Robotic Gripper with Ring Detection for Piston Stuffing
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Solution Overview
Problem
Current piston stuffing technologies, both manual and automated, are labor-intensive, prone to worker injury, and limited in precision, with existing automation being inflexible and costly, and fail to accurately align piston skirts with cylinder bores due to reliance on operator skill or machine precision, leading to increased failure rates and limited applicability across different engine types.
Innovation Solution
A gripper system for industrial robots that includes a detection unit for piston rings, a pushing/suction unit with a suction cup, and force-controlled functionality to actively search and insert piston subassemblies into cylinder bores, capable of adapting to various engine block configurations, such as inline, v-block, and w-block, using multiple robots to streamline the piston stuffing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual piston stuffing is performed with two persons, then the process can be completed with simple equipment, but it is labor intensive and prone to worker injury
Solution Approach 1:
The robot system performs piston stuffing autonomously without requiring human operators to manually handle the piston and connecting rod assembly. The robot gripper automatically grasps, positions, and inserts the piston subassembly into the cylinder bore, enabling the system to serve itself and eliminating labor-intensive manual operations.
Solution Approach 2:
The patent replaces the manual mechanical system with an automated robotic system. The robot uses a specialized gripper with suction cups and pushers to mechanically perform the piston stuffing operation, substituting human manual labor with automated mechanical manipulation controlled by sensors and programming.
2Productivity
If dedicated automation machines are used for piston insertion, then labor intensity is reduced, but the machines are huge, costly, and inflexible
Solution Approach 1:
The robot system is designed to be universally applicable across different engine types and configurations. The gripper can adapt to various piston and connecting rod assemblies, and the robot can be programmed to handle different cylinder bore positions and orientations, making a single system suitable for multiple applications rather than requiring dedicated machines for each engine type.
Solution Approach 2:
The patent employs dynamic adjustment capabilities in the gripper system, including adjustable suction cup positions, extendable pushers, and force-controlled insertion. The robot can dynamically adapt its gripping force, insertion speed, and positioning based on real-time sensor feedback, allowing flexible operation without requiring oversized rigid machinery.
3Manufacturing precision
If passive floating tool or table is used to align piston skirt with cylinder bore, then alignment is achieved, but the success depends on operator skill or machine precision
Solution Approach 1:
The robot system incorporates sensors that provide real-time feedback on the position of the piston subassembly relative to the cylinder bore. The system uses this feedback to actively adjust its positioning and insertion motion, ensuring accurate alignment without relying on passive floating tools or operator skill. The feedback loop enables active correction during the stuffing process.
Solution Approach 2:
The patent introduces an active control system as an intermediary between the robot gripper and the piston subassembly. This control system processes sensor data and generates real-time commands to adjust the gripping force, positioning, and insertion speed, acting as a mediator that ensures precise and reliable alignment regardless of variations in the piston or cylinder bore dimensions.
4Manufacturing precision
If the gap between cylinder bore and piston skirt is reduced for emission control, then engine efficiency is improved, but the piston stuffing failure rate increases
Solution Approach 1:
The robot system uses sensors to detect the actual gap between the piston skirt and cylinder bore before insertion. Based on this feedback, the system adjusts its insertion force and speed in real-time, ensuring that the piston is inserted with consistent and appropriate force regardless of the specific gap dimension. This feedback control prevents both excessive force that could cause damage and insufficient force that could result in misalignment.
Solution Approach 2:
The patent employs dynamic parameter adjustment during the piston stuffing process. The robot controller modifies insertion speed, gripping force, and pusher extension based on detected parameters such as the gap size and resistance encountered during insertion. This adaptive parameter change allows the system to handle varying gap dimensions while maintaining reliable and damage-free insertion.
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
The gripper system enhances precision and reduces labor intensity by actively searching and inserting piston subassemblies with consistent force control, enabling efficient piston stuffing across diverse engine configurations, reducing failure rates and operational costs, and improving engine efficiency by minimizing the gap between cylinder bores and piston skirts.
Implementation Method 1
a pushing/suction unit for picking up the piston subassembly, the pushing/suction unit comprising a suction cup mounted on a pusher
Data Source
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AI summary
A gripper (800) for gripping a piston subassembly (607) comprising a connecting rod and a piston head provided with one or more rings, the gripper (800) comprising a detection unit for detecting the presence of said one or more rings. A robot equipped with such a gripper is used in engine piston installation process.