Fixtureless Robotic Assembly Using AI Vision Alignment
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Solution Overview
Problem
The existing manufacturing processes require dedicated hardware fixtures for securing and locating sheet metal parts for welding, which are costly and need frequent updates due to minor changes or product changes, leading to high fixturing costs in industries like automobile manufacturing.
Innovation Solution
A reconfigurable, fixtureless manufacturing system assisted by learning A.I. software, which uses material handling robots and machine vision systems to grasp and align parts, eliminate the need for physical fixtures by using virtual datums, and optimize the assembly process through iterative learning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated hardware fixtures are used to secure and locate sheet metal parts for welding, then manufacturing precision and stability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces the mechanical fixture system with a robotic system equipped with sensors and control algorithms. Robots use vision systems and force sensors to detect part positions and apply corrective forces, eliminating the need for complex mechanical fixtures while maintaining positioning precision through software-controlled adjustments.
Solution Approach 2:
The system enables parts to self-align and self-position through controlled manipulation by robots. The robotic system allows parts to naturally settle into correct positions through guided movement and feedback control, replacing the need for pre-configured mechanical locators and fixtures that traditionally enforce positioning.
2Manufacturing precision
If dedicated hardware fixtures are designed and manufactured for each subassembly, then manufacturing precision is improved, but adaptability deteriorates due to frequent updates needed for product changes
Solution Approach 1:
The patent implements a dynamic system where robotic fixtures can be reconfigured through software control rather than physical redesign. The system adapts to different products by loading different control programs and parameters, allowing the same hardware to maintain precision across multiple product variants without requiring fixture updates for each change.
Solution Approach 2:
The robotic system serves multiple functions: positioning, clamping, and alignment, all controlled through software. A single robotic platform can handle different subassemblies and product configurations by changing control parameters, replacing the need for dedicated fixtures for each product type and enabling universal application across product families.
3Adaptability or versatility
If flexible fixture systems are used to accommodate product changes, then adaptability is improved, but device complexity and manufacturing cost increase due to design complexity
Solution Approach 1:
The patent replaces complex mechanical flexibility mechanisms with software-based adaptability. Instead of designing physically reconfigurable fixtures, the system uses programmable robots with sensor feedback to achieve the same flexibility, reducing mechanical complexity while maintaining or improving adaptability through digital control.
Solution Approach 2:
The system achieves flexibility by changing control parameters rather than physical configuration. The robotic fixtures maintain constant physical structure but adapt to different products by modifying control software parameters, sensor thresholds, and positioning algorithms, eliminating the need for complex mechanical adjustment mechanisms.
4Productivity
If robots and automated assembly systems with physical fixtures are used, then productivity is improved, but device complexity and initial cost increase
Solution Approach 1:
The patent extracts the positioning and alignment functions from the physical fixture system and transfers them to the robotic control system. This separation allows the robot to handle multiple tasks (material handling, positioning, joining) without requiring complex integrated fixtures, reducing overall system complexity while maintaining high productivity through automated operation.
Data Source
AI summary
Systems and methods for automated manufacture are provided. Nominal data measurements are obtained for an article. An identification scan is performed of parts within the work area by a machine vision system. An initial scan of the parts within or adjacent to the work area identified as being needed to form said article is performed by the machine vision system to identify target points. The target points are compared at a controller with the nominal data measurements. Automated material handling machines are commanded to grasp and move the parts within said work area to form the article.