Robotic Assembly of Interlocking Segments With Vision Verification
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Solution Overview
Problem
The assembly of modular interlocked components, such as link-style conveyor belts, requires significant human intervention, leading to inefficiencies, errors, and increased costs due to the need for manual selection and assembly of varying component types and frequent hinge interlocks.
Innovation Solution
A computer-controlled robotic system for selecting and assembling interchangeable component parts, utilizing an assembly table, robotic manipulator arms, machine vision for verification, traction grippers, and a fastener-insertion device, to automate the assembly process and reduce manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly of link segments is used, then flexibility in handling various component types is maintained, but productivity is low and labor costs are high
Solution Approach 1:
The system uses machine vision to automatically identify and verify link segment types, and programmable logic to automatically determine the correct assembly sequence, eliminating the need for manual identification and decision-making while maintaining adaptability to different component types
Solution Approach 2:
Manual mechanical handling and visual inspection are replaced with an automated robotic system that uses machine vision for identification and programmable logic for sequence determination, significantly increasing assembly speed while maintaining flexibility
2Manufacturing precision
If manual selection and assembly of link segments is performed, then adaptability to different component types is maintained, but manufacturing precision is insufficient
Solution Approach 1:
Manual visual inspection and positioning are replaced with machine vision systems and programmable logic that automatically verify component identities and control assembly precision, ensuring consistent millimeter-level tolerances while managing system complexity through automation
Solution Approach 2:
The machine vision system continuously monitors and verifies the identity and position of link segments during assembly, providing real-time feedback to the control system to ensure precision and correct any deviations before they affect the final product
3Productivity
If automated assembly is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The robotic manipulator is designed with multiple degrees of freedom and interchangeable end effectors to handle various link segment types and assembly operations, allowing a single automated system to perform multiple functions and reducing the need for multiple specialized devices
Solution Approach 2:
A programmable logic controller serves as an intermediary between the machine vision system, robotic manipulator, and assembly operations, coordinating all automated functions through software that manages the complexity while maintaining high productivity
Data Source
AI summary
A device and method for automated computer controlled manufacture of assemblies composed of discrete linked product segments includes reciprocating product segment grippers having surface features engageable with the product segments, at least one robotic manipulating device whereby the product segments may be engaged by the product segment grippers.