Fixtureless Robotic Assembly Cells for Flexible Vehicle Structures
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Solution Overview
Problem
Conventional vehicular manufacturing systems are economically and time-inefficient due to their reliance on static assembly lines with specific fixtures for each robot, limiting production flexibility and scalability.
Innovation Solution
The implementation of dynamic manufacturing cells with robots that can translate and interact fixturelessly to assemble various vehicle structures, allowing for the use of multiple robots to assemble different types and configurations of vehicles without the need for specific fixtures, enabling more efficient use of space and resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional assembly lines use static fixtures for each robot, then assembly precision and reliability are maintained, but production flexibility and adaptability deteriorate
Solution Approach 1:
The patent implements universal robots that can perform multiple assembly tasks across different workstations without requiring dedicated fixtures for each robot-part combination. The robots are designed to handle various structural components and perform different assembly operations, replacing the conventional approach where each robot was dedicated to a specific task with specialized fixtures.
Solution Approach 2:
The system transitions from static fixtures to dynamic robot positioning. Robots can move between different workstations and adjust their positions dynamically based on the assembly requirements. This dynamic capability allows the same robot to work at multiple locations and handle different component types, eliminating the need for fixed, dedicated fixtures.
2Productivity
If assembly lines are configured for mass production of one assembly type, then production efficiency is maximized, but production time for different vehicle types increases
Solution Approach 1:
The system enables dynamic reconfiguration by allowing robots to move between workstations and adapt their operations programmatically. When a change in vehicle type is required, the robots receive updated instructions and can seamlessly transition to assembling different components, eliminating the need for physical reconfiguration of fixtures and reducing downtime.
Solution Approach 2:
The system changes operational parameters through software control rather than physical reconfiguration. By modifying program parameters, robot positions, and assembly sequences, the system can quickly adapt to different vehicle types while maintaining high assembly speeds, avoiding the time-consuming process of physically reconfiguring dedicated fixtures.
3Manufacturing precision
If multiple dedicated robots with specific fixtures are used, then assembly precision is maintained, but space utilization and resource efficiency deteriorate
Solution Approach 1:
The patent employs universal robots that can perform multiple assembly functions across different workstations, replacing numerous dedicated robots with specialized fixtures. This consolidation reduces the overall space required for the assembly line while maintaining assembly precision through programmable control and dynamic positioning capabilities.
Solution Approach 2:
The system merges the functions of multiple dedicated robots into fewer universal robots. By combining material handling, positioning, and assembly capabilities in single robotic systems that can operate at multiple workstations, the patent reduces the total number of robots and fixtures needed, thereby optimizing space utilization.
4Productivity
If sequential part addition is used in conventional assembly lines, then assembly reliability is ensured, but production time and cost increase
Solution Approach 1:
The system enables continuous assembly operations by allowing robots to move between workstations without interrupting the assembly process. Multiple robots can work simultaneously on different components of the same assembly, and robots can transition between tasks seamlessly, eliminating idle time and maintaining continuous productive action throughout the assembly line.
Solution Approach 2:
The system performs preliminary positioning and preparation of components and robots in advance. Robots are pre-positioned and components are pre-prepared based on the assembly sequence, allowing for smoother transitions and reduced waiting time during the assembly process, thereby maintaining reliability while reducing overall cycle time.
Data Source
AI summary
In an aspect of the disclosure, a first manufacturing cell for assembling a structure is provided. The first manufacturing cell for assembling the structure may include a plurality of first robots positioned around a common point in a first configuration, and a plurality of second robots positioned around the common point in a second configuration, the second configuration being closer to the common point than the first configuration. One of the plurality of first robots is configured to translate towards and away from the common point to interact with one of the plurality of second robots or one of the plurality of second robots is configured to translate towards and away from the common point to interact with one of the plurality of first robots.