Vehicle Powertrain Assembly Flow Using Autonomous Mobile Robots
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Solution Overview
Problem
Conventional vehicle electrification component assembly processes involve excessive logistics costs and inadequate quality control due to the division of production and assembly factories, leading to inefficiencies in powertrain manufacturing.
Innovation Solution
A smart factory system where an autonomous mobile robot assembles powertrain components, including a drive-motor, stator, and speed reducer, within a single factory, utilizing sections for component supply, stator assembly, speed reducer assembly, sub-assembly, and testing to ensure quality and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If production and assembly are divided across different factories, then specialized manufacturing can be achieved, but logistics costs increase and quality control becomes insufficient
Solution Approach 1:
The patent combines production and assembly operations into a single integrated factory system. The autonomous mobile robot moves through different assembly sections (drive-motor assembly, stator assembly, speed reducer assembly, etc.) within one facility, eliminating the need for separate production and assembly factories. This merging reduces logistics costs while maintaining manufacturing specialization through dedicated assembly sections.
2Adaptability or versatility
If components are assembled in multiple factories, then production flexibility is improved, but quality control and cleanliness become insufficient
Solution Approach 1:
The patent integrates multiple assembly operations (drive-motor assembly, stator assembly, speed reducer assembly, electrical connection) into a single controlled factory environment. This unified approach ensures consistent quality control and cleanliness standards across all assembly processes while maintaining flexibility through the autonomous robot's ability to perform different assembly tasks in sequence.
Solution Approach 2:
The autonomous mobile robot is equipped with sensors (vision sensors, lidars) that provide real-time feedback on assembly status and component positioning. This feedback mechanism enables continuous quality monitoring and adjustment throughout the assembly process, ensuring high reliability while maintaining production flexibility.
3Productivity
If drive-motor is moved factory to factory in semi-assembled state, then production distribution is achieved, but product cleanliness and quality control deteriorate
Solution Approach 1:
The patent consolidates all assembly operations within a single factory, eliminating the need to move the drive-motor between factories in a semi-assembled state. The autonomous robot completes all assembly steps (motor assembly, stator assembly, speed reducer assembly, electrical connection) in one location, ensuring product cleanliness and quality control throughout the entire process.
4Reliability
If powertrain assembly is completed in a single factory, then quality control and response time are improved, but factory complexity increases
Solution Approach 1:
The autonomous mobile robot autonomously navigates through the factory, positions itself at different assembly sections, and performs assembly operations without human intervention. The robot self-manages its movement, component handling, and assembly execution, reducing the need for complex human-operated machinery and control systems while maintaining high quality control standards.
Data Source
AI summary
A smart factory system for an electrified vehicle includes a components supplying section in which a drive-motor and a one-kit module of speed reducer component parts for forming a speed reducer to be assembled to the drive-motor are supplied to an upper portion of an autonomous mobile robot, a stator assembling section in which a stator to be assembled to the drive-motor is assembled, a speed reducer assembling section configured to sequentially assemble the speed reducer component parts to the drive-motor, a sub-assembling section in which the drive-motor, the stator, and the speed reducer component parts are electrically interconnected, and a test section in which an assembly quality of the drive-motor, the stator, and the speed reducer component parts is checked.