Robotic Production Line for Flexible Mixed-Workpiece Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual and semi-automatic production systems face challenges in achieving accuracy, consistency, and efficiency in tasks like glue dispensing, gasket dispensing, potting, weighing, assembling, and quality control due to operator variability, leading to increased cycle times, material waste, and safety risks, while also struggling with the complexity of handling diverse product types and sizes.
Innovation Solution
A compact robotic production line equipped with articulated robots, process conveyors, robot controllers, and multi-purpose end effectors that can perform a variety of tasks with flexibility and precision, allowing for mixed and small batch production by processing workpieces of different types and sizes with different task combinations in a single production cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual or semi-automatic operations are used for glue dispensing, gasket dispensing, potting, weighing, assembling, and quality control tasks, then operator flexibility and adaptability to different product types are maintained, but accuracy, consistency, and repeatability deteriorate due to operator variability
Solution Approach 1:
The patent replaces manual mechanical operations with automated robotic systems equipped with computer-controlled dispensing mechanisms. Robots perform glue dispensing, gasket dispensing, potting, weighing, assembling, and quality control tasks with precise control over dispensing trajectory and dosing quantity, eliminating operator variability while maintaining adaptability through programmable operations.
Solution Approach 2:
The system changes operational parameters dynamically based on workpiece identification. The controller adjusts dispensing parameters such as trajectory, dosing quantity, and process parameters according to the specific type and size of each workpiece, enabling both high precision and adaptability to different product types.
2Adaptability or versatility
If manual operations are used for repetitive tasks, then adaptability to different product types is maintained, but cycle time and production efficiency worsen due to longer operation times
Solution Approach 1:
Manual operations are replaced with automated robotic systems that perform tasks continuously without fatigue or breaks. The robotic system maintains adaptability to different product types through programmable operations while achieving significantly shorter cycle times and higher production efficiency through automated, continuous operation.
Solution Approach 2:
The robotic system enables continuous operation without the interruptions inherent in manual work cycles. The automated system maintains consistent operation across different product types, eliminating idle time and achieving continuous productive action that improves overall production efficiency.
3Extent of automation
If semi-automatic operations are used for production tasks, then some automation benefits are achieved, but set-up time and adaptation time for workers during product type change worsen
Solution Approach 1:
The system replaces semi-automatic operations with fully automated robotic control. The robotic controller automatically adjusts dispensing parameters, trajectory, and process settings based on workpiece identification, eliminating the need for manual reconfiguration during product type changes and significantly reducing set-up time.
Solution Approach 2:
The system performs preliminary identification and parameter configuration automatically before production begins. The workpiece identification system detects product type and size in advance, and the controller pre-configures all necessary parameters, eliminating manual adaptation time during product type transitions.
4Adaptability or versatility
If manual glue dispensing and potting operations are used to ensure bonding or sealing, then adaptability to different workpiece types is maintained, but material consumption worsens due to excessive glue or potting material
Solution Approach 1:
The robotic dispensing system dynamically adjusts dosing parameters based on workpiece identification. The controller modifies glue and potting material dispensing quantities according to the specific type and size of each workpiece, ensuring optimal material usage that guarantees bonding or sealing while minimizing excessive consumption.
Solution Approach 2:
The system uses workpiece identification feedback to control material dispensing. The identification system detects workpiece characteristics and provides feedback to the controller, which then adjusts dispensing parameters in real-time to achieve precise material application that matches each workpiece's specific requirements.
Data Source
AI summary
A robotic production line assembly has a recipe programmed in order to process a workpiece, an articulated robot having the recipe assigned thereto, an end effector attached to a wrist of the robot, a feeding system that transfers the workpiece, an unloading system that unloads the workpiece from a process conveyor, a plurality of working stations cooperative with the robot, a workpiece identification system, a robotic controller and a system controller. The robotic production line is compact and is capable of flexible and chaotic production.