Pass-Through Suction End-Effector for Precise Emblem Placement
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Solution Overview
Problem
Manual application of vehicle emblems is time-consuming and lacks precision, with varying shapes, sizes, and materials complicating the process, and existing robotic systems are not designed to efficiently and accurately apply a wide variety of emblems with consistent force and positioning.
Innovation Solution
A robotic system equipped with interchangeable pass-through suction modules, each shaped to match specific emblem variations, which includes a suction module with a front side matching the emblem and a rear side connectable to a suction line, an end-effector with alignment devices and actuators for precise positioning and force application, and a gripper for handling foam carriers and face liners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual application of emblems is used, then flexibility in handling various emblem configurations is maintained, but time consumption increases and precision decreases
Solution Approach 1:
The system segments emblem handling into modular components: interchangeable suction modules matched to specific emblem types, standardized mounting interfaces, and separable end-effectors. This allows rapid configuration changes without redesigning the entire system, enabling high-speed automated application while maintaining adaptability to various emblem configurations.
Solution Approach 2:
The robotic system dynamically adjusts suction force parameters, positioning coordinates, and application pressure to match specific emblem characteristics. By changing operational parameters rather than physical hardware for each emblem type, the system achieves both high productivity and adaptability across diverse emblem configurations.
2Adaptability or versatility
If a single robotic end-effector design is used for all emblem types, then device complexity is reduced, but adaptability to various emblem shapes, sizes, and materials decreases
Solution Approach 1:
The system employs universal mounting interfaces and standardized communication protocols that allow different suction modules to be interchangeably mounted on the same end-effector. This universal design enables a single robotic system to handle multiple emblem types through module interchangeability rather than designing separate systems for each emblem variation.
Solution Approach 2:
The end-effector structure incorporates nested modular components where suction modules can be attached and detached from the main body. The standardized interface allows quick replacement of suction modules while retaining the core end-effector structure, reducing overall system complexity while maintaining high adaptability.
3Manufacturing precision
If consistent suction force is applied to all emblems, then application quality is improved, but damage to delicate emblem materials may occur
Solution Approach 1:
The suction modules incorporate locally optimized suction force distribution tailored to specific emblem materials and geometries. Each module is designed with suction cup arrangements and force parameters matched to the particular emblem type it handles, applying precise localized force where needed while avoiding excessive force on delicate areas.
Solution Approach 2:
The system incorporates force sensing and vision feedback mechanisms that monitor suction force application in real-time. When an emblem is detected or force feedback indicates approaching damage thresholds, the system automatically adjusts suction force parameters to maintain precise positioning while preventing material damage.
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 efficient, accurate, and repeatable application of emblems with consistent force, improving precision and reducing manual labor while accommodating various emblem configurations, ensuring reliable and high-quality emblem placement on vehicle panels.
Implementation Method 1
a suction module shaped to mate with one of the component variations... a rear side with a coupling that is connectable with a suction line
Data Source
AI summary
Robotic systems are provided for flexibility in assembly operations. A robotic system includes a suction module having a front side with a face shaped to match a mating component and a rear side with a coupling for a suction line. Openings extend through the face. The suction module defines internal passages connecting the coupling with the at least one opening through the face. An end-effector has a base plate, a mounting plate selectively moveable relative to the base plate, and a clamp. The suction module is selectively mounted to the mounting plate and releasably secured by the clamp. An actuator is mounted to selectively move the mounting plate and the suction module relative to the base plate.