Robot Tool Vacuum Pushrod for Automated Plug Mounting
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Solution Overview
Problem
Manual setting of plugs in industrial production, particularly in motor vehicle manufacturing, is inefficient and labor-intensive, requiring significant human intervention to position and secure plugs in various locations.
Innovation Solution
A robot tool with a vacuum feed pushrod and pivoting holder is integrated with an industrial robot, allowing for automated plug picking and mounting, eliminating the need for separate storage stations and enabling secure plug handling through vacuum-assisted movement and adjustable positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual setting of plugs is used, then operational flexibility is maintained, but productivity is low and labor intensity is high
Solution Approach 1:
The robot tool is equipped with an integrated plug magazine that automatically feeds plugs to the pushrod without requiring external intervention or separate storage stations. The system serves itself by containing the entire plug supply mechanism within the tool, enabling continuous automated operation while maintaining high productivity
Solution Approach 2:
The invention combines the plug storage magazine, vacuum feed mechanism, and mounting tool into a single integrated robot tool assembly. This merging of functions eliminates the need for separate storage stations and multiple tools, achieving high automation while maintaining operational efficiency
2Device complexity
If separate storage stations are used for plugs, then plug availability is ensured, but device complexity increases and space requirements grow
Solution Approach 1:
The plug magazine is integrated directly into the robot tool body, combining storage and application functions in one unit. This eliminates separate storage stations, reduces overall system complexity, and ensures reliable plug supply through direct access from the magazine to the mounting position
Solution Approach 2:
The robot tool serves multiple functions: it stores plugs in the integrated magazine, retrieves them via vacuum feed, positions them through robot movement, and mounts them precisely. This multi-functionality eliminates the need for separate dedicated storage stations while ensuring reliable plug supply
3Reliability
If vacuum feed is applied at pushrod end, then plug holding security is improved, but energy consumption increases
Solution Approach 1:
The vacuum feed operates periodically rather than continuously - activating only when the pushrod needs to pick up or secure a plug. This periodic operation maintains reliable plug holding security while significantly reducing overall energy consumption compared to continuous vacuum application
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 robot tool significantly simplifies and automates plug setting, reducing manual labor and enabling quick, precise placement of plugs with minimal robot movement, enhancing production efficiency by allowing plug preloading and individual retrieval from integrated magazines.
Implementation Method 1
A vacuum feed is integrated in the pushrod of the robot tool. The vacuum feed is configured and disposed to apply a vacuum at a free end of the pushrod to hold a plug on the free end of the pushrod.
Data Source
AI summary
A robot tool for setting plugs (18) in industrial production has a robot attachment region (2) for attaching the robot tool (1) to an industrial robot. To further simplify or automate the setting of plugs in industrial production, in particular of motor vehicles, the robot tool (1) has a pushrod (42) that can be moved back and forth and with which a plug (18) can be picked up and advanced.