Robot-Mounted Post-Process Tool for Laser Brazing Bead Grinding

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Solution Overview

Problem

The existing vehicle body assembly process is aesthetically unsatisfactory and costly due to the external appearance of resin loop molding between side and loop panels, and it increases material and manpower costs.

Innovation Solution

A post-process tool with a grinding assembly and bead inspector mounted on a robot, capable of grinding, inspecting, and marking the brazing bead in a loop laser brazing system, ensuring quality and reducing costs by simplifying equipment and investment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If resin loop molding is attached to the laminating region between side panel and loop panel, then the assembly is completed, but the outer appearance becomes unaesthetical and material cost increases

Engineering Contradiction:

Improveassembly completionVSAvoidouter appearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent removes the resin loop molding from the laminating region by extracting this component entirely. Instead, it uses laser brazing technology to directly join the side panel and loop panel, eliminating the need for additional molding materials and improving aesthetic appearance while maintaining structural integrity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical attachment method (resin loop molding) with a thermal joining method (laser brazing). This substitution eliminates the need for external molding materials and creates a cleaner, more aesthetically pleasing joint while reducing material costs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If resin loop molding is attached to the laminating region, then the assembly is completed, but manpower cost increases

Engineering Contradiction:

Improveassembly completionVSAvoidmanpower cost

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces manual or mechanical attachment processes with automated laser brazing technology. This automation reduces the need for manual labor in attaching loop molding, thereby reducing manpower costs while improving assembly efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the joining process parameters from mechanical attachment to thermal brazing, which enables automated processing and reduces dependency on manual labor, thereby reducing manpower costs

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If grinding assembly is added to post-process tool, then brazing bead quality is improved, but device complexity increases

Engineering Contradiction:

Improvebrazing bead qualityVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple post-processing functions (grinding, inspection, marking) into a single integrated tool that is mounted on the robot. This merging approach improves brazing bead quality through precise grinding while avoiding the need for separate equipment, thereby limiting the increase in overall device complexity

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If multiple functions are integrated in single post-process tool, then productivity is improved, but device complexity increases

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidtool complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges grinding, inspection, and marking functions into a single integrated post-process tool mounted on the robot. This integration enables simultaneous or sequential execution of multiple operations, improving productivity while consolidating equipment rather than multiplying it

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The post-process tool is designed with multi-functionality, capable of performing grinding, inspection, and marking operations. This universal tool replaces the need for multiple separate devices, improving productivity while the modular design keeps complexity manageable

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 tool ensures excellent quality of the loop laser brazing bead by simultaneously performing grinding, quality inspection, and marking, reducing costs and complexity while automatically compensating for vehicle body position variations.

Implementation Method 1

a grinding wheel coupled with a drive shaft of the grinding motor... grinding a lamination region

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS10118270B2Post-process tool

Publication Date: 2018.11.06 HYUNDAI MOTOR CO LTD

AI summary

A post-process tool includes: a fixing bracket mounted in at least one robot; and a grinding assembly installed at one side of the fixing bracket, being moved in a longitudinal direction of the vehicle body, and configured to grind a lamination region. The grinding assembly includes a grinding bracket mounted at the one side of the fixing bracket, a grinding motor reciprocatably installed in the grinding bracket and moving in upward and downward directions; and a grinding wheel coupled to a drive shaft of the grinding motor.