Robot Arm Assembly Locking for Fixture-Free Subcomponent Positioning
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Solution Overview
Problem
Current manufacturing systems require multiple part locating fixtures for different sizes and shapes of components, which is inefficient and lacks a method to apply external forces without traditional fixtures during assembly operations.
Innovation Solution
A method and system using robot arms with end-of-arm tools that grasp subcomponents, apply initial forces, lock them together, switch to force control to compensate for gravitational forces, and apply external loads to distort the components into a working position, allowing assembly without dedicated fixtures, using interlocking mechanisms and linear actuators for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional part locating fixtures with fixed pins and clamps are used, then components can be accurately located and held in place, but the system requires multiple fixtures for different part sizes and shapes, increasing device complexity and reducing adaptability
Solution Approach 1:
The robot arm with end-of-arm tool is designed to perform multiple functions: grasping components, applying forces, positioning parts, and maintaining them during assembly operations. This single multi-functional system replaces the need for multiple dedicated fixtures for different part types, directly resolving the contradiction between adaptability and device complexity
Solution Approach 2:
The system transitions from static fixed pins and clamps to dynamic robot-controlled end-of-arm tools that can adapt their position, force application points, and gripping mechanisms based on the specific component being assembled. This dynamic capability enables a single system to handle various part sizes and shapes without requiring multiple fixed fixtures
2Manufacturing precision
If robot arms with force control are used to apply external loads and distort subcomponents, then precise positioning and predictable thermal deformation can be achieved, but the control system complexity increases
Solution Approach 1:
The system replaces complex mechanical positioning fixtures with robot arms equipped with force control capabilities. The force control system allows the robot to apply precise external loads and monitor reactions, achieving predictable thermal deformation during welding without requiring complex mechanical positioning mechanisms
Solution Approach 2:
The force control system incorporates feedback mechanisms that monitor the forces applied to and reactions from the components being assembled. This feedback enables real-time adjustment of the robot arm's actions to maintain precise positioning and control thermal deformation, achieving high manufacturing precision through intelligent control rather than mechanical complexity
3Adaptability or versatility
If multiple fixtures are used for different assembly operations, then various part sizes and shapes can be accommodated, but the changeover time and productivity are reduced
Solution Approach 1:
The robot arm with programmable end-of-arm tools serves as a universal assembly system that can handle various part sizes and shapes through software configuration rather than physical fixture changes. This eliminates fixture changeover time and maintains high productivity while accommodating design variations
Solution Approach 2:
The system accommodates different part sizes and shapes by changing operational parameters (grasping forces, positioning coordinates, force application magnitudes) rather than physical fixtures. This parameter-based adaptability allows rapid reconfiguration for different components without stopping the assembly line for fixture changes
Data Source
AI summary
A component assembly system comprises a first robot arm having a first end-of-arm tool mounted thereon and adapted to grasp a first subcomponent; a second robot arm having a second end of arm tool mounted thereon and adapted to grasp a second subcomponent. A system controller is adapted to control the first and second robot arms and first and second end-of-arm tools to position the first and second subcomponents relative to one another. A first interlocking mechanism is mounted onto the first end-of-arm tool and a second interlocking mechanism is mounted onto the second end-of-arm tool, wherein the first and second interlocking mechanisms engage one another and lock the first end-of-arm tool to the second end-of arm tool, thereby locking the first and second subcomponents into an initial position relative to one another.