Fixtureless Assembly Sequencing for Robotic Precision and Flexibility
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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 to generate and optimize assembly sequences, eliminating the need for fixtures by controlling robots to join structures without fixtures, reducing development costs and optimizing assembly processes.
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 methods. This eliminates the need for expensive fixtures while maintaining assembly precision through software-controlled robot coordination.
Solution Approach 2:
The patent replaces the mechanical fixture system with a software-controlled robotic system. Instead of using physical fixtures to constrain and position parts, the system uses robot positioning algorithms, sensor feedback, and coordinated motion control to achieve the same positioning and assembly functions.
2Stability of the object's composition
If fixtures are used for robotic assembly, then assembly stability is improved, but design flexibility deteriorates
Solution Approach 1:
The patent introduces dynamic adaptability to the assembly system by replacing static fixtures with software-controlled robot positioning. The system can dynamically adjust assembly sequences, robot trajectories, and positioning parameters based on different vehicle models and design requirements, enabling rapid reconfiguration without physical retooling.
Solution Approach 2:
The patent changes the control parameters from fixed mechanical constraints to software-defined variables. By modifying assembly sequences, robot positioning parameters, and coordination algorithms, the system can adapt to different vehicle models and design specifications, maintaining stability through controlled parameter adjustments rather than physical reconfiguration.
3Manufacturing precision
If fixtures are used for robotic assembly, then assembly accuracy is improved, but update cycle time increases
Solution Approach 1:
The patent performs preliminary programming and simulation of assembly sequences before actual production. By pre-configuring robot paths, positioning parameters, and coordination logic in software, the system can rapidly adapt to new vehicle models without the time-consuming process of designing, manufacturing, and installing new fixtures.
Solution Approach 2:
The patent uses digital models and simulations to replicate and test assembly sequences before implementation. Virtual prototypes and software simulations allow the system to validate assembly accuracy and optimize parameters without physical trial-and-error, reducing update cycle time while maintaining precision.
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.