Joining Station Control Using Feedback for Precise Element Placement
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Solution Overview
Problem
The challenge in manufacturing processes, such as those for motor vehicles, is the precise and efficient placement of joining elements like bolts on workpieces, which is often hindered by variations in positioning and orientation due to the use of multiple joining stations.
Innovation Solution
A control unit for a joining system that determines actual data from sensors and customizes control instructions to ensure precise placement of joining elements on workpieces by adjusting the position and orientation based on setpoint data, allowing for the efficient production of physically identical workpieces with identical joining elements across multiple stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple joining stations are used to increase production capacity, then productivity increases, but positioning precision and orientation accuracy of joining elements deteriorate due to variations between different stations
Solution Approach 1:
The patent merges the control functions of multiple joining stations into a single centralized control unit that manages all stations. This unification allows consistent control parameters and coordination across stations, eliminating positioning variations that would otherwise occur with independent station control, thereby maintaining precision while enabling high-volume production through multiple stations working in coordination
Solution Approach 2:
The control unit implements feedback mechanisms that monitor the actual position and orientation of joining elements applied at each station. This feedback is used to dynamically adjust control parameters for subsequent operations, compensating for variations between stations and ensuring consistent precision across all joining stations regardless of their individual differences
2Productivity
If multiple joining stations are used to increase production capacity, then throughput increases, but system complexity increases
Solution Approach 1:
The control unit is designed as a universal system that can manage multiple different types of joining stations through standardized interfaces and coordinated control. This multi-functional control architecture allows a single control unit to handle diverse joining operations across multiple stations, reducing the need for separate control systems for each station and thereby managing complexity while maintaining high throughput
3Manufacturing precision
If precise placement of joining elements is achieved through manual adjustment, then positioning accuracy improves, but production time increases
Solution Approach 1:
The control unit performs preliminary calculations and pre-positioning of joining elements based on workpiece geometry and desired final positions. By pre-computing optimal placement parameters and preparing control instructions before actual joining operations, the system achieves high placement accuracy without requiring time-consuming manual adjustments during production
Solution Approach 2:
The patent replaces manual mechanical adjustment mechanisms with an automated control system that uses computational algorithms to determine precise joining element positions. This substitution of mechanical adjustment with automated computational control eliminates the time loss associated with manual intervention while maintaining or improving placement accuracy through algorithmic optimization
Data Source
AI summary
A control unit and method for a joining system having at least one joining station, which is designed to join at least one first joining element to a workpiece, determines actual data with respect to a first joining element joined to a current workpiece by the joining station. The control unit and method determine, in accordance with the actual data, a subsequent control instruction for the joining station for joining a first joining element to a subsequent workpiece.