Jigless Robot Arm for Vehicle Body Component Assembly
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Solution Overview
Problem
Conventional vehicle body component assembly processes require significant space, high initial investment, and complex processes due to the need for storage systems, sliding jigs, array/clamp jigs, and welding robots, leading to inefficient loading and assembly of components.
Innovation Solution
An all-in-one jigless projection loading system that integrates a fixing bracket, position adjusting member, grippers, array unit, and welding unit on a robot arm, utilizing a video camera and controller to precisely load, array, and projection-weld body components directly to the vehicle body, eliminating the need for separate jigs and robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate storage systems, sliding jigs, array/clamp jigs, and welding robots are used for assembling body components, then the assembly process can be performed, but the space requirement increases, initial investment cost increases, and process complexity increases
Solution Approach 1:
The patent combines multiple separate devices (storage system, sliding jig, array/clamp jig, and welding robot) into a single integrated robot system. The robot arm executes multiple functions including component extraction, sliding, arraying, clamping, and welding through programmable movements and integrated end effectors, eliminating the need for separate dedicated equipment for each operation.
Solution Approach 2:
The robot system is designed as a universal platform capable of performing multiple different functions. The same robot arm and end effector can extract components from storage, slide them to positions, array them in correct sequences, clamp them during assembly, and perform welding operations, replacing multiple specialized single-function devices.
2Ease of manufacture
If storage systems, sliding jigs, array/clamp jigs, and welding robots are installed for component assembly, then assembly operations can be performed, but the initial investment cost increases
Solution Approach 1:
Multiple expensive specialized devices are merged into a single robot system, reducing the total quantity of equipment required. Instead of investing in separate storage systems, sliding jigs, array/clamp jigs, and welding robots, the patent uses one integrated robot platform that performs all functions, thereby reducing initial capital expenditure.
Solution Approach 2:
The universal robot system replaces multiple specialized devices, reducing the overall equipment investment. The same robot hardware can be reprogrammed to perform different functions as needed, eliminating the need to purchase and maintain multiple separate specialized machines.
3Ease of manufacture
If multiple separate devices are used for extracting, arraying, clamping, and welding body components, then the assembly can be performed, but the space required increases
Solution Approach 1:
The patent merges multiple space-consuming separate devices into a single compact robot system. The robot arm with integrated end effectors performs extraction, arraying, clamping, and welding in sequence at or near the vehicle body, eliminating the need for distributed storage systems and jigs that would occupy significant factory floor space.
Solution Approach 2:
The robot system segments the assembly process into discrete programmable operations (extraction, sliding, arraying, clamping, welding) that can be performed sequentially by a single mobile platform, rather than requiring all operations to occur simultaneously across a large fixed workspace with multiple dedicated stations.
4Ease of manufacture
If conventional jig-based loading methods are used, then body components can be assembled, but the loading precision deteriorates
Solution Approach 1:
The patent replaces the mechanical jig-based positioning system with a robot-controlled system that uses sensors, vision systems, and programmable motion control. The robot can precisely position and place components based on digital data and real-time feedback, achieving higher precision than fixed mechanical jigs while allowing for flexibility and adaptability.
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
This system simplifies the assembly process, reduces space and investment costs, and improves loading precision by enabling all-in-one extracting, arraying, clamping, and welding of body components, enhancing efficiency and reducing manual labor.
Implementation Method 1
a welding unit installed at the fixing bracket, and projection-welding the body component to a vehicle body
Data Source
AI summary
An all-in-one jigless projection loading system for a vehicle is adapted to load and assemble a body component to a vehicle body. The all-in-one jigless projection loading system may include: a fixing bracket fixed to an arm of a robot; a position adjusting member rotatably mounted to the fixing bracket; a gripper mounted to the fixing bracket to be movable backward and forward, and gripping the body component; an array unit mounted to the position adjusting member, and arraying the body component; and a welding unit mounted to the fixing bracket, and projection-welding the body component to a vehicle body.