Roof Gripping Tool Reference Model for Laser Braze Assembly

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Solution Overview

Problem

Current vehicle body assembly processes face delays in achieving high-quality brazing due to the sequential convergence of quality criteria, particularly the geometric conformity of the vehicle frame being determined late, which hinders the development of the roof lifting/removal tool, leading to inefficiencies and delayed fit quality.

Innovation Solution

A device comprising a load-bearing structure with reference elements replicating the vehicle body geometry, allowing independent development and control of the gripping/placing tool, ensuring precise alignment and positioning of parts before frame assembly, using machined cast iron blocks for reference elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a tool is gripped manually by an operator during assembly operations, then the tool can be positioned and adjusted, but contamination of the assembly zone and impaired laser beam quality occur due to skin outgassing and reflections

Engineering Contradiction:

Improvemanual tool positioningVSAvoidcontamination and laser interference

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual mechanical gripping with an automated robotic system. The tool is gripped by a robot gripper that can be precisely positioned and controlled, eliminating the need for human operators to physically handle tools in the assembly zone. This substitution resolves the contradiction by maintaining ease of operation through automation while eliminating harmful factors associated with human presence.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary robotic system between the operator and the tool. Instead of direct manual handling, the robot acts as a mediator that transfers and positions the tool, thereby protecting the assembly zone from contamination and laser interference while still enabling precise tool positioning and adjustment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If tools and parts are handled manually in the assembly zone, then flexibility and adaptability are maintained, but the risk of contamination and safety hazards increases

Engineering Contradiction:

Improvemanual handling flexibilityVSAvoidassembly zone cleanliness

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Manual handling is replaced with automated robotic manipulation. The robotic system maintains flexibility and adaptability through programmable control and programmable motion paths, while eliminating the reliability issues associated with manual handling such as contamination and safety hazards.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic system is equipped with sensors and control systems that enable it to autonomously adjust and adapt to different tools and parts. The system can independently position, orient, and manipulate components without human intervention, maintaining versatility while ensuring assembly zone cleanliness and safety.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If operators work close to the assembly zone for tool adjustment, then precise positioning is achieved, but exposure to harmful laser radiation and contamination occurs

Engineering Contradiction:

Improvetool positioning accuracyVSAvoidlaser radiation exposure

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

Manual tool adjustment is replaced with automated robotic positioning. The robot can achieve precise tool positioning through programmable control systems and high-precision actuators, eliminating the need for operators to work close to the assembly zone and thereby protecting them from laser radiation exposure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses sensors and vision systems to create digital representations of the assembly zone and tool positions. This allows for precise positioning and monitoring without requiring physical presence of operators in the hazardous environment. The digital model enables accurate control while keeping humans at a safe distance.

Inventive Principle:

Principle #26Copying

Data Source

PatentEP3233394B1Device for developing and controlling a tool for gripping/depositing a part to be assembled especially during a method of assembly by laser braze-welding between two parts

Publication Date: 2022.09.14 PSA AUTOMOBILES SA

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AI summary

The invention relates to a device for developing and controlling a tool for gripping/depositing a part to be assembled on a vehicle body, characterised in that it comprises a carrier structure (2) on which elements (31, 32) are positioned, which reproduce the geometry of the part of the vehicle body that is to receive the part to be assembled, said elements (31, 32) forming a geometrical reference model corresponding to the theoretical digital definition of the part of the vehicle body on which the part to be assembled is to be deposited by the gripping/depositing tool (7).