Vehicle Component Assembly Control Using Force Feedback Positioning
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Solution Overview
Problem
The assembly of large vehicle components, such as aircraft fuselage sections, often requires human intervention due to limitations in automated positioning systems, particularly in managing reaction forces and complex geometrical orientations.
Innovation Solution
A cyber-physical production system that integrates positioner units, force sensors, and a computer-based control system to automate the assembly process by determining assembly positions and reaction forces, using multi-agent systems and neural networks for self-optimization and autonomous control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated positioning systems are used to assemble large vehicle components, then productivity is improved, but manufacturing precision deteriorates due to inability to manage reaction forces and complex geometrical orientations
Solution Approach 1:
The patent implements a feedback mechanism where force sensors continuously monitor reaction forces at mounting points during the positioning process. The control system receives this force data and automatically adjusts the positioning trajectory to maintain reaction forces within acceptable limits, thereby preserving manufacturing precision while maintaining automated productivity
Solution Approach 2:
The system performs self-correction by automatically adjusting positioning trajectories based on real-time force measurements without human intervention. The control system autonomously manages reaction forces and compensates for deviations, enabling the automated system to maintain precision independently
2Manufacturing precision
If human operators intervene to manage reaction forces and positioning, then manufacturing precision is maintained, but productivity deteriorates due to manual intervention requirements
Solution Approach 1:
The system autonomously monitors reaction forces through force sensors and automatically adjusts positioning trajectories without human intervention. This self-service capability maintains manufacturing precision while eliminating manual intervention, thereby resolving the contradiction between precision and productivity
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses force sensor data to computationally determine optimal positioning trajectories. This substitution of mechanical human operation with automated sensing and control maintains precision while increasing assembly speed
3Device complexity
If system boundaries are defined for automated positioning, then device complexity is reduced, but adaptability deteriorates when components leave predefined boundaries
Solution Approach 1:
The patent implements dynamic positioning boundaries that can adapt during the assembly process. The control system continuously adjusts acceptable reaction force limits and positioning trajectories based on real-time force measurements and component characteristics, allowing the system to handle varying component geometries and mounting conditions while maintaining controlled complexity
Solution Approach 2:
The system dynamically changes positioning parameters such as reaction force limits, trajectory points, and gripping forces based on real-time feedback from force sensors and position measurement systems. This parameter adaptation enables the system to handle diverse components without requiring complex predefined boundaries for each scenario
Data Source
Figure 1a~2
Figure 3
Figure 4a~4b
AI summary
The present invention pertains to a production system (50) for the automated assembly of vehicle components (1). The production system (50) comprises positioner units (2) being configured to grip the respectively associated vehicle component (1) at mounting points (7) and move the respectively associated vehicle component (1) into an assembly position (3), a position-measurement system (4) being configured to determine the assembly position (3) of each vehicle component (1), force sensors (5) being configured to determine reaction forces and/or moments of each gripped vehicle component (1) at the mounting points (7) in the assembly position (3), and a computer-based control system (20) being in data communication with the positioner units (2), the position-measurement system (4), and the force sensors (5), and being configured to control the positioner units (2) based on the determined assembly positions (3) and the determined reaction forces and/or moments of the vehicle components (1).