Sealant-Coated Connector Assembly Tool for One-Axis Joining
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Solution Overview
Problem
Automated assembly processes in manufacturing lack optimization in connecting components with sealants, leading to potential quality issues and inefficiencies in reproducibility and quality control.
Innovation Solution
A sealant application station and assembly tool system that applies sealant to connectors using a gripper and drive unit for rotational application, ensuring uniform coverage and integration with an assembly tool for precise component connection, allowing for improved quality and efficiency in connecting components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual assembly processes are replaced by automated assembly processes, then quality and reproducibility are improved, but device complexity and cost increase
Solution Approach 1:
The automated assembly system is designed to perform multiple functions: drilling holes, inserting connectors, and applying sealant, all through a single integrated robot arm and end effector. This multi-functionality reduces the need for separate manual operations while maintaining quality and reproducibility.
Solution Approach 2:
A sealant application station is introduced as an intermediary component that applies sealant to connectors before they are inserted into the workpiece. This intermediary step ensures proper sealing without requiring complex manual coordination, thereby improving reliability while managing device complexity through modular design.
2Productivity
If automated assembly processes are used, then throughput time is reduced, but manufacturing precision may be compromised due to lack of optimization
Solution Approach 1:
The sealant is applied to the connector in advance, before the connector is inserted into the workpiece. This preliminary action ensures that the sealant is properly positioned and distributed, maintaining manufacturing precision while allowing the automated process to proceed efficiently without waiting for sealant application during the insertion step.
Solution Approach 2:
The end effector is designed with dynamic capabilities, including rotation of the gripper about a rotation axis, allowing the sealant application unit to access different surfaces of the connector. This dynamic adjustment ensures uniform sealant coverage and maintains precision requirements while keeping the automated process efficient.
3Reliability
If sealant is applied during automated assembly, then sealing quality improves, but device complexity increases
Solution Approach 1:
The sealant application unit is merged with the end effector, combining the sealing function with the existing connector insertion mechanism. This integration ensures that sealant application is performed automatically as part of the assembly process, improving sealing quality without requiring a completely separate complex system.
Solution Approach 2:
The automated system performs sealant application autonomously through the integrated sealant application unit, eliminating the need for manual sealant application. The system serves itself by automatically positioning and applying sealant to connectors during the assembly process, thereby improving sealing quality while managing complexity through automation.
4Manufacturing precision
If gripper rotation is used for sealant application, then uniform sealant coverage is achieved, but processing time increases
Solution Approach 1:
The gripper rotation and sealant application are performed continuously in a single automated motion sequence, rather than as separate discrete steps. The robot arm continuously rotates the gripper while the sealant application unit applies sealant, ensuring uniform coverage without interrupting the overall assembly flow, thereby minimizing processing time loss.
Data Source
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AI summary
An assembly system (1) comprising a sealant application station (200) and an assembly tool (300) is described. The assembly system serves to join two or more components together. The sealant application station applies a sealant to a connector. The sealant application station is arranged in a feed system for the connectors. The connectors coated with sealant are then transferred to the assembly tool (300). The assembly tool (300) contains a drill spindle (311) in which a connector (215) and a drill bit (315) can be axially aligned so that the drill spindle (311) can, with a linear movement along a machining axis (319), both drill a hole into the components to be joined and position the connector (215) in the drilled hole.For these work steps, the drill spindle only moves along the machining axis (319), so that a linear drive can be used for these work steps.