Seat Frame Assembling Unit with Universal Holding Mechanism
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Solution Overview
Problem
Industrial robots face challenges in efficiently assembling vehicle seat components with different shapes, leading to displacement issues and decreased manufacturing efficiency, as well as compromised dimensional precision during welding due to the need for frequent changes in holding portions and interference between components during conveyance.
Innovation Solution
A seat frame assembling unit comprising a first device for arranging outer and inner frame components and a second device for installing them side by side and between each other, with a holding portion that can adapt to different shapes and sizes using magnetic and clamping mechanisms to prevent interference and ensure precise assembly and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are conveyed in the same conveyor pathway, then manufacturing efficiency is improved, but components may not be stably installed in place due to varying holding portions
Solution Approach 1:
The robot is designed with a universal holding portion that can accommodate multiple types of components (outer frame components and inner frame components) through a standardized interface, allowing the same robot to handle different component shapes without requiring separate robots or complex reconfiguration
2Manufacturing precision
If components are aligned before being held by the robot, then stable installation is achieved, but manufacturing efficiency decreases
Solution Approach 1:
Components are pre-positioned on conveyors at predetermined locations before the robot picks them up. The conveyors are designed to deliver components in the correct orientation and position, eliminating the need for additional alignment operations by the robot and thereby maintaining high manufacturing efficiency while ensuring precise installation
3Adaptability or versatility
If a setting robot including a plurality of kinds of holding portions is used, then different shapes of components can be held, but manufacturing efficiency decreases due to frequent changes in holding portions
Solution Approach 1:
Instead of equipping the robot with multiple specialized holding portions for different component shapes, a single universal holding portion is designed that can accommodate various component types through standardized interfaces, eliminating the need for frequent changes and maintaining high manufacturing efficiency
4Productivity
If components are installed in a state where installation position displacement has occurred, then assembly continues, but dimensional precision of welded portions is deteriorated
Solution Approach 1:
The system incorporates sensors and detection mechanisms that monitor the installation position of components in real-time. When displacement is detected, the system provides feedback to adjust the positioning or alert operators, ensuring that welding operations are performed only when components are correctly positioned, thereby maintaining high dimensional precision
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
The solution enhances manufacturing efficiency by preventing component interference and ensuring precise assembly, allowing for stable welding of vehicle seat frames with improved dimensional precision and the ability to hold multiple component types with the same holding portion.
Implementation Method 1
using magnetic and clamping mechanisms to prevent interference and ensure precise assembly
Implementation Method 2
using magnetic and clamping mechanisms to prevent interference and ensure precise assembly
Data Source
AI summary
A seat frame assembling unit includes: a setting device and a setting robot. The setting device is driven in a state where side frames, a connecting frame, a pan frame, a member frame and an upper frame are arranged. The setting robot installs the side frames side by side and subsequently installs the connecting frame, the pan frame, the member frame and the upper frame between the side frames. The setting device moves the side frames to positions in which the side frames are to be assembled with the connecting frame, the pan frame, the member frame and the upper frame.