Robot Roll Folding Control Using Force Feedback for Flange Quality
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Solution Overview
Problem
Existing roll folding processes in the automotive industry require manual adjustments and costly optimization procedures to achieve desired fold quality, especially in production lines with high variability, due to factors like material properties, flange geometry, and robot-specific stiffness.
Innovation Solution
An automated procedure for optimizing the roll folding process using a robot-controlled folding device, which includes a control unit, measurement technology, and self-learning algorithms to detect actual folding processes, adjust folding forces, and record actual geometries to achieve target fold quality specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustments and optimization procedures are used to achieve desired fold quality, then folding quality can be improved, but time consumption and costs increase significantly
Solution Approach 1:
The system implements a closed-loop feedback mechanism where the actual folding process force is continuously measured during the folding operation. The control unit compares this measured force with a target folding process force and automatically adjusts the robot's positioning and folding forces in real-time to minimize deviations, eliminating the need for time-consuming manual optimization loops while maintaining high folding quality
Solution Approach 2:
The patent replaces manual mechanical adjustment procedures with an automated control system that uses force measurement data to automatically adjust folding parameters. The control unit processes force measurements and autonomously modifies robot positioning and folding forces, substituting human expertise and manual trial-and-error with automated computational control
2Manufacturing precision
If manual adjustments are performed by specialists to optimize robot path offset, then folding quality can be improved, but process complexity and expertise requirements increase
Solution Approach 1:
The system performs self-optimization by automatically measuring actual folding forces and adjusting its own control parameters without requiring external specialist intervention. The control unit autonomously processes force measurement data and modifies robot positioning and folding forces, enabling the system to self-correct and self-optimize the folding process
Solution Approach 2:
The patent dynamically changes control parameters based on measured force data. The control unit adjusts robot positioning coordinates and folding forces in real-time based on deviations from target values, automatically adapting process parameters to achieve optimal folding quality without manual intervention
3Manufacturing precision
If complex optimization loops are performed to correct force and flange contact points, then folding quality can be improved, but productivity decreases due to repeated adjustments
Solution Approach 1:
The system implements continuous force measurement and adjustment during the folding process rather than performing discrete optimization loops between production cycles. The control unit continuously monitors actual folding forces and makes real-time adjustments, eliminating idle optimization time and maintaining continuous productive operation while ensuring consistent folding quality
Solution Approach 2:
Real-time feedback from force measurements enables immediate corrective action during the folding process, preventing quality deviations rather than requiring post-processing optimization loops. This continuous feedback-control mechanism eliminates repeated adjustment cycles and maintains steady-state productive operation
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
This solution enables automated optimization and maintenance of fold quality, reducing the need for manual adjustments and costly optimization processes, thereby improving efficiency and cost-effectiveness in series production.
Implementation Method 1
an actual folding process force acting on the folding roller by the robot during the forming process is detected
Data Source
Figure 1
Figure 2~3a
Figure 3b~3c
AI summary
The present invention relates to a method for setting up a roll folding process for folding a plurality of identical component assemblies (50), wherein a folding roller (1) arranged on a robot is guided by the robot according to a predetermined folding path (4) for forming a folding flange of a component of a component assembly (50), wherein a folding process force (10) acting on the folding roller (1) during the forming process is detected, the folding process force (10) can be changed by corresponding control of the robot, and a target folding quality (20) to be achieved is specified. The robot is controlled to achieve the target folding quality (20) taking into account the detected folding process force (10) and the actual geometry of a formed folding flange resulting from the forming process.Furthermore, the invention relates to a roll folding method which is set up using a method described above, and to a roll folding device which is designed to carry out the method.