Automated Robot Assembly with Force Feedback Control
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Solution Overview
Problem
Manual assembly of tiny electronic components is inefficient and inaccurate, with high insertion force risks damaging fragile components.
Innovation Solution
An automatic assembly system using a vision robot with a 6-axis multi-freedom robot, end effectors, force sensors, and cameras for precise chip and housing insertion, along with a cutting and bending mechanism to prepare components, ensuring controlled insertion forces and high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion is used to assemble tiny members, then flexibility and adaptability are maintained, but assembly efficiency and accuracy deteriorate with insertion tolerance beyond ±0.05mm
Solution Approach 1:
The patent replaces the manual mechanical insertion system with an automated robot system equipped with a force sensor. The robot controller receives force sensor signals and automatically adjusts insertion parameters, substituting human operation with an automated electromechanical system that achieves both high efficiency and precision within ±0.05mm tolerance
Solution Approach 2:
The patent implements a feedback control mechanism where the force sensor detects insertion force in real-time and transmits signals to the robot controller. The controller adjusts insertion parameters based on this feedback, enabling dynamic control to maintain both high assembly speed and precise tolerance control
2Adaptability or versatility
If manual insertion is used for fragile members, then adaptability to different components is maintained, but component reliability deteriorates due to uncontrolled insertion force causing damage
Solution Approach 1:
The force sensor provides real-time feedback on insertion force, allowing the robot controller to detect when the force approaches the damage threshold for fragile components. This feedback mechanism enables dynamic adjustment to prevent component damage while maintaining adaptability to different component types
Solution Approach 2:
The patent dynamically changes insertion parameters including force magnitude, insertion speed, and positioning based on component characteristics detected by the force sensor. This parameter adaptation allows safe handling of fragile members while maintaining versatility across different component types
3Productivity
If automated assembly is implemented without force control, then productivity increases, but manufacturing precision deteriorates due to inability to control insertion force
Solution Approach 1:
The force sensor continuously monitors insertion force and provides feedback to the robot controller, enabling real-time adjustments to maintain precise insertion accuracy while operating at high automated speeds. This closed-loop control resolves the contradiction between speed and precision
Solution Approach 2:
The patent replaces simple automated mechanical insertion with an intelligent automated system that incorporates force sensing and control. This substitution enables the system to maintain both high productivity and precise insertion accuracy through automated force regulation
Data Source
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AI summary
An automatic assembling system, comprising: a robot (100) capable of performing an operation of inserting a first member into a second member; a force sensor (113) for detecting an insertion force exerted on the first member by the robot (100); and a controller (800) for controlling the insertion force with a close loop feedback control according to a difference between the insertion force detected by the force sensor (113) and a predetermined insertion force, so that the insertion force is less than the predetermined insertion force to prevent the first member and/or the second member from damage due to an overlarge insertion force. Furthermore, the present invention also discloses a method for automatically assembling a product.