Robotic Patch Applicator for Vehicle Hole Sealing
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Solution Overview
Problem
Manual application of closure tape to cover holes in vehicle parts is inefficient, ergonomically challenging, and lacks accuracy and repeatability in rapid assembly line environments.
Innovation Solution
A robotic patch applicator system with a movable robotic arm, spring-loaded applicators, vacuum generators, and a camera for automated and precise application of patches, ensuring accurate coverage and verification of hole sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual application of closure tape is used, then ease of operation is maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The applicator head automatically performs multiple functions: the vacuum generator captures the patch, the spring-loaded plunger applies pressure, and the system verifies placement through camera feedback. This self-service mechanism eliminates the need for manual operation while maintaining operational simplicity through automated coordination of these components.
Solution Approach 2:
The robotic arm with interchangeable applicator heads provides multi-functionality, capable of performing different patching operations and accommodating various patch types. The system integrates multiple functions (patch pickup, application, pressure control, and verification) into a single automated platform, improving productivity without proportionally increasing overall system complexity.
2Manufacturing precision
If manual application of closure tape is used, then device complexity is low, but manufacturing precision and repeatability are poor
Solution Approach 1:
The camera system captures images of the applied patch and provides feedback to the control system, which can verify correct placement and trigger alerts or rework procedures if placement is incorrect. This feedback loop ensures high manufacturing precision by continuously monitoring and validating patch application quality.
Solution Approach 2:
The system replaces manual mechanical placement with a robotic arm that uses vision guidance and programmed positioning to achieve precise patch placement. The robotic arm's controlled movement and the applicator head's precise actuation replace human hand movements, providing repeatable and accurate positioning that improves manufacturing precision while managing system complexity through automation.
3Productivity
If automated robotic application is used, then productivity is high, but ease of operation deteriorates
Solution Approach 1:
The automated system performs all operations autonomously: the robotic arm positions the applicator, the vacuum generator captures patches, the spring-loaded plungers apply pressure, and the camera verifies placement. This self-service capability maximizes productivity by eliminating manual intervention while the system manages its own operation through integrated control of all components.
Solution Approach 2:
The camera system provides real-time feedback on patch placement quality, allowing the control system to automatically adjust or trigger rework procedures. This closed-loop feedback ensures high productivity by minimizing errors and rework, while the automation handles the complexity of monitoring and adjustment, reducing the operational burden on operators.
4Manufacturing precision
If automated robotic application is used, then manufacturing precision is high, but device complexity increases
Solution Approach 1:
The robotic arm with vision guidance replaces manual positioning mechanisms, providing precise and repeatable patch placement. The automated control system manages the complexity of coordinating the robotic arm's movements with the applicator head's actuation, achieving high manufacturing precision while centralizing control to manage overall system complexity.
Solution Approach 2:
The camera system provides feedback on patch placement, enabling the control system to verify and adjust positioning as needed. This feedback mechanism ensures high manufacturing precision by continuously monitoring placement accuracy, while the automated verification process manages the complexity of quality control without requiring additional manual inspection steps.
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
The system enables fast, accurate, and repeatable coverage of holes, improving efficiency and reducing ergonomic strain by automating the patch application process while ensuring proper placement verification.
Implementation Method 1
Each vacuum generator connected to the respective spring loaded applicator at the vacuum source inlet on the plunger. Each vacuum generator creates a vacuum pressure that is applied to the vacuum source inlet
Data Source
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AI summary
A patch applicator arrangement (100) for securing a patch (102) over a hole (104a, 104b, 104c) in a vehicle part (106). The arrangement (100) provides a robotic arm having at least one movable joint that allows the robotic arm (108) to move about several axes. At the end of the robotic arm (108) is a spindle (118) that has several spring loaded patch applicators (128a, 128b, 128c, 128d) connected. The arrangement (100) also includes a patch dispensing apparatus (202) that the arrangements uses along with the robotic arm (108) to place patches (102) over holes (104a, 104b, 104c) in a vehicle part (106). The arrangement (100) also provides a verification method to make sure the holes (104a, 104b, 104c) have been properly covered.