Robot-Controlled Application Head for Local Stiffening
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Solution Overview
Problem
Existing methods for stiffening metal components in car body production using fiber-reinforced plastics are laborious and cost-intensive, making it difficult to integrate them into the production process.
Innovation Solution
A robot-controlled method for pressing a fiber-reinforced plastic insert onto a metal component using a pressure piston, allowing for local stiffening and integration into existing car body production lines, with optional heating and counter-pressure assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional pressing techniques with large presses are used, then fiber-reinforced plastic inserts can be pressed onto metal components, but the process becomes cost-intensive and laborious
Solution Approach 1:
The pressing process is segmented into localized operations using a robot-controlled application head with a pressure piston that can apply pressure only to specific areas where stiffening is needed, rather than requiring a large press to handle the entire component. This segmentation reduces equipment complexity while achieving the desired stiffening effect.
Solution Approach 2:
The traditional mechanical pressing system (large presses) is replaced with a robot-controlled application head that uses a pressure piston for localized pressing. This substitution reduces device complexity and enables integration into automated production lines.
2Strength
If traditional hybridization methods are used, then metal components can be stiffened with fiber-reinforced plastics, but the process cannot be integrated into car body production lines
Solution Approach 1:
The application head is mounted on a robot arm, providing dynamic positioning and movement capabilities. This allows the pressing operation to be integrated into the automated flow of car body production lines, where the robot can move the application head to different positions and orientations as needed, enabling seamless integration without disrupting production productivity.
Solution Approach 2:
The robot-controlled application head serves multiple functions: picking up the fiber-reinforced plastic insert, positioning it on the metal component, and applying pressure for bonding. This multi-functionality consolidates multiple operations into a single integrated unit that can be incorporated into existing production lines without requiring separate dedicated equipment for each step.
3Strength
If fiber-reinforced plastic inserts are pressed onto metal components, then local stiffening is achieved, but pre-heating is typically required which increases cycle time
Solution Approach 1:
The fiber-reinforced plastic insert is pre-heated in a heating element integrated into the application head before the pressing operation. This preliminary heating action ensures that the insert is at the correct temperature for bonding when pressing begins, eliminating the need for separate pre-heating steps and reducing overall cycle time while achieving effective local stiffening.
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
Enables efficient and cost-effective local stiffening of metal components, reducing cycle time and eliminating the need for pre-heating, thus integrating the hybridization process seamlessly into car body production.
Implementation Method 1
the fiber-reinforced plastic insert is pressed onto the metal component by means of a pressure piston located on the application head
Implementation Method 2
the fiber-reinforced plastic insert is heated in a heating element prior to picking it up by the application head
Data Source
AI summary
In order to optimize a method for stiffening a metal component by pressing a fiber-reinforced plastic insert onto the metal component in such a way that the method can be integrated into the serial production of the car body, it is proposed that the fiber-reinforced plastic insert be picked up by means of a robot-controlled application head and pressed onto the metal component.