Robotic Fastening System with Proximity Sensors for Mesh-to-Frame Assembly
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Solution Overview
Problem
Current methods for fastening mesh structures to frame structures in automated manufacturing are inefficient, leading to reduced operational speed, accuracy, and increased rework, which impacts the quality and productivity of manufactured items like furniture and bedding.
Innovation Solution
A mesh-fastening system comprising a materials receiving zone and a working zone with a robotic fastening system, a conveyor, and retractable boundary structure, where a fastening tool autonomously secures the mesh subassembly to the frame subassembly at multiple sites using proximity sensors and actuators to adjust its movement and deployment of fasteners based on detection criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated fastening systems are implemented, then productivity and operational speed are improved, but device complexity increases
Solution Approach 1:
The automated fastening system is divided into distinct functional modules: a robotic system for positioning and deploying fasteners, a conveyor system for transporting frame subassemblies, and a control system for coordination. This segmentation allows each module to be optimized independently while working together to achieve high productivity through automated operation.
2Manufacturing precision
If robotic fastening systems with sensors are used, then manufacturing precision and accuracy are improved, but device complexity increases
Solution Approach 1:
Proximity sensors are integrated into the robotic fastening system to detect the position of frame subassemblies and mesh structures. The sensor data provides real-time feedback to the control system, which adjusts the robotic positioning and fastener deployment to ensure precise alignment and accurate fastening at designated sites, thereby improving manufacturing precision.
3Productivity
If automated conveyor systems are implemented, then operational continuity and productivity are improved, but device complexity increases
Solution Approach 1:
The conveyor system is designed to continuously transport frame subassemblies through the fastening process without interruption. Multiple conveyor zones work in sequence, with the first conveyor advancing subassemblies to the working zone and the second conveyor removing completed assemblies, ensuring uninterrupted production flow and maximizing operational continuity.
Data Source
AI summary
A robotic fastening system is operative to autonomously fasten a first subassembly to a second subassembly at a plurality of fastening sites. A set of actuators arranged to move a fastening tool to the various ones of the fastening sites. A proximity sensor is fixed proximate the fastening tool and movable with the fastening tool. A controller circuit is operative to individually control each of the set of actuators and to read an output of the proximity sensor, where the controller circuit is programmed to execute a fastening-tool movement routine to move the fastening tool to a first one of the fastening sites.