Fixtureless Robotic Assembly for Precise Joining Without Dedicated Fixtures

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Solution Overview

Problem

The automobile industry's reliance on expensive and inflexible fixtures for robotic assembly leads to high capital investment, limited design flexibility, and reduced consumer choice due to the need for unique fixtures for each part, which are costly and require significant time and resources to update.

Innovation Solution

A fixtureless assembly method using robotic apparatuses that engage and retain structures without fixtures, employing robots to directly manipulate structures with end effectors and utilizing additively manufactured features for stability and adhesives to facilitate precise joining operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If fixtures are used for robotic assembly of each part, then assembly precision and stability are improved, but manufacturing cost and device complexity increase significantly

Engineering Contradiction:

Improveassembly precisionVSAvoidfixture complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single robotic assembly system that can handle multiple different parts without requiring dedicated fixtures for each part. The robotic system with adaptive end effectors and sensor-based positioning can universally accommodate various structural components, eliminating the need for thousands of specialized fixtures while maintaining assembly precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces the traditional mechanical fixture system with a robotic system that uses sensors, vision systems, and intelligent control algorithms for positioning and assembly. This substitution eliminates complex mechanical fixtures while achieving comparable or superior positioning accuracy through software-based control and real-time feedback.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If dedicated fixtures are designed for each part, then assembly stability is improved, but capital investment and production time increase

Engineering Contradiction:

Improveassembly stabilityVSAvoidfixture design and update time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The patent applies dynamics by creating an adaptive robotic assembly system that can dynamically adjust to different parts and assembly requirements. The system uses real-time sensing and control algorithms to maintain assembly stability without relying on fixed, dedicated fixtures. The robotic system can adapt its positioning and manipulation strategies based on the specific part being assembled, providing stability equivalent to dedicated fixtures without the lead time for design and manufacturing.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If fixtures are used for each part, then assembly accuracy is improved, but flexibility for design changes is reduced

Engineering Contradiction:

Improveassembly accuracyVSAvoiddesign flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies parameter changes by using a robotic system that can dynamically adjust assembly parameters such as positioning coordinates, gripper forces, and motion speeds based on the specific part being assembled. The system uses sensors and vision systems to detect part variations and automatically adjusts assembly parameters to maintain accuracy, providing flexibility for design changes without requiring physical fixture modifications.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If thousands of fixtures are purchased for robotic assembly, then complete assembly capability is achieved, but capital investment becomes prohibitively high

Engineering Contradiction:

Improveassembly capabilityVSAvoidfixture cost

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses digital modeling and simulation to create virtual representations of parts and assembly processes. The robotic system uses these digital models to plan and execute assembly operations, replacing the need for physical fixtures with software-based positioning and control. This digital copying approach enables complete assembly capability without the prohibitive cost of physical fixtures for each part.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS20250269612A1Fixtureless robotic assembly

Publication Date: 2025.08.28 DIVERGENT TECHNOLOGIES INC

AI summary

A computing system may direct a first robotic arm to a first position based on a first set of coordinates. The computing system may cause the first robotic arm to engage with a first structure based on the first position of the first robotic arm. Further, the computing system may direct the first robotic arm to a second position based on a second set of coordinates such that the first structure is brought within a joining proximity of a second structure without a fixture retaining the first structure and without a fixture retaining the second structure, wherein the first structure is configured to be joined with the second structure when the first and second structures are within the joining proximity, the joining proximity being a proximity at which the first and second structures can be joined together.