Rotor Assembly Cell With Mobile Multi-Axis Robot for Flexible Variants
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of electric motor rotors with varying sizes and magnet configurations poses challenges for dynamic and flexible manufacturing, leading to complex assembly lines that impede efficient production across different platforms, such as in the automotive industry.
Innovation Solution
A rotor assembly system comprising a central robotic system and multi-axial auxiliary robotic systems, which include a conveyor platform and multi-axial robots, coordinated through a control system to perform various manufacturing processes such as core stack assembly and mold-pressing, enabling efficient assembly of rotor components across different sizes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rigid assembly lines are used to accommodate varying rotor sizes and magnet configurations, then manufacturing flexibility is improved, but device complexity and production efficiency deteriorate
Solution Approach 1:
The robotic assembly system is designed with multi-functional capabilities to handle various rotor sizes and magnet configurations using the same equipment. The system can perform multiple assembly operations (core stacking, magnet insertion, winding) with a single robotic platform, eliminating the need for dedicated assembly lines for each rotor type and thereby reducing overall device complexity while maintaining manufacturing flexibility.
Solution Approach 2:
The assembly line incorporates dynamic reconfigurable elements that allow the system to adapt its configuration based on the specific rotor being assembled. This includes programmable robotic movements, adjustable positioning systems, and flexible tooling that can be reconfigured through software control rather than physical reassembly, reducing complexity while enabling versatility across different platforms.
2Adaptability or versatility
If traditional rigid assembly lines are used to accommodate varying rotor sizes and magnet configurations, then manufacturing flexibility is improved, but productivity deteriorates
Solution Approach 1:
The robotic assembly system operates continuously without the downtime associated with reconfiguring traditional assembly lines for different rotor types. The automated robotic platform can seamlessly transition between different assembly tasks through programmable control, maintaining continuous production flow and eliminating idle time, thereby improving productivity while accommodating varying rotor specifications.
Solution Approach 2:
The system utilizes programmable parameters and software-controlled adjustments to adapt to different rotor sizes and magnet configurations. Rather than physically reconfiguring the assembly line, the system changes its operational parameters through software, allowing rapid adaptation between product variants without interrupting production, thus maintaining high productivity across different platforms.
3Adaptability or versatility
If multiple specialized assembly lines are created for different rotor platforms, then adaptability is improved, but device complexity and loss of time increase
Solution Approach 1:
A single robotic assembly system is designed to perform all assembly operations for multiple rotor platforms, eliminating the need for multiple specialized assembly lines. The system achieves platform-specific optimization through programmable control and configurable tooling rather than dedicated hardware, thereby eliminating reconfiguration time while maintaining adaptability across different rotor types.
Data Source
AI summary
A rotor assembly system includes a central robotic system, which itself includes a conveyor platform and a multi-axial central robot arranged on the conveyor platform. The multi-axial central robot is configured to perform a set of manufacturing processes from among a plurality of rotor manufacturing processes related to at least one rotor component. The conveyor platform is operable to move the multi-axial central robot within the manufacturing cell to transfer the at least one rotor component between one or more rotor manufacturing processes from among the plurality of rotor manufacturing processes.