Robot Roller Hemming Device with Force Sensor
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Solution Overview
Problem
Existing roller hemming devices face challenges in maintaining high processing quality due to positional errors between the robot manipulator and the workpiece, and in varying pressing force effectively, especially when dealing with curved workpieces, leading to complications in tool structure and increased costs.
Innovation Solution
A roller hemming device equipped with a position detecting part, force measuring part, and controlling part to correct positional errors and apply predetermined pressing forces, allowing for precise control of the roller's movement and force application during pre-hemming and hemming processes, including the use of positional error calculation and start point correction mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot manipulator is used to move the roller during pre-hemming and hemming processes, then productivity and automation are improved, but positional accuracy between the roller and workpiece deteriorates due to manipulator errors
Solution Approach 1:
The patent employs feedback control by detecting the actual position of the roller relative to the workpiece and using this information to correct the manipulator's movement commands. Position detectors monitor the roller's position, and the control unit adjusts the manipulator's trajectory in real-time to compensate for positional deviations, thereby maintaining high manufacturing precision while utilizing automated robot manipulation.
Solution Approach 2:
The patent replaces traditional mechanical positioning systems with sensor-based detection and software-based correction. Instead of relying solely on mechanical precision of the manipulator, the system uses position detectors and computational algorithms to achieve accurate positioning, substituting mechanical rigidity with intelligent control.
2Manufacturing precision
If pressing force is increased to improve processing quality, then manufacturing precision is improved, but the risk of workpiece deformation or damage increases
Solution Approach 1:
The patent applies dynamic control of pressing force rather than static fixed force. The control unit continuously adjusts the pressing force based on real-time feedback from position detectors and force sensors, optimizing the force magnitude during the hemming process to achieve high processing quality while preventing workpiece deformation through adaptive force management.
3Manufacturing precision
If guide rails are added to guide the roller at the mold, then positional accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical guide rails with a sensor-based guidance system. Position detectors and force sensors provide real-time feedback on the roller's position and contact forces, and the control unit computationally determines the optimal roller trajectory, eliminating the need for complex mechanical guidance infrastructure while maintaining high positioning accuracy.
4Manufacturing precision
If multiple rollers are arranged to improve positional accuracy, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses feedback control with position detectors and force sensors to enable a single roller to achieve high positioning accuracy through intelligent control. The system detects the roller's actual position and contact forces, and the control unit adjusts the manipulator's movement to compensate for deviations, eliminating the need for multiple rollers while maintaining precision through software-based correction.
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 solution enables high-quality pre-hemming and hemming processes by accurately correcting positional errors and varying pressing forces, improving processing quality without the need for guide rails and reducing complexity and costs.
Implementation Method 1
a force measuring part arranged between a wrist section of the robot manipulator and the roller
Data Source
AI summary
A roller hemming device capable of correcting a positional error between a robot manipulator and a workpiece, and carrying out a pre-hemming and/or hemming process with appropriate pressing force. The roller hemming device has a position detecting part adapted to detect a current position of a roller attached to a front end of the robot manipulator; a force sensor arranged between a wrist section of the robot manipulator and the roller; and a controller adapted to control the position of the roller by using an output of the position detecting part and an output of the force sensor, so that pressing force applied to a mold by the roller is a predetermined value.