Seal Position Detection for In-Line Automotive Seal Application
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Solution Overview
Problem
Current methods for detecting the position of seals on vehicle components, such as door seals, are inefficient and prone to errors due to manual processes, limited consideration of component tolerances, and high rework costs, leading to premature wear and increased noise/moisture issues.
Innovation Solution
A device using sensors to continuously measure the position of seals during application, accounting for component tolerances and spatial features, allowing for real-time quality assessment and correction, utilizing a method that can detect seals on both sides and account for complex geometries with triangulation and fan-shaped detection areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual position detection using calipers or templates is used, then measurement can be performed, but time consumption increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical measurement tools (calipers, templates, steel rulers) with an automated optical sensor system. The sensor device automatically detects seal position and compares it against tolerance ranges, eliminating the need for manual measurement operations while maintaining measurement accuracy and significantly increasing inspection speed.
Solution Approach 2:
The system performs self-inspection by automatically detecting seal positions, comparing them against predefined tolerance ranges, and identifying deviations without human intervention. The automated sensor system serves itself to perform quality control functions that previously required manual operator involvement.
2Productivity
If seal position is not detected during application, then manufacturing process continues smoothly, but rework time increases significantly when errors are discovered
Solution Approach 1:
The patent implements preliminary detection of seal position during or immediately after the sealing application process. By detecting position deviations at the moment they occur rather than later during final inspection, the system enables immediate correction before the component proceeds to subsequent manufacturing steps, thereby preventing rework time accumulation.
Solution Approach 2:
The system provides real-time feedback on seal position accuracy by continuously monitoring detected positions against tolerance ranges. This feedback mechanism allows for immediate process adjustment or correction, preventing defective components from advancing to later stages where correction would be more time-consuming.
3Ease of manufacture
If component tolerances are not considered during seal application, then application process is simpler, but seal position accuracy decreases
Solution Approach 1:
The patent incorporates component tolerance parameters directly into the detection and evaluation process. The sensor system detects seal positions and automatically compares them against predefined tolerance ranges that account for component variations. This allows the system to distinguish between acceptable variations due to component tolerances and actual application errors, maintaining manufacturing precision without complicating the application process.
4Productivity
If random sampling inspection is used, then inspection process is faster, but quality assurance reliability decreases
Solution Approach 1:
The patent transitions from intermittent random sampling inspection to continuous automated inspection. The sensor system continuously monitors seal positions throughout the manufacturing process, providing uninterrupted quality assurance. This continuous detection ensures that every component is verified rather than relying on statistical sampling, thereby maintaining high productivity while significantly improving quality assurance reliability.
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 precise and efficient seal application, reducing rework time from 50 minutes to 5 minutes, ensuring proper seal placement and preventing noise/moisture issues, while allowing for immediate correction during the application process.
Implementation Method 1
uses at least one sensor (3), each with a detection range (8), to detect the seal (1) during or after its application and/or the component (2)
Data Source
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AI summary
The problem is solved by features of the main claims. Furthermore, the problem is solved by implementing the features of the independent claim. The invention relates to a method for the automated position detection of a seal (1) with respect to a component (2) or at least part of a component (2) during or after the automated application of a seal (2) wherein the relative position of the seal (1) to the component (2) or to at least part of a component (2) is detected by means of a sensor (3). The invention also relates to a device for carrying out the method for the automated position detection of a peripheral or at least partially peripheral seal (1) with respect to a component (2) or at least part of a component (2) by means of at least one sensor (2) during or after applying the seal (1), wherein the at least one sensor (3) is arranged such that the main detection direction (6) is perpendicular to direction of extension (7) of the seal (1) or the component (2) or at least part of the component (2) or at an angle of up to 45 degrees with respect thereto, and the at least one sensor (3) with a detection range (8) detects the seal (1) and/or the component (2) or at least part of the component (2).