Radiation-Cured Retention Features for Fixtureless Structural Assembly
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Solution Overview
Problem
Conventional robotic assembly of vehicle structural components requires numerous design-specific fixtures, leading to increased costs and inefficiencies, as each part needs a unique fixture, limiting the assembly process's flexibility and scalability.
Innovation Solution
A fixtureless assembly system using robots with end effectors to directly engage and retain structures, employing a combination of structural adhesives and quick-cure adhesives that cure faster under EM radiation, allowing for the assembly of vehicle components without fixtures, enabling flexible and efficient joining of structures through a tongue-and-groove mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixtures are used to retain structural components during robotic assembly, then the components can be securely held and positioned, but the cost increases due to the large number of design-specific fixtures required
Solution Approach 1:
The patent extracts the retention function from external fixtures and integrates it directly into the structural components themselves through molded-in retention features. These features are built into the components during manufacturing, eliminating the need for separate fixtures and reducing device complexity while maintaining secure retention capability.
Solution Approach 2:
The retention features are designed to be universal and adaptable to different component types and assembly configurations. The same basic retention feature design can be applied across multiple component variants, reducing the number of unique fixture designs needed and lowering overall system complexity.
2Manufacturing precision
If design-specific fixtures are used for each structural component, then precise positioning can be achieved, but the assembly process becomes less flexible and scalable
Solution Approach 1:
The retention features incorporate adjustable and reconfigurable elements that can adapt to different component geometries and positioning requirements. This dynamic capability allows the same retention feature design to maintain positioning precision across various component types while providing flexibility for different assembly configurations.
Solution Approach 2:
The retention features utilize adjustable parameters such as engagement depth, positioning force, and geometric configuration that can be modified to accommodate different component specifications. This allows precise positioning to be achieved across multiple component types without requiring completely different fixture designs for each.
3Manufacturing precision
If multiple unique fixtures are manufactured for different parts, then each part can be assembled correctly, but the assembly cost increases
Solution Approach 1:
The retention function is segmented and integrated directly into each structural component during its manufacturing process, rather than being provided by separate external fixtures. This segmentation eliminates the need to manufacture, store, and deploy multiple unique fixtures, thereby reducing assembly costs while maintaining correct assembly precision.
Solution Approach 2:
Each structural component provides its own retention and positioning functionality through built-in features, making the assembly system self-sufficient. This self-service approach eliminates the need for expensive external fixtures and reduces dependency on complex fixture infrastructure, lowering overall assembly costs.
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 approach reduces the need for multiple fixtures, lowers assembly costs, and enhances the efficiency of the robotic assembly process by allowing for the flexible joining of various structural components without the constraints of specific fixtures, improving the assembly process's scalability and reducing the risk of misalignment and structural integrity issues.
Implementation Method 1
The adhesive material may be any adhesive material known to one of skill in the art, including, but not limited to, UV curable adhesives, cyanoacrylate adhesives, epoxy adhesives, acrylic adhesives, and the like.
Data Source
AI summary
Retention features are provided for joining at least two structural components in a fixtureless assembly system. A first structure including a groove may be configured to contain at least one adhesive, and a second structure may include a tongue configured to contact the at least one adhesive to join the first and second structures. The first structure may also include at least one window that receives electromagnetic (EM) radiation from an EM radiation source into the groove. The at least one adhesive is configured to cure at a first rate upon exposure to one of time or heating, and the at least one adhesive is configured to cure at a second rate faster than the first rate upon exposure to the EM radiation.