Robot-Assisted Assembly Positioning for Faster Commissioning
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Solution Overview
Problem
Current methods for commissioning complex assembly systems are largely manual and time-consuming, requiring significant adjustments during the transition from a virtual design phase to real-world implementation, leading to high assembly costs and lack of traceable documentation.
Innovation Solution
A system comprising robots, a measuring system, and a computer that enables absolute robot-assisted positioning by monitoring and optimizing movement parameters such as direction, speed, force, and torque, allowing for automated and precise assembly tasks without human intervention, using a network of communication and measurement technologies to synchronize and adapt robot movements based on real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual commissioning methods are used to adapt robots from virtual design to real assembly, then robot positioning accuracy can be adjusted, but the commissioning time and costs increase significantly
Solution Approach 1:
The patent replaces manual mechanical teaching methods with an automated optical measurement system. A measuring device with markers tracks robot positions and coordinates automatically, eliminating the need for manual coordinate input and system adaptation, thereby reducing commissioning time while maintaining positioning accuracy
Solution Approach 2:
The patent creates a digital copy of the real assembly environment by measuring actual positions of assembly elements and comparing them with virtual model coordinates. This copying approach allows automatic generation of robot movement sequences that match real-world conditions without manual intervention
2Ease of operation
If manual teaching methods are used to program robot movement sequences, then robot can perform assembly tasks, but the process requires significant human intervention and lacks traceable documentation
Solution Approach 1:
The system enables self-service programming by automatically generating robot movement sequences through optical measurement and coordinate comparison. The robot system programs itself by comparing measured real-world coordinates with virtual model data, eliminating manual teaching and automatically creating traceable documentation of the process
Solution Approach 2:
The patent implements feedback by continuously measuring actual robot positions and assembly element locations, comparing them with planned trajectories, and automatically adjusting movement sequences. This closed-loop approach ensures traceable documentation of deviations and corrections throughout the assembly process
3Manufacturing precision
If traditional commissioning methods are used, then robot deviations can be compensated, but the source of deviations cannot be isolated and documented
Solution Approach 1:
The patent segments the assembly process into discrete measurable events using markers on assembly elements and robot end-effectors. Each position and movement is individually recorded with timestamps and coordinate data, allowing precise identification and isolation of deviation sources through detailed measurement records
Solution Approach 2:
The patent replaces manual deviation analysis with automated optical measurement and digital documentation. The measuring device automatically detects, records, and analyzes position deviations, replacing manual inspection and providing traceable digital evidence of deviation sources
Data Source
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AI summary
A system for implementing an absolute robot-assisted positioning method to optimize a real assembly task defined by theoretically defined work steps, wherein the system comprises: e. at least one robot that performs the assembly task, f. at least one measuring system that monitors the robot's parameters, and g. at least one computer, h. wherein the computer comprises at least one storage unit, one processing unit, one transmission interface, and one communication interface and is configured to: • store a program that represents the theoretically defined assembly task, • derive coordinated work steps for precisely the robot from the program using the processing unit with a predefined algorithm, • transmit the program to the robot via the transmission interface, • monitor the robot, the measuring system, and the sensors via the communication interface.to complete the assembly task, • to receive measurement data from the measuring system via the communication interface and save it for documentation purposes, and • to compare this received measurement data with the specified data and, in the event of any deviations exceeding a specified limit, to decide whether the assembly task should be aborted or stopped immediately or at a later time.