Robot Plug Mounting for Vehicle Body Exhaust Hole Sealing

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Solution Overview

Problem

Conventional manual plug mounting processes for vehicle body exhaust holes are prone to errors and musculoskeletal disorders due to repetitive motion and varying plug shapes and sizes, leading to potential water tightness issues and noise/exhaust gas leaks.

Innovation Solution

An automatic plug mounting system utilizing a handling robot and plug mounting tool with a socket module that operates along a teaching path, featuring a punch rod mechanism with a socket member for force-fitting and elastic reciprocation, and a plug transfer unit for handling different plug specifications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual plug mounting is performed by workers, then flexibility in handling different plug shapes and sizes is maintained, but musculoskeletal disorders occur due to repetitive motion and mounting errors happen due to worker carelessness

Engineering Contradiction:

Improvehandling different plug shapes and sizesVSAvoidmounting accuracy

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces the manual mechanical mounting system with an automated robot system. The robot equipped with a specialized end effector automatically mounts plugs into exhaust holes, eliminating repetitive manual motion that causes musculoskeletal disorders. The system maintains adaptability through programmable control that can handle different plug shapes and sizes while ensuring consistent, error-free mounting execution.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robot system performs self-guided mounting operations through automated control. The end effector is designed to automatically grasp plugs of varying specifications and position them correctly into exhaust holes without human intervention, enabling the system to serve itself in completing the mounting task accurately and repeatedly.

Inventive Principle:

Principle #25Self-service

2Reliability

If automatic robot mounting is implemented, then mounting errors are eliminated, but the system complexity increases

Engineering Contradiction:

Improvemounting accuracyVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The automated mounting system is divided into distinct functional modules: a robot for movement and positioning, a specialized end effector for grasping and inserting plugs, and a control system for coordination. This segmentation allows each component to be optimized independently and simplifies maintenance while achieving reliable automated mounting without excessive overall system complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The end effector is designed as a universal tool that can handle multiple plug types and specifications through adjustable gripping mechanisms. This multi-functionality reduces the need for multiple specialized tools, thereby managing system complexity while maintaining the ability to mount various plug types accurately.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If plugs are mounted manually into exhaust holes, then the process is simple, but water tightness issues and noise leaks occur due to improper mounting

Engineering Contradiction:

Improvemounting process simplicityVSAvoidwater tightness and noise prevention

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The manual mounting process is replaced with an automated robotic system that ensures consistent, proper insertion of plugs into exhaust holes. The robot applies controlled force and precise positioning to guarantee correct mounting every time, eliminating the water tightness and noise leakage issues that arise from improper manual installation, while the overall process remains efficient and scalable.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If workers perform repetitive plug mounting, then the task is completed, but productivity decreases due to musculoskeletal disorders and errors requiring rework

Engineering Contradiction:

Improvemounting efficiencyVSAvoidworker health and error rate

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces human workers with an automated robot system for plug mounting operations. This substitution eliminates musculoskeletal disorders caused by repetitive motion and removes human error from the process. The robot can operate continuously without fatigue, significantly improving productivity while maintaining high reliability in mounting quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic system enables continuous mounting operations without the interruptions caused by worker fatigue, breaks, or errors. The robot can maintain a steady pace of work throughout production hours, ensuring uninterrupted mounting operations and maximizing productivity while consistently delivering error-free results.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS11027376B2Automatic plug mounting system for vehicle body

Publication Date: 2021.06.08 HYUNDAI MOTOR CO LTD

AI summary

An automatic plug mounting system for a vehicle body is disclosed to automatically mount plugs into exhaust holes in the vehicle body being transferred along a transfer line. The automatic plug mounting system includes: a handling robot which operates along a teaching path set to correspond to the exhaust holes; and a plug mounting tool which is installed at an arm of the handling robot and, when a cylinder is actuated, places the plugs into the correct positions at the exhaust holes while at least one of the plugs is restrained.