Robot-Guided Plug Setting Tool With Rotating Magazine
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stopper setting techniques lack precision, efficiency, and flexibility in setting plugs on body parts, requiring separate drives and complex programming, and are not adaptable to various plug formats.
Innovation Solution
A robot-guided stopper setting tool with a multi-axis industrial robot, a stopper magazine, and a plug receptacle that allows for tactile handling, overlapping loading and setting processes, and modular design with adjustable drives, enabling precise alignment and secure transfer of plugs without additional actuators, and accommodating different plug formats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an independent setting drive in the plug receptacle is used, then the setting precision is improved, but the device complexity increases
Solution Approach 1:
The patent combines the setting drive function with the industrial robot's end effector, eliminating the need for a separate independent setting drive in the plug receptacle. The robot's multi-axis control system provides the necessary precision while reducing overall device complexity through functional integration.
Solution Approach 2:
The industrial robot serves multiple functions: it positions the plug receptacle, provides the setting drive through its end effector, and controls the overall setting process. This multi-functionality replaces what would otherwise require separate specialized components, reducing device complexity while maintaining precision.
2Productivity
If a single plug receptacle is used, then the device complexity is reduced, but the productivity decreases
Solution Approach 1:
The patent enables overlapping of the loading process and the setting process in time. While one plug is being set, another can be loaded into the receptacle, creating continuous productive action without idle time. This temporal overlap increases productivity without requiring multiple simultaneous receptacles.
Solution Approach 2:
The plug receptacle is designed to be dynamically reconfigurable with multiple receiving locations that can be selectively activated. This allows the system to adapt its capacity based on production needs, providing high productivity when required while maintaining simpler operation when lower capacity suffices.
3Manufacturing precision
If the plug receptacle is fixed rigidly, then the manufacturing precision is improved, but the adaptability to various plug formats decreases
Solution Approach 1:
The plug receptacle is segmented into multiple independent receiving locations, each capable of holding different plug formats. This segmentation allows the system to maintain rigid positioning of the receptacle itself for precision while accommodating variety in individual plug types through the modular receiving locations.
Solution Approach 2:
The plug receptacle is designed as a universal holder that can accommodate various plug formats through its multiple receiving locations. The rigid receptacle structure provides stable positioning, while the versatile receiving locations adapt to different plug types, combining precision with adaptability.
4Productivity
If the loading and setting processes are performed sequentially, then the device complexity is reduced, but the productivity decreases
Solution Approach 1:
The patent implements temporal overlap between the loading process and the setting process. While the industrial robot is setting one plug, the loading device can simultaneously load the next plug into the receptacle. This continuous operation eliminates idle time and increases productivity without requiring complex multi-robot coordination.
Solution Approach 2:
The plug receptacle serves as an intermediary buffer between the loading device and the setting operation. This buffer allows the two processes to operate on different time scales and be coordinated through the receptacle's positioning, simplifying the overall control architecture while enabling parallel operations.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a robot-guided tool (3) for automatically setting plugs (5) on vehicle body parts (6) as well as to a setting method. The plug setting tool (3) comprises a frame (10) that has a connection (11) for an industrial robot (2), a plug magazine (12) and a setting unit (18) that includes a plug holder (19) and a rotating mechanism (20) for moving the plug holder (19) between a charging position (40) on the plug magazine (12) and a setting position (39). The plug holder includes one or more holding heads (26, 27) which is/are connected to the rotating mechanism (20) and each of which comprises a setting ram (28) and a plug quiver (29) for accommodating a single plug (5). The setting ram (28) is supported in the axial direction thereof, preferably secured on the frame, and the plug quiver (29) is mounted so as to be able to axially deviate relative to the setting ram (28). 1