Robotic Fastening Cell Layout for Large Workpiece Assembly
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Solution Overview
Problem
Traditional manufacturing processes for large structural workpieces are inefficient due to the need for large, floor-mounted machine tools that occupy excessive space, are costly, and require manual processes, leading to bottlenecks in the manufacturing process.
Innovation Solution
A system and method for assembly manufacturing that utilizes a material-handling system and multiple operation cells, including staging, tacking, fastening, and extraction cells, with robotic fastening machines capable of six degrees of freedom movement to automate the assembly process, reducing the need for manual labor and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional floor-mounted machine tools are used for assembling large workpieces, then the assembly operation can be performed, but excessive floor space is occupied and the system cannot be reconfigured between different workpiece types
Solution Approach 1:
The assembly system is divided into multiple operational cells (staging cell, tacking cell, fastening cell, extraction cell) that can be independently configured. Each cell contains specialized equipment for specific assembly tasks, allowing the system to be reconfigured by repositioning or retooling individual cells rather than moving entire monument machines.
Solution Approach 2:
The patent employs movable and reconfigurable equipment within operational cells, including robotic assemblies with multiple degrees of freedom and adjustable positioning systems. This dynamic capability allows the same physical space to accommodate different workpiece types and assembly configurations without requiring permanent floor-mounted installations.
2Productivity
If large workpieces are moved by crane in traditional manufacturing, then material handling can be performed, but the process is time-consuming and creates bottlenecks
Solution Approach 1:
A robotic assembly with multiple degrees of freedom acts as an intermediary between workpiece storage and assembly positions. The robotic assembly automatically transfers workpieces between operational cells and positions them for assembly operations, eliminating the need for manual crane operations and reducing material handling time significantly.
Solution Approach 2:
The system enables continuous assembly operations by maintaining workpieces in a ready state within operational cells. Multiple robotic assemblies can work simultaneously on different workpieces or different sections of large workpieces, eliminating idle time and maintaining continuous productive action throughout the assembly process.
3Productivity
If manual fastening processes are used in traditional assembly, then the operation can be performed, but labor costs are high and manual intervention creates bottlenecks
Solution Approach 1:
The fastening system is designed to be self-servicing through automated robotic assemblies that perform drilling, countersinking, and fastener installation operations autonomously. The robotic assemblies include integrated tooling and control systems that automatically position fasteners, drill holes, and install fastening elements without manual intervention, significantly increasing assembly speed and reducing labor requirements.
4Ease of operation
If monument machines with multiple custom axes are used, then all surfaces of workpieces can be reached, but the device complexity and cost increase significantly
Solution Approach 1:
The robotic assemblies are designed with multi-functionality, capable of performing multiple assembly operations (drilling, countersinking, fastener installation, positioning) through a single integrated system. The robotic assemblies can access all workpiece surfaces by coordinating movement across multiple operational cells rather than requiring each machine to have multiple custom axes for single-point access.
Data Source
AI summary
A method for assembly manufacturing including positioning a workpiece in an assembly position within an operational cell, positioning a fastening machine relative to the workpiece, wherein the fastening machine includes a robot frame comprising a throat, an assembly end effector coupled to the frame about the throat, and a plurality of linear actuators coupled to the frame, moving, by the plurality of linear actuators, the fastening machine about at least one of six degrees of freedom to receive at least a portion of the workpiece within the throat and position the assembly end effector relative to the workpiece, and performing, by the fastening machine, a fastening operation on the workpiece.