Robot Tool Elastic Lip for Plug Magazine
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual insertion of plugs into body component openings is ergonomically unfavorable, prone to errors, and inefficient, with existing robotic tools being limited by single plug capacity, energy-intensive compressed air usage, and lack of HRC-compliance for collaborative operation.
Innovation Solution
A robotic tool with a plug magazine and elastic lip for secure, variable plug placement without reloading, using an electric spindle drive for precise positioning and an exchangeable setting device, ensuring correct seating and reducing human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual plug insertion is used, then flexibility in handling different plug diameters is maintained, but ergonomic strain and error susceptibility increase significantly
Solution Approach 1:
The patent replaces the manual mechanical insertion system with an automated robotic system. The robot tool equipped with a setting device automatically inserts plugs into openings, eliminating the need for workers to manually handle plugs. This substitution resolves the ergonomic strain issue while maintaining adaptability through programmable control that can accommodate different plug diameters.
2Ease of operation
If robotic plug insertion is implemented, then ergonomic strain is reduced, but productivity decreases due to single plug capacity and constant reloading
Solution Approach 1:
The patent segments the plug storage and delivery system into a magazine component that holds multiple plugs and a setting device that sequentially receives and inserts them. This segmentation allows the robot to access multiple plugs from the magazine without returning to a reloading station, thereby maintaining continuous operation and high productivity while keeping the robot tool lightweight and ergonomic.
3Ease of manufacture
If compressed air is used for plug ejection, then plug ejection is achieved, but energy consumption increases and safety risks arise from hoses
Solution Approach 1:
The patent extracts the ejection mechanism from the compressed air system and implements a spring-based mechanical ejection system. The spring-loaded mechanism propels plugs from the magazine to the setting device without requiring compressed air supply lines, thereby eliminating energy consumption associated with compressed air generation and distribution, and removing safety hazards from hoses.
4Device complexity
If non-exchangeable vacuum head is used, then device complexity is reduced, but adaptability to different plug diameters is limited
Solution Approach 1:
The patent designs the setting device with a universal gripping mechanism that can accommodate multiple plug diameters. The gripping component features adjustable or modular elements that can adapt to different plug sizes without requiring replacement of the entire vacuum head or setting device, thereby achieving multi-functionality while maintaining relatively simple device architecture.
5Productivity
If plugs are set without verification, then process speed is maintained, but reliability of seal quality decreases
Solution Approach 1:
The patent incorporates a sensor system that provides feedback on plug insertion quality. The sensors detect whether plugs are properly seated in the openings and can identify insertion errors. This feedback mechanism allows the system to verify plug seating quality automatically, ensuring reliability while maintaining productivity through rapid sensing and immediate error detection without requiring manual inspection.
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
Enhances plug placement speed and security, reduces ergonomic strain, minimizes errors, saves energy, and enables HRC-compliant collaborative operation, improving production efficiency and quality while eliminating the need for compressed air.
Implementation Method 1
An encircling elastic lip is provided at an outlet of the setting device, which lip holds the plug in the plug magazine and can be elastically bent over by an axial movement of the plug in the axial direction of the robot tool
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a robot tool (1) for setting sealing plugs (2) in openings in a vehicle body component by means of a setting device (3), in which a plug magazine (4) having a plurality of plugs (2) is accommodated, which can be set into the respective openings in direct succession by means of the setting device (3) without reloading. The invention further relates to a method for securely setting the plugs (2), wherein a peripheral elastic lip (10) is provided at an outlet (9) of the setting device (3), which lip retains the plugs (2) in the plug magazine (4) and can be elastically bent by means of an axial motion of the plugs (2) in the axial direction of the robot tool (1).