence of assembly may provide the highest robot utilization, the shortest cycle time, the greatest assembly accuracy of the final assembly, or any combination thereof. The processing system disclosed herein may be configured to generate assembly sequences for a plurality of parts and determine an optimal assembly sequence from the generated assembly sequences by comparing the generated assembly sequences.