Modular Robot Assembly With Optical Fixtures for Product Flexibility
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Solution Overview
Problem
Current automated assembly systems are inflexible and costly to set up and reconfigure for different products, especially in low-volume or high-mix manufacturing, requiring specialized machines and fixtures that are difficult to repurpose.
Innovation Solution
A modular assembly system using a hybrid, reactive, and deliberative automated machine architecture that splits the assembly process into logistic distribution and assembly operations, with optically localized fixtures and cameras for precise part handling, and automated motion generation to enable flexible and collision-free robot motion planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional special-purpose assembly machines with fixtures are used, then manufacturing precision is improved, but device complexity and adaptability worsen
Solution Approach 1:
The patent implements a universal robot system that can assemble multiple different products by loading different process plans and 3D models, replacing multiple specialized machines with a single multi-functional system. The robot can adapt to different products through software configuration rather than hardware reconfiguration, achieving both precision and versatility.
Solution Approach 2:
The patent replaces traditional mechanical fixtures and specialized mechanical assembly devices with a robot system guided by 3D models and process plans. The positioning and assembly functions previously achieved through mechanical means are now achieved through digital modeling and automated control, enabling both precision and adaptability.
2Manufacturing precision
If traditional assembly line machines are used, then manufacturing precision is improved, but ease of manufacture and adaptability worsen
Solution Approach 1:
The patent uses 3D models as digital copies of the actual products and components. These digital models contain all the geometric and positional information needed for assembly, eliminating the need to manufacture physical fixtures and templates for each product variant. The 3D models serve as reusable digital blueprints that can be loaded into the system without physical reconfiguration.
Solution Approach 2:
The patent performs preliminary digital planning by creating process plans and 3D models before actual assembly begins. All positioning, motion paths, and assembly sequences are pre-calculated in the digital domain, allowing rapid setup by simply loading the pre-prepared digital instructions rather than physically reconfiguring machinery.
3Manufacturing precision
If specialized fixtures and devices are used, then manufacturing precision is improved, but device complexity worsens
Solution Approach 1:
The patent extracts the positioning and assembly intelligence from physical fixtures and devices and transfers it into 3D models and process plans. The robot system with digital modeling replaces the need for complex specialized fixtures, achieving precision through information-based control rather than mechanical 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
Reduces setup costs and allows for easy adaptation to new products by reusing system hardware and updating product databases and fixtures, enabling efficient and accurate assembly of various products with reduced capital investment and waste.
Implementation Method 1
a camera is used to detect a position of the product part on the distribution fixture
Data Source
AI summary
It is proposed to assemble a product on a modular basis from product parts to be assembled, wherein the product assembling being split into two separate operations, by (i) automated machine fetching as well as automated machine placing the product parts part-by-part from a delivery area on optically localized distribution fixtures at a hand-over area in the course of a logistic distribution operation and a distribution fixture placed product part from optically localized distribution fixtures at the hand-over area on optically localized assembly fixtures at an assembly workspace in the course of an assembly operation, (ii) computing and executing by automated machine motion generation primary kinematic machine-motion-sequences and secondary kinematic machine-motion-sequences, (iii) providing an automated machine architecture to enable or ensure, based on a “world model for automated machines”, a three-dimensional model of an assembly environment, information ANG, of the product and the product parts and an “automated machine workflow.”