Automated Robot Mounting of Insulating Elements

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Solution Overview

Problem

Manual mounting of insulating elements on structural vehicle components is labor-intensive, ergonomically unfavorable, and prone to errors, making it costly and inefficient, especially when dealing with irregularly shaped cavities that require precise sealing and reinforcement to prevent moisture ingress and noise transmission.

Innovation Solution

An automated method using a multi-axis robot with a gripper to mount insulating elements, featuring expandable materials and redesigned fixing elements that allow for more robust and efficient sealing, with insulating elements pre-stacked for easier handling and reduced confusion, and a sensor system for quality control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If insulating elements are mounted manually on structural elements, then the mounting process is flexible and adaptable to different positions, but the process is labor-intensive, ergonomically unfavorable, and prone to errors

Engineering Contradiction:

Improvemanual mounting flexibilityVSAvoidmounting efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical mounting system with an automated robot system. The robot is equipped with a gripper that can automatically grasp insulating elements and position them on structural elements, eliminating the need for manual labor while maintaining precise positioning capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The insulating elements are designed with self-aligning features including guide elements that automatically align with corresponding guide openings in the structural elements. This self-service mechanism ensures correct positioning without requiring manual adjustment, enabling the robot to mount elements efficiently and accurately.

Inventive Principle:

Principle #25Self-service

2Strength

If insulating elements are mounted manually, then complex fixing elements can be used, but the mounting process becomes more difficult and time-consuming

Engineering Contradiction:

Improvefixing element robustnessVSAvoidmounting complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The robot system replaces manual manipulation, enabling the use of more robust fixing elements that would be difficult to install by hand. The automated gripper and positioning system can apply the necessary forces and precision to install complex fixing elements efficiently, eliminating the trade-off between strength and mounting ease.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If insulating elements are designed with special alignment features for manual mounting, then incorrect orientation is prevented, but the design becomes more complex and costly

Engineering Contradiction:

Improvemounting accuracyVSAvoidinsulating element design

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating elements incorporate self-aligning guide elements that automatically orient the element correctly as it is inserted into the structural element. This self-service alignment mechanism ensures reliable positioning and prevents incorrect orientation without requiring complex asymmetric designs or additional fastening steps, maintaining simplicity while ensuring accuracy.

Inventive Principle:

Principle #25Self-service

4Ease of repair

If manual mounting is used, then insulating elements can be easily replaced or adjusted, but the process is slow and labor-intensive

Engineering Contradiction:

Improveelement replaceabilityVSAvoidmounting time

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The mounting system uses discrete, modular insulating elements with standardized fixing mechanisms. Each element can be independently mounted or removed by the robot system, enabling easy replacement and adjustment while maintaining high speed through automation. The segmentation allows for flexible maintenance without requiring complete disassembly.

Inventive Principle:

Principle #1Segmentation

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

The automated method significantly reduces labor costs, minimizes errors, allows for more robust material usage, and enhances the efficiency of the insulating element design, enabling better sealing and noise reduction while maintaining lightweight construction.

Implementation Method 1

an expandable material which is arranged on the carrier

Methodology Applied

Scientific EffectExpansion:

Data Source

PatentUS20240300590A1Method for automated attachment of insulating elements to structural elements

Publication Date: 2024.09.12 SIKA TECH AG

AI summary

A method for the automated mounting of insulating elements on structural elements of motor vehicles includes the following steps: providing a plurality of insulating elements, wherein an insulating element in each case includes a carrier, an expandable material which is arranged on the carrier, and at least one fixing element for fixing the insulating element on the structural element; gripping individual insulating elements by a robot, wherein the robot is designed as a multi-axis robot with a gripper; and mounting in each case an insulating element on a structural element by the robot, wherein the at least one fixing element of the insulating element is inserted into an opening in the structural element.