Smart Active Control Roller Hemming Device
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Solution Overview
Problem
Conventional hemming devices experience inconsistencies in hemming pressure, leading to variable hemming angles and quality, which can result in assembly interference and damage to molds, affecting productivity and panel quality.
Innovation Solution
A smart active control hemming system employing a robot arm with hemming rollers driven by electric motors, equipped with pressure detection sensors and a hemming pressure active controller, which adjusts and maintains target pressure values to ensure consistent hemming angles and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an air cylinder is used as a hemming driver, then the device structure is simple, but the hemming pressure is not constant and errors occur between target and actual pressure values
Solution Approach 1:
The patent implements a feedback control system where a pressure sensor detects the actual hemming pressure, compares it with the target pressure value, and automatically adjusts the control motor to correct any deviation. This closed-loop feedback mechanism ensures that the hemming pressure accurately matches the target value, resolving the precision issue while maintaining reasonable device complexity.
Solution Approach 2:
The patent replaces the traditional air cylinder mechanical system with an electric control motor system. This substitution allows for more precise control of hemming pressure through electrical signals and feedback control, significantly improving pressure accuracy while enabling better integration with automated manufacturing systems.
2Device complexity
If conventional hemming devices are used, then the device structure is simple, but the hemming angle and quality are not constant
Solution Approach 1:
The feedback control system continuously monitors hemming pressure and adjusts it to maintain consistent hemming quality. By ensuring the actual pressure matches the target pressure, the system produces constant hemming angles and quality across different operations, resolving the stability issue.
Solution Approach 2:
The patent enables dynamic adjustment of hemming pressure parameters through the control motor system. By precisely controlling pressure parameters based on feedback, the system maintains optimal hemming conditions, ensuring consistent hemming quality and angle while accommodating different panel requirements.
3Device complexity
If pressure errors occur in hemming, then the device structure remains simple, but the hemming time increases and productivity decreases
Solution Approach 1:
The feedback control system rapidly detects pressure deviations and automatically corrects them in real-time, preventing rework and ensuring each hemming operation is completed correctly on the first attempt. This reduces the need for repeated adjustments and improves overall hemming efficiency and productivity.
Solution Approach 2:
The electric control motor system responds more quickly and precisely than traditional pneumatic systems, enabling faster pressure adjustment and more efficient hemming operations. This substitution improves productivity by reducing cycle time and eliminating the need for manual pressure adjustments.
Data Source
AI summary
A smart active control hemming device is provided. The device includes a robot arm and a hemming roller unit that is disposed at a front end portion of the robot arm. The hemming roller unit includes a plurality of hemming rollers, a control motor that is driven with an electric motor to adjust a hemming pressure or position of at least one of the hemming rollers, and a pressure detection sensor that detects a hemming pressure of the hemming roller in which a hemming pressure is adjusted by the control motor.