Perpendicularity Sensor for Robot Rivet Gun Alignment
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Solution Overview
Problem
The existing methods for setting up robot-carried self-piercing rivet guns rely on subjective manual judgments to ensure that workpieces are normal to the rivet gun, which can lead to improper programming and compromised joint integrity.
Innovation Solution
A perpendicularity sensor is integrated into the self-piercing rivet gun system, using a micro-plunger actuated switch to detect when a workpiece is flat against a flat end surface, providing an alert signal to verify that the workpieces are perpendicular to the rivet gun during programming, ensuring accurate orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual judgment methods are used to verify workpiece perpendicularity during setup, then the setup process is simple and quick, but the accuracy and reliability of perpendicularity verification deteriorates due to subjective judgment errors
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical sensor system. The perpendicularity sensor optically detects whether the workpiece is normal to the rivet gun, eliminating subjective human judgment and providing objective, precise measurement. This substitution of mechanical/manual systems with optical automation directly resolves the contradiction by improving measurement accuracy while accepting increased system complexity.
Solution Approach 2:
The setup system performs self-verification through the perpendicularity sensor that automatically detects and signals when the workpiece is properly oriented. The system provides its own verification capability without requiring external manual measurement tools or operator expertise, thereby improving reliability while the integrated nature of the sensor minimizes additional complexity.
2Reliability
If automated perpendicularity sensing is implemented, then the reliability of riveting process improves through objective verification, but the device complexity and cost increase
Solution Approach 1:
The patent replaces unreliable manual verification with an automated optical sensor system that objectively determines workpiece perpendicularity. This mechanical-to-optical substitution improves reliability by eliminating human error while the sensor integration, though adding complexity, provides a straightforward technical solution to the reliability problem.
Solution Approach 2:
The perpendicularity sensor provides real-time feedback to the operator during setup, indicating when the workpiece is properly oriented relative to the rivet gun. This feedback mechanism ensures reliable verification by continuously monitoring and signaling the correctness of the setup, improving process reliability while the feedback loop adds manageable system complexity.
3Manufacturing precision
If manual setup verification is used, then the setup time is short and process is simple, but the manufacturing precision of the riveted joint deteriorates due to improper alignment
Solution Approach 1:
The patent replaces manual alignment verification with an automated optical sensor system that quickly and accurately determines workpiece perpendicularity. This substitution improves manufacturing precision by providing objective alignment verification, and although it adds some setup time, the automated nature of the sensor actually reduces total adjustment time compared to iterative manual trial-and-error methods.
Solution Approach 2:
The perpendicularity sensor is integrated into the rivet gun setup system, allowing alignment verification to be performed as part of the initial setup process rather than as a separate subsequent check. This preliminary verification ensures proper alignment is established before riveting begins, improving manufacturing precision while minimizing additional time loss by combining verification with the setup workflow.
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
This solution minimizes subjectivity in programming, ensuring that workpieces are properly aligned with the rivet gun, thereby maintaining the integrity of the riveted joint by objectively verifying the perpendicularity of the workpieces during the riveting process.
Implementation Method 1
a micro-plunger actuated switch with a micro-plunger having an end that projects from an end of the body of the perpendicularity sensor having the flat end surface and that switches the switch to provide the alert signal when the micro-plunger is depressed
Data Source
AI summary
A method of verifying that a robot carried self-piercing rivet gun system is set-up so that workpieces that are to be riveted will be normal to a self-piercing rivet gun of the robot carried self-piercing rivet gun system during riveting includes utilizing a perpendicularity sensor to verify that the workpieces will be normal to the self-piercing gun during riveting.