Robot-Mounted Separator for Shorter Joining Element Feed Paths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial joining systems face challenges with precise transfer and storage of joining elements due to complex and costly profile hoses, which require short transport distances and significant compressed air energy, leading to air leaks and manufacturing difficulties.
Innovation Solution
A compact device mounted on a joining robot for storing and separating joining elements, utilizing a compact separator with a storage container, orientation device, and output device with circular ring turntables to efficiently route joining elements to joining tools, reducing hose length and energy consumption, and enabling automated refueling and filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If joining elements are transported over long distances via feed hoses, then the transport distance is increased, but the hose length increases leading to air leaks and higher energy consumption
Solution Approach 1:
The system segments the transport function by placing intermediate bunkers at strategic locations along the robot's path. These bunkers act as local storage points that break the continuous long-distance transport into shorter segments, reducing the required hose length and associated energy loss from air leaks.
Solution Approach 2:
The solution transitions from a linear transport approach to a multi-dimensional system by positioning intermediate bunkers in three-dimensional space around the robot's working area. This allows joining elements to be stored and retrieved from multiple locations, effectively reducing the maximum transport distance in any single direction.
2Manufacturing precision
If precise connection between refueling station and joining tongs is created, then transfer precision is improved, but device complexity increases due to difficult manufacturing tolerances
Solution Approach 1:
The intermediate bunkers are designed to be automatically filled and emptied through sensor-controlled mechanisms. The system self-regulates the transfer process by detecting when bunkers need filling or emptying, eliminating the need for complex manual coordination and reducing overall system complexity while maintaining precision.
Solution Approach 2:
The intermediate bunkers serve as intermediary storage points between the refueling station and the joining tongs. This mediation allows for more relaxed connection tolerances at each interface, as the bunkers buffer the precision requirements, thereby reducing overall device complexity while maintaining transfer accuracy.
3Productivity
If disordered joining elements are transferred in larger numbers, then productivity is improved, but blockages and errors increase requiring sensor monitoring
Solution Approach 1:
Sensor systems are integrated at each intermediate bunker to provide real-time feedback on the presence, quantity, and status of joining elements. This feedback loop allows the control system to monitor for blockages and errors while managing bulk transfers, maintaining high productivity through automated detection and response to reliability issues.
Solution Approach 2:
The system uses multiple intermediate bunkers distributed throughout the workspace, each handling partial quantities of joining elements. This distributed approach allows bulk transfers to occur in parallel across multiple stations, increasing overall productivity while reducing the risk of system-wide blockages since failures are localized to individual bunkers.
4Length of stationary object
If compact separator is mounted on joining robot, then hose length is reduced, but device weight and complexity on robot increase
Solution Approach 1:
The compact separator and intermediate bunkers are designed to be space-efficient and potentially nested within or adjacent to the robot's existing structure. The bunkers can be positioned in unused spaces or mounted on the robot's frame in a compact arrangement, minimizing the additional weight and volume while achieving the hose length reduction benefit.
Data Source
Figure 1~2
Figure 3a~3c
AI summary
The invention relates to a compact device (10) arranged on a joining robot for storing and singulating joining elements and a method for operating the device.