Robotic 3D Assembly Cells for Reconfigurable Transport Manufacturing
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Solution Overview
Problem
Traditional manufacturing facilities face inflexibility and high costs due to fixed infrastructure and the need for extensive tooling, limiting their ability to produce a variety of transport structures efficiently.
Innovation Solution
The development of flexible and modular robotic manufacturing systems that include variable robotic assembly stations and automated constructors capable of performing multiple vehicle manufacturing processes with automated reconfiguration, combined with the use of 3-D printing for customized parts and connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fixed robotic assembly systems are used on assembly lines, then efficient production at volume is achieved, but the manufacturing system becomes inflexible and can only produce a handful of models with expensive tooling
Solution Approach 1:
The patent implements dynamic reconfigurable manufacturing systems where robotic assembly systems can be reconfigured between different product models without permanent fixed infrastructure. The system transitions from static fixed tooling to dynamic reconfigurable tooling that can be adjusted based on production needs, allowing the same facility to efficiently produce multiple models by changing software configurations and modular tooling attachments rather than physical retooling
Solution Approach 2:
The patent creates universal robotic assembly systems that can perform multiple functions across different product models. Instead of dedicated assembly lines for each model, a single multi-functional robotic system with reconfigurable end-effectors and modular tooling can assemble various transport structure models, eliminating the need for separate specialized facilities for each product variant
2Productivity
If factory infrastructure is permanently configured to produce specific models, then initial production efficiency is improved, but the factory becomes underutilized when producing underperforming models due to amortization costs
Solution Approach 1:
The patent implements preliminary digital modeling and virtual commissioning of reconfigurable tooling systems before physical deployment. Software configurations and robotic paths are pre-programmed for different product models, allowing rapid switching between models by loading different digital instructions rather than performing extensive physical retooling, significantly reducing retooling time and enabling quick response to changing market demands
3Ease of manufacture
If additive manufacturing is conducted at a dedicated location away from the assembly line, then 3-D printing capabilities are established, but the factory has little flexibility to modify AM capabilities to accommodate changes in circumstances
Solution Approach 1:
The patent merges additive manufacturing capabilities directly with robotic assembly systems by integrating 3-D printers into the robotic workcells. The robotic system can switch between manipulating pre-manufactured parts and on-demand 3-D printing components at the assembly location, creating a hybrid system that combines subtractive and additive manufacturing in a single reconfigurable platform, enabling immediate production of custom parts without separate dedicated facilities
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 enables efficient and flexible production of various transport structures without the need for significant retooling, reducing costs and improving factory utilization by allowing for real-time reconfiguration of manufacturing processes.
Implementation Method 1
a first automated constructor including a 3-D printer 3-D prints a component or a portion
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning.