Static OBC Housing Assembly With Dual-Side PCBA Placement
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Solution Overview
Problem
The existing processes for assembling printed circuit board assemblies (PCBAs) onto the housings of onboard chargers for electrified vehicles are complex and time-consuming, requiring multiple process stations and resulting in high production time and investment.
Innovation Solution
A system utilizing a tooling head with two manipulators, coupled to a robotic arm assembly, allows for the concurrent or sequential placement of two PCBAs onto opposite sides of an onboard charger housing while the housing remains static, reducing the need for multiple process stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-station assembly process is used to install PCBAs onto housing, then assembly reliability is maintained, but production time increases and device complexity increases
Solution Approach 1:
The patent combines multiple assembly stations into a single integrated robotic system. The robotic arm with interchangeable end effectors performs multiple assembly operations (installing first PCBA, rotating housing, installing second PCBA) that previously required separate stations, thereby reducing the number of process stations while maintaining assembly reliability
Solution Approach 2:
The robotic arm serves multiple functions by using interchangeable end effectors. The same robotic arm installs the first PCBA, rotates the housing, and then installs the second PCBA with a different end effector, making a single device perform multiple tasks that previously required multiple specialized stations
2Productivity
If housing is rotated between assembly stations to access opposite sides, then both PCBAs can be installed, but production time increases
Solution Approach 1:
Instead of rotating the housing to access opposite sides (conventional approach), the patent inverts the approach by keeping the housing static and rotating the robotic arm with different end effectors to access opposite sides. This eliminates the time-consuming housing rotation step while still allowing installation of PCBAs on both sides
3Manufacturing precision
If multiple specialized manipulators are used for different PCBAs, then assembly precision is maintained, but device complexity increases
Solution Approach 1:
The patent uses a dynamic system where the robotic arm can interchange end effectors based on the specific assembly task. Instead of having fixed specialized manipulators, the system dynamically adapts by equipping the robotic arm with appropriate end effectors (suction cup gripper for first PCBA, two-finger gripper for second PCBA), maintaining precision while reducing the number of manipulators
Data Source
AI summary
A system for assembling an onboard charger (OBC) for an electrified vehicle according to the present disclosure includes a tooling head, a first manipulator, and a second manipulator. The tooling head is coupled for movement with a robotic arm assembly. The first manipulator is coupled to a first arm extending from the tooling head and is configured to engage a first printed circuit board assembly (PCBA). The second manipulator is coupled to a second arm extending from the tooling head and is configured to engage a second PCBA. The first and second manipulators are configured to move the first and second PCBA's onto distinct sides of the OBC while the OBC remains static.