Fixtureless Robotic Assembly for Precision Multi-Part Positioning
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Solution Overview
Problem
Current manufacturing systems require multiple part locating fixtures for different sizes and shapes of components, leading to inefficiencies and a need for a more flexible and adaptable assembly method.
Innovation Solution
A fixtureless component assembly system using robot arms with end-of-arm tools and sensors to position and assemble subcomponents based on visual location and force measurements, allowing for flexible assembly without dedicated fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If part locating fixtures with fixed pins and clamps are used, then assembly precision is maintained, but device complexity and adaptability deteriorate due to requiring multiple fixtures for different part sizes and shapes
Solution Approach 1:
The patent applies universality by using a single robotic assembly system with force sensors and vision systems that can adapt to multiple part types and sizes, replacing the need for multiple dedicated fixtures. The force control mechanism provides universal positioning capability across different component configurations.
Solution Approach 2:
The patent applies dynamics by transitioning from static fixed pins and clamps to dynamic robotic arms with force feedback control. The system continuously adjusts positioning forces based on real-time sensor data, enabling adaptive precision assembly for varying part geometries without physical reconfiguration.
2Manufacturing precision
If multiple part locating fixtures are used for different parts, then assembly precision is maintained, but device complexity and setup time increase
Solution Approach 1:
The patent extracts the locating function from physical fixtures and implements it through a robotic system with force sensors. Instead of using multiple mechanical locating devices, the system extracts positioning capability into a programmable robotic platform that can be reconfigured through software for different assembly tasks.
Solution Approach 2:
A single robotic assembly system performs the function of multiple dedicated fixtures, providing universal positioning and assembly capabilities across different part types through force control and vision guidance, thereby reducing overall device complexity.
3Manufacturing precision
If fixed pin fixtures are used, then positioning accuracy is achieved, but flexibility and reconfiguration capability deteriorate
Solution Approach 1:
The patent replaces static pin fixtures with dynamic robotic positioning systems that use force feedback control. The robotic arms can be reprogrammed for different assembly configurations, providing both positioning accuracy and manufacturing flexibility without physical reconfiguration.
Solution Approach 2:
The patent substitutes mechanical pin-based locating systems with a robotic system using force sensors and control algorithms. This replacement maintains positioning accuracy through force feedback while dramatically improving reconfiguration capability through software programming.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise assembly of components without dedicated fixtures, accommodating various sizes and shapes, and allows for thermal distortion compensation and verification of geometry, enhancing manufacturing flexibility and efficiency.
Implementation Method 1
Using a camera to visually locate the interface surfaces on the first and second subcomponents
Implementation Method 2
Scanning the first and second subcomponents locating assembly datums with a non-contact measuring device
Data Source
AI summary
A method of assembling a plurality of subcomponents to form a finished component comprises gripping a first subcomponent with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm and grasping a second subcomponent with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm. Moving the first and second end-of-arm tools to position the first subcomponent relative to the second subcomponent in a pre-assembly position and then moving the first and second end-of-arm tools to engage interface surfaces of the first and second subcomponents. Forming a joint between the first subcomponent and the second subcomponent with a joining tool attached to a joining robot arm to thereby assemble the finished component.