Robot-Mounted Piston Insertion Module for Precise Bore Alignment
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Solution Overview
Problem
Existing piston insertion equipment, whether fully-automated or semi-automated, faces challenges such as high manufacturing costs, complex structures, large installation space, inconsistent assembly quality, and reliance on operator skill, which affect efficiency and accuracy.
Innovation Solution
A piston insertion apparatus and method utilizing a compact piston insertion module mounted on an insertion robot, featuring a gripper with adjustable gripping force, centering mechanism, and push mechanism, along with sensors and a controller for precise alignment and automated operation, reducing equipment costs and improving insertion accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If fully-automated piston insertion equipment with multiple robots and units is used, then automation level and insertion accuracy are improved, but manufacturing cost and equipment complexity increase
Solution Approach 1:
The patent combines the piston insertion module directly with the robot arm to form an integrated assembly system. The piston insertion module includes a gripper and push mechanism that are mounted on the robot arm, eliminating the need for separate transfer robots and block handling equipment. This merging reduces the number of independent units while maintaining full automation capability.
Solution Approach 2:
The robot arm serves multiple functions: it transfers the piston assembly, positions it over the cylinder block, and controls the insertion process through the integrated piston insertion module. This multi-functionality replaces the need for dedicated transfer robots and positioning equipment, simplifying the overall system while maintaining automation.
2Extent of automation
If fully-automated piston insertion equipment with multiple robots is used, then automation level and insertion accuracy are improved, but installation space requirement increases
Solution Approach 1:
By integrating the piston insertion module with the robot arm, the patent eliminates the need for separate transfer stations and positioning areas that would be required for multiple independent robots. This consolidation reduces the footprint of the automation system while maintaining full robotic control over the insertion process.
3Device complexity
If semi-automated equipment with manual piston insertion is used, then equipment cost is reduced, but assembly quality consistency and operational efficiency deteriorate
Solution Approach 1:
The system uses sensors to automatically detect the position of the piston assembly and cylinder block, and the controller automatically adjusts the robot arm and piston insertion module to achieve precise alignment and insertion. This eliminates reliance on operator skill while maintaining simple equipment architecture.
4Device complexity
If semi-automated equipment with manual piston insertion is used, then equipment cost is reduced, but productivity and operational rate deteriorate
Solution Approach 1:
The automated detection and control system continuously monitors the insertion process and automatically adjusts parameters to optimize cycle time. The sensor-controller-robot system operates autonomously at high speed without the delays associated with manual operation, achieving both simplicity and high productivity.
Data Source
AI summary
Provided is an apparatus for piston insertion, including an insertion robot having a plurality of robot arms connected by a plurality of articulated joints, a piston insertion module directly mounted on the insertion robot, gripping a piston assembly, and inserting the piston assembly into a cylinder bore of a cylinder block, and a controller controlling an operation of the insertion robot and an operation of the piston insertion module.