Mobile Robot Arm with Sensor Ring for Ergonomic Assembly
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Solution Overview
Problem
Existing manufacturing systems face challenges in efficiently and ergonomically connecting heavy components, requiring significant operator effort and lacking efficient energy transmission methods.
Innovation Solution
A production system equipped with a movable robot arm and a sensor ring for low-force guidance, combined with an inductive energy supply and image recognition for autonomous and human-controlled operation modes, allowing for ergonomic assembly and contactless energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a robot arm is mounted on a fixed base to manipulate heavy components, then the robot arm can provide stable support, but the system lacks mobility and requires significant operator effort for repositioning
Solution Approach 1:
The robot arm system is mounted on a mobile platform (vehicle) that can move freely within the workspace. This dynamic configuration allows the heavy robot arm to be repositioned easily by moving the vehicle, eliminating the need for fixed installation and reducing operator effort for system reconfiguration while maintaining operational stability during assembly tasks
2Ease of operation
If traditional mechanical coupling is used to connect sensor ring to robot arm for guidance, then the connection is structurally simple, but it requires significant force and compromises ergonomic operation
Solution Approach 1:
The mechanical coupling between the sensor ring and robot arm is replaced with a magnetic coupling system. The sensor ring contains a magnet that magnetically couples with a ferromagnetic material in the robot arm, creating a force-free mechanical connection. This allows the operator to guide the robot arm by simply moving the sensor ring without exerting significant force, dramatically improving ergonomic operation while maintaining precise guidance control
3Adaptability or versatility
If contact-based energy supply is used to power the mobile vehicle, then energy transmission is efficient, but it requires physical contact and reduces system versatility
Solution Approach 1:
The contact-based electrical connection for powering the mobile vehicle is replaced with an inductive power transmission system. A transmitter unit on the ground wirelessly transmits electrical energy through electromagnetic induction to a receiver unit on the vehicle, enabling contactless energy supply. This maintains high energy transmission efficiency while significantly improving system versatility, allowing the vehicle to move freely without physical contact constraints
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 ergonomic assembly of heavy components with reduced operator effort and efficient energy supply, facilitating the connection of components with high precision and minimal physical strain.
Implementation Method 1
a sensor ring is connected to the robot arm for low-force guidance of a first component picked up by the robot arm
Implementation Method 2
the vehicle has a secondary winding which can be inductively coupled to a primary conductor arranged on the ground for the transmission of electrical energy
Implementation Method 3
a capacitor is connected in series or parallel to the secondary winding such that the resonant frequency of the resulting resonant circuit corresponds to the frequency of the alternating current impressed into the primary conductor
Data Source
Figure 1
AI summary
Manufacturing plant and method for operating a manufacturing plant for producing a product, in particular a geared motor, from a first component, in particular an electric motor, and from a second component, in particular a gearbox, wherein the manufacturing plant has a robot arm 2 which is arranged on a vehicle 1 which is movable, in particular on a floor of the manufacturing plant, wherein a sensor ring is connected to the robot arm for low-force guidance of a first component picked up by the robot arm.