Roller Hemming Force Feedback for Consistent Flange Quality
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Solution Overview
Problem
The roller hemming process in the automotive industry requires time-consuming and costly optimization to achieve desired hemming quality, mainly due to dependencies on material, flange geometry, and robot-specific uncertainties, necessitating manual adjustments and expertise.
Innovation Solution
A method for automated optimization of the roller hemming process using a control unit to adjust hemming forces and geometry, with self-learning algorithms and optical sensors to detect and correct the hemming path, allowing for precise control of the hemming roller and flange formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual optimization of robot path with offset correction is used, then hemming quality can be improved, but time consumption and cost increase significantly
Solution Approach 1:
The patent implements a feedback mechanism where the actual hemming force is measured during the process and fed back to the control unit. The control unit automatically adjusts the robot path offset based on this feedback to achieve target hemming quality, eliminating the need for manual trial-and-error optimization loops.
Solution Approach 2:
The system performs self-optimization by automatically adjusting its own parameters (robot path offset) based on measured hemming forces. The control unit autonomously corrects the hemming process without requiring manual intervention or expertise, making the system self-sufficient in achieving quality optimization.
2Manufacturing precision
If manual optimization with expert intervention is performed, then hemming quality can be optimized, but process complexity and cost increase
Solution Approach 1:
The patent replaces manual expert intervention (mechanical/human system) with an automated control system that uses force measurement and algorithmic processing. The control unit automatically translates force measurements into path corrections, substituting human expertise with an automated decision-making system.
Solution Approach 2:
The control unit acts as an intermediary between the force measurement and the robot path adjustment. It processes the measured hemming forces and automatically generates the necessary offset corrections, serving as a mediator that eliminates the need for direct human intervention while maintaining optimization capability.
3Adaptability or versatility
If robot-guided roller hemming is used for flexibility, then adaptability to different components is improved, but force control precision deteriorates due to robot uncertainties
Solution Approach 1:
The patent introduces force feedback measurement that directly monitors the actual hemming forces applied by the robot-guided roller. This feedback enables automatic compensation for robot-specific uncertainties and elasticities, maintaining force control precision despite the flexibility benefits of robot guidance.
Solution Approach 2:
The system dynamically changes the robot path parameters (offset values) based on measured force deviations. By automatically adjusting these parameters in response to actual hemming conditions, the system compensates for robot uncertainties while maintaining the flexibility of robot-guided operation.
Data Source
AI summary
A method for setting a roller hemming process for hemming a plurality of identical component arrangements comprises guiding a hemming roller arranged on a robot by the robot in accordance with a predetermined hemming path for forming a hemming flange of a component of a component arrangement, wherein a hemming process force acting on the hemming roller by the robot during forming is detected, wherein the hemming process force can be changed by a corresponding control of the robot, and a target hemming quality to be achieved is predetermined. The robot is controlled to achieve the target hemming quality, taking into account the detected hemming process force and an actual geometry of a formed hemming flange resulting from the forming process.