Mobile Robot Arm Assembly with Low-Force Component Guidance
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Solution Overview
Problem
Existing production systems lack ergonomic solutions for efficiently and safely handling and connecting heavy components, requiring significant operator effort and lacking efficient energy transmission methods.
Innovation Solution
A method utilizing a mobile robot arm with a sensor ring and image recognition for low-force component guidance, allowing for autonomous and human-controlled operating modes, and inductive energy transmission, enabling ergonomic assembly and reduced effort in connecting components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mobile robot arm is used to handle heavy components, then operator effort is reduced and ergonomics are improved, but device complexity increases due to the need for vehicle mobility and control systems
Solution Approach 1:
The robot arm system performs self-positioning and self-alignment through autonomous navigation and image recognition, eliminating the need for complex manual control systems. The vehicle autonomously transports the robot arm to the work area, and the system automatically aligns components using vision guidance, reducing operator burden without proportionally increasing control complexity
Solution Approach 2:
The patent replaces manual mechanical handling with an automated robot arm system that uses image recognition and autonomous navigation. The complex mechanical task of positioning heavy components is substituted with sensor-based detection and automated control algorithms, improving ergonomics while managing complexity through intelligent automation
2Object-affected harmful factors
If inductive energy transmission is implemented for contactless power supply, then safety and cleanliness are improved, but energy transmission efficiency deteriorates due to coupling strength limitations
Solution Approach 1:
The inductive power transmission system operates using periodic alternating current at optimized frequencies to enhance magnetic coupling between transmitter and receiver coils. By using AC instead of DC and optimizing the frequency, the system achieves contactless power transmission while improving energy transfer efficiency through resonant coupling effects
Solution Approach 2:
The system optimizes energy transmission efficiency by adjusting key parameters including operating frequency, coil geometry, and magnetic core materials. The patent employs parameter optimization to maximize coupling strength between inductive elements, thereby reducing energy losses while maintaining contactless power supply benefits
3Productivity
If autonomous operation mode is used, then productivity is improved through automated component pickup and transport, but flexibility deteriorates as the operator cannot intervene in the process
Solution Approach 1:
The system implements dynamic operation modes that can switch between autonomous and manual control based on operational requirements. The robot arm and vehicle can operate autonomously for routine tasks to maximize productivity, while the operator can take control when flexibility or intervention is needed, providing adaptability without sacrificing automated efficiency
4Manufacturing precision
If position control mode is used for robot arm and vehicle drives, then precision is improved during human-guided operation, but complexity increases due to continuous position monitoring and control
Solution Approach 1:
The system employs feedback control where sensors continuously monitor the actual positions of the robot arm and vehicle, and the control system adjusts actuator commands based on the difference between target and actual positions. This feedback mechanism achieves precise positioning while managing complexity through closed-loop control algorithms that adapt to operational conditions
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 and efficient assembly of heavy components with reduced operator effort and contactless energy supply, enhancing productivity and safety in manufacturing processes.
Implementation Method 1
a sensor ring (3) connected to the robot arm (2) for low-force guidance of a first component (4) picked up by the robot arm (2)
Implementation Method 2
an image recognition unit arranged on the vehicle and connected to the control system that controls the robot arm (2)
Implementation Method 3
specifically by generating a torque that depends on the time-dependent difference between the actual and target positions
Implementation Method 4
the vehicle has a secondary winding which can be inductively coupled to a primary conductor located on the ground for the transmission of electrical energy
Implementation Method 5
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
The invention relates to a production plant and to a method for operating a production plant for manufacturing a product, in particular a gear motor, from a first component, in particular an electric motor, and from a second component, in particular a gearbox, wherein the production plant comprises a robotic arm (2) arranged on a vehicle (1) movable in particular on the floor of the production plant, a sensor ring being connected to the robotic arm for effortlessly guiding a first component carried by the robotic arm.