Robot Punching Cell With Ultrasonic Tooling for Flexible Bumper Holes
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Solution Overview
Problem
Existing punching cells for vehicle bumpers are costly, complex, and inflexible, requiring custom designs for specific models, leading to high manufacturing costs and inefficient use of space due to the need for multiple cells to accommodate varying bumper configurations and sporadic usage.
Innovation Solution
A punching cell comprising an industrial robot with a detachable tooling system, including an ultrasonic puncher tool and a support fixture with sensors, allowing for precise and adaptable hole punching in various workpiece designs without the need for custom cells, enabling quick tool changes and reduced material deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom designed punching cells with multiple punchers and hydraulic systems are used, then punching accuracy and productivity are improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent replaces the traditional mechanical punching system with hydraulic actuators with an ultrasonic punching system. The ultrasonic puncher uses high-frequency vibrations (20-100 kHz) to create holes through material fatigue and micro-fractures, eliminating the need for complex hydraulic pressure systems while maintaining punching accuracy. This substitution reduces device complexity while preserving manufacturing precision.
Solution Approach 2:
The patent employs an industrial robot with programmable control that can be reconfigured for different punching patterns, positions, and orientations through software programming. The robot wrist can be detached and replaced with different toolings to accommodate various workpiece types. This universal approach allows a single cell to handle multiple bumper models and hole configurations, reducing the need for multiple custom-designed cells while maintaining high precision for each specific application.
2Adaptability or versatility
If multiple custom punching cells are provided for different bumper models, then adaptability to various workpiece designs is improved, but space requirements and investment costs increase
Solution Approach 1:
The patent creates a universal punching cell using an industrial robot that can be programmed to handle different bumper models and hole configurations. The robot system with detachable wrists and programmable control paths can adapt to various workpiece geometries and punching requirements, eliminating the need for multiple dedicated cells for different bumper models while reducing space requirements.
Solution Approach 2:
The patent implements dynamic adaptability through programmable robot control systems that can be reconfigured via software for different punching patterns, positions, and orientations. The detachable wrist mechanism allows physical reconfiguration for different tooling requirements. This dynamic flexibility enables a single cell to serve multiple bumper models without requiring permanent dedicated configurations, thereby reducing space and investment needs.
3Force
If traditional mechanical punchers are used, then punching force is sufficient, but material deformation and workpiece damage increase
Solution Approach 1:
The patent replaces traditional high-force mechanical punching with an ultrasonic vibration-based punching system. The ultrasonic puncher generates high-frequency vibrations (20-100 kHz) that progressively fatigue and fracture the material through micro-scale impacts, achieving hole formation with significantly lower peak forces. This substitution eliminates the harmful effects of high mechanical pressure while maintaining sufficient punching capability, reducing material deformation, cracks, and workpiece damage.
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 provides a cost-effective, flexible, and accurate punching system that can adapt to different workpiece designs, reducing manufacturing costs and space requirements while ensuring precise and clean hole formation with minimal material deformation.
Implementation Method 1
An ultrasonic puncher may vibrate between 10 KHz-70 KHz, and it may penetrate the workpiece material (which may usually be, in the case of vehicle bumpers, a plastic material), without the need of applying high pressure on the tool.
Data Source
AI summary
The present disclosure relates to a punching cell for punching holes in workpieces, the cell comprising an industrial robot comprising a base, a wrist and at least four robot axes between the base and the wrist; a tooling comprising a frame to be detachably attached/mounted to the wrist axis of the industrial robot, an ultrasonic puncher tool mounted on the frame, a die mounted on the frame and aligned with the puncher, and a servomotor configured to drive the puncher tool towards the die; the cell further comprising a support fixture to position the workpiece to be punched, and a control unit to control the operation of the industrial robot to punch a hole in the workpiece.