Robot Straightening of Vehicle Parts With Adaptive Deviation Feedback
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Solution Overview
Problem
Existing methods for forming vehicle parts, such as those made of metal, face challenges in maintaining precision due to unwanted deformations caused by processing, storage, and temperature fluctuations, leading to high cycle times and scrap rates, as manual correction is costly and inaccurate force measurements complicate automated straightening processes.
Innovation Solution
A method using a robot system that measures initial deviations, determines transformation parameters from stored data sets, and iteratively forms parts to achieve desired dimensions, incorporating adaptive adjustments for material properties and elastic behavior, with data storage and retrieval to refine forming parameters across multiple runs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual machining and rework are used to correct deformations, then manufacturing precision is maintained, but productivity decreases and cycle time increases
Solution Approach 1:
The system enables self-service by automatically measuring deviations, determining correction parameters, and executing forming operations without manual intervention. The robot system autonomously completes the entire correction process, eliminating the need for manual machining while maintaining high precision and reducing cycle time.
Solution Approach 2:
The system implements feedback by measuring initial deviations, using these measurements to determine correction parameters, executing forming operations, and potentially measuring final deviations. This closed-loop feedback ensures high manufacturing precision while automating the process to improve productivity.
2Manufacturing precision
If continuous force measurement is implemented during forming, then manufacturing precision can be improved through closed-loop control, but device complexity increases due to imprecise sensor measurements
Solution Approach 1:
The system extracts the measurement function from force sensors and implements it through dedicated deviation measurement devices that capture geometric deviations directly. This separation eliminates the complexity of force measurement while maintaining the ability to control forming accuracy through precise geometric measurements.
Solution Approach 2:
The system replaces mechanical force measurement with optical or geometric measurement methods. By measuring deviations in position and geometry rather than forces, the system achieves high forming accuracy without the complexity and imprecision of force sensors.
3Manufacturing precision
If data from multiple forming runs is stored and used, then manufacturing precision improves through adaptive parameter adjustment, but loss of time increases due to data processing
Solution Approach 1:
The system performs preliminary actions by storing measurement data and forming parameters from previous runs in advance. This pre-collected data is then rapidly processed to determine correction parameters for current parts, improving precision without significant time loss because the data accumulation happens during normal production.
Solution Approach 2:
The system creates copies of successful forming parameters and deviation patterns from previous runs. By copying and adapting proven parameters rather than processing all raw data, the system achieves high precision while minimizing data processing time through efficient use of representative data samples.
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
This approach significantly reduces final deviations and cycle time, achieving precise part formation with a lower reject rate by leveraging data-driven adaptive forming parameters and accounting for material changes over multiple forming runs.
Implementation Method 1
Measuring initial deviations at predetermined measuring points of a current part to be formed; Measuring final deviations at at least one of the predetermined measuring points after forming
Implementation Method 2
forming, in particular by means of at least one bending step, of the current part to be formed at least on the basis of the forming parameter
Implementation Method 3
The elastic behavior of a part changes depending on the number of deformations it has undergone
Data Source
Figure 1
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AI summary
The invention relates to a method for forming, in particular corrective forming and/or straightening, parts, preferably vehicle parts, with at least one robot system, wherein the method comprises at least one forming run (U) with the following steps: a) measuring initial deviations (zi) at predetermined measuring points of a current part to be formed; b) determining at least one forming parameter (α) for measured initial deviations (zi) using a data structure (D); c) forming, in particular by means of at least one bending step, of the current part to be formed at least on the basis of the forming parameter (α); d) measuring final deviations (zf) at at least one of the predetermined measuring points after forming in step c); and e) storing additional values, which specify the initial deviations (zi), the forming parameter (α) and the final deviations (zf), in the data structure (D);wherein the forming process (U) for at least one further part is carried out using the additional values stored in the data structure. Furthermore, the invention describes a computer-readable medium according to claim 17 and a robot system according to claim 18. The invention achieves particularly short cycle times with particularly low reject rates.