Servo Press Calibration for Vehicle Payload Sensors
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Solution Overview
Problem
In manufacturing environments, accurately calibrating vehicle payload systems is challenging due to variations in vehicle geometries and payloads, which can lead to damage and inaccuracies in payload calibration routines.
Innovation Solution
A method and system utilizing a robot and servo press to apply a known weight to reference identifiers on a vehicle, with payload sensors providing data for calibration, and a controller selecting the calibration routine based on the vehicle's wheelbase and payload limits, ensuring accurate calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a payload calibration routine is performed on vehicles with varying geometries and payloads, then the vehicle load capacity can be determined, but the accuracy of calibration deteriorates and damage to vehicle components may occur
Solution Approach 1:
The system performs preliminary identification of vehicle type and selection of appropriate calibration routine before actual calibration. The controller identifies vehicle characteristics and pre-selects the specific calibration protocol, ensuring the correct procedure is applied before measurement begins, which resolves the contradiction by preparing the system in advance for vehicle variations.
Solution Approach 2:
The system dynamically adapts the calibration routine based on real-time vehicle identification. The controller adjusts calibration parameters, weight magnitudes, and procedures according to the specific vehicle type detected, making the system flexible and adaptive to different vehicle geometries and payloads while maintaining calibration accuracy.
2Ease of manufacture
If multiple vehicle types with different wheelbases and payload limits are calibrated using a fixed procedure, then the calibration process is simple, but the calibration accuracy deteriorates
Solution Approach 1:
The system changes calibration parameters including weight magnitudes, application points, and procedural steps based on vehicle type identification. The controller automatically adjusts these parameters for different wheelbases and payload limits, maintaining calibration accuracy across vehicle variants while keeping the process automated and simple to execute.
Solution Approach 2:
The calibration system is segmented into multiple specialized routines, each optimized for specific vehicle types. Instead of one universal procedure, the system divides calibration into type-specific segments that are automatically selected and executed, maintaining simplicity through automation while achieving accuracy through specialization.
3Measurement precision
If a robot and servo press are used to apply known weights to vehicles, then calibration accuracy improves, but device complexity increases
Solution Approach 1:
The robot and servo press system operates autonomously under controller direction, performing vehicle identification, routine selection, weight application, and data collection without manual intervention. The system serves itself by automatically adapting to different vehicle types, which justifies the increased device complexity through automated self-management and reduced operational complexity.
Data Source
AI summary
A method includes positioning, by a robot, a servo press proximate one or more reference identifiers of the vehicle. The method includes applying, by the servo press, a known weight to the vehicle. The method includes calibrating the payload monitoring system of the vehicle based on data from a plurality of payload sensors in response to applying the known weight.