Robotic Assembly Motion Compensation for Moving Line Alignment
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Solution Overview
Problem
The challenge in automotive assembly is that movement irregularities and vibrations during the final trim and assembly stage, caused by continuously moving vehicles, hinder accurate part alignment and repeatability, making traditional teach and repeat position-based robot motion control ineffective.
Innovation Solution
A robotic system that uses an inertial measurement unit (IMU) sensor to measure motion data, compensating the movement of the robot base and arms to align and assemble parts accurately, even when both the assembly base and robot base are moving, by adjusting the robot's motion based on the measured data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional teach and repeat position based robot motion control is used, then the robot control system is simple to operate, but the assembly repeatability deteriorates due to movement irregularities and vibrations on moving assembly lines
Solution Approach 1:
The system employs IMU sensors to continuously measure motion data from the robot base and assembly base, feeding this information back to the robot controller which then compensates for detected movements and vibrations in real-time, thereby maintaining assembly repeatability despite the moving platform
Solution Approach 2:
The patent replaces traditional mechanical position-based control with a sensor-based measurement and compensation system using IMU sensors to detect motion irregularities and algorithmically compensate for them, substituting mechanical rigidity with electronic sensing and computational correction
2Productivity
If the assembly base moves continuously to improve productivity, then the production output increases, but the manufacturing precision deteriorates due to vibrations and position changes affecting part alignment
Solution Approach 1:
The system transitions from static position control to dynamic motion compensation, where the robot controller continuously adjusts robot base and arm positions based on real-time IMU sensor data to counteract vibrations and movement irregularities, enabling precise assembly while the assembly base moves continuously
Solution Approach 2:
The IMU sensors act as intermediary devices between the moving assembly base and the robot control system, measuring motion data and enabling the controller to compensate for movements, thereby mediating the conflict between continuous motion and precise alignment
3Manufacturing precision
If the robot base is made stationary to improve positioning accuracy, then the part alignment precision improves, but the adaptability deteriorates as the assembly line cannot accommodate moving vehicles
Solution Approach 1:
The robot base is designed to be dynamically movable rather than statically fixed, with the robot controller using IMU sensor data to compensate for base movements, allowing the system to adapt to moving vehicles while maintaining positioning accuracy through real-time motion correction
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 ensures consistent and accurate assembly by compensating for vibrations and position changes, enhancing the repeatability and precision of the assembly process on moving assembly lines.
Implementation Method 1
Motion data is measured by an inertial measurement unit (IMU) sensor
Implementation Method 2
Movement of the robot base or moveable arm is then compensated based on the measured motion to align the first and second parts with each other
Data Source
AI summary
A robotic system is provided for assembling parts together. In the assembly process, both parts are moving separately with one part moving on an assembly base and another part moving on a moveable arm of a robot base. Motion data is measured by an inertial measurement unit (IMU) sensor. Movement of the robot base or moveable arm is then compensated based on the measured motion to align the first and second parts with each other and assemble the parts together.