Flexible Punch-Weld Cell With 3D Vision for Fixture-Free Positioning
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Solution Overview
Problem
Current flexible manufacturing systems for vehicle parts require dedicated fixtures and machines, leading to high costs, increased cycle times, and inefficient use of space due to reliance on CNC cut nests for part positioning and tooling, which limits flexibility and repeatability.
Innovation Solution
A flexible production cell system incorporating intelligent locating and positioning with non-dedicated fixtures, 3D vision systems, and programmable robots, which allows for multiple product support with minimal tooling changeovers and reduced nesting requirements, utilizing AI and part position sensing technologies to achieve high-speed production and efficient part processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated fixtures and machines are used for each part, then manufacturing precision and repeatability are improved, but device complexity and capital costs increase
Solution Approach 1:
The patent implements a universal robot system that can perform multiple operations (punching, welding, drilling, sealing) on multiple product types using a single programmable robot arm. The robot replaces multiple dedicated machines and fixtures with one multi-functional system that achieves the same manufacturing precision through software control and adaptive positioning algorithms.
Solution Approach 2:
The system uses programmable parameters and software-controlled positioning to adapt to different part geometries and processing requirements. Instead of physical reconfiguration of dedicated fixtures, the robot system changes operational parameters (paths, speeds, forces, positions) through programming to accommodate different products while maintaining manufacturing precision.
2Manufacturing precision
If CNC cut nests are used for part positioning, then part position repeatability is improved, but manufacturing time and cycle time increase
Solution Approach 1:
The patent replaces the mechanical CNC cut nest positioning system with a robot-based vision-guided positioning system. Instead of using pre-cut physical nests to locate parts, the system uses sensors and vision systems to detect part positions and dynamically adjusts robot paths, eliminating the time required for CNC nest processing while maintaining positioning accuracy.
Solution Approach 2:
The system performs preliminary sensing and positioning detection before the actual manufacturing operation. By using sensors to pre-identify part locations and characteristics, the robot can immediately begin processing without requiring time-consuming CNC nest operations, thus reducing cycle time while maintaining precision.
3Adaptability or versatility
If multiple stations are used to accommodate different products, then adaptability is improved, but device complexity and floor space increase
Solution Approach 1:
The patent merges multiple dedicated stations into a single integrated robot system that can handle multiple product types. Instead of having separate punching stations, welding stations, and drilling stations for different products, one programmable robot performs all operations in sequence, reducing device complexity and floor space while maintaining adaptability through software reconfiguration.
Solution Approach 2:
The system uses dynamic reprogramming and adaptive control to switch between different products and operations. Instead of static dedicated stations, the robot system dynamically adjusts its program, paths, and parameters based on the current product being processed, enabling one machine to perform the work of multiple dedicated stations.
4Adaptability or versatility
If tooling changeover is implemented for different products, then adaptability is improved, but loss of time and productivity decrease
Solution Approach 1:
The patent replaces physical tooling changeover with software-based operation switching. Instead of mechanically changing punches, weld tips, or drill bits for different products, the robot system uses programmable toolpaths and force control parameters to adapt to different operations, eliminating tooling changeover time while maintaining adaptability.
Solution Approach 2:
The robot system is designed with universal end-effectors that can perform multiple operations (punching, welding, drilling) without requiring dedicated tooling for each operation or product. This multi-functional capability eliminates the need for tooling changeover while maintaining the ability to switch between different products through software programming.
Data Source
AI summary
A flexible assembling system incorporating at least one manufacturing cell including at least one universal fixture, at least one position monitoring device (e,g., monitoring system, 3D vision system, 3D vision system/scanner, artificial intelligence position determination and monitoring, artificial intelligence vision system to locate part or a feature(s) of the part, and combinations thereof), and at least one programmable robot or machine (e.g., punch, weld, etc.). The at least one universal fixture is a non-dedicated fixture such that the fixture is usable with various products and not dedicated to only one specific part being manufactured.