Smart Loader for Trunk Lid Hinge Positioning
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Solution Overview
Problem
Existing labor-saving apparatuses for mounting trunk lid hinges on vehicle bodies lack accurate positional control and versatility, leading to increased workload and workplace risks due to musculoskeletal diseases from repetitive tasks.
Innovation Solution
A smart loader apparatus that collaborates with workers, utilizing a hinge alignment jig, a transfer gripper, an articulated arm, a force and torque sensor, and proximity sensors to accurately position and safely transfer trunk lid hinges, preventing collisions and adapting to various vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a weight balance type labor-saving apparatus is used to reduce worker burden, then the worker's physical load is reduced, but accurate positional control is lost and work burden increases during fastening
Solution Approach 1:
The patent combines a robot (articulated arm with transfer gripper) and a weight balance type labor-saving apparatus into a hybrid system. The robot provides precise positional control and positioning, while the labor-saving apparatus assists the worker with force balance during the fastening operation, thus achieving both accuracy and reduced worker burden
Solution Approach 2:
The control unit acts as an intermediary that coordinates between the robot's positioning actions and the labor-saving apparatus's force assistance. It integrates signals from both systems and coordinates their operations to achieve synchronized precise positioning and force-balanced fastening
2Measurement precision
If a robot is used to achieve precise positional control, then positioning accuracy is improved, but adaptability to various vehicle types is reduced
Solution Approach 1:
The system employs dynamic adjustability where the robot's movement range, positioning parameters, and operational characteristics can be modified through control unit programming. This allows the same robotic system to adapt to different vehicle types and hinge positions by changing control parameters rather than physical reconfiguration
Solution Approach 2:
The control unit enables parameter changes in the robot's operational characteristics, such as movement speed, positioning precision, and range of motion, to accommodate different vehicle models and hinge configurations while maintaining precise control
3Productivity
If the articulated arm operates continuously to maintain productivity, then production efficiency is improved, but collision risks and workplace safety increase
Solution Approach 1:
Proximity sensors provide continuous feedback about objects near the articulated arm's path. The control unit receives this feedback and can interrupt or adjust the robot's operation to prevent collisions, enabling safe continuous operation through real-time monitoring and responsive control
Solution Approach 2:
The proximity sensors detect potential collision risks before actual contact occurs, allowing the control unit to take preventive actions such as slowing down or stopping the articulated arm's movement, thus cushioning against potential harmful effects before they materialize
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 smart loader apparatus enables precise positional control and collision prevention, reducing musculoskeletal disease risks and enhancing workplace safety while being applicable to diverse vehicle models.
Implementation Method 1
a gas spring that elastically upwardly supports the vertically moving member through a rod inserted into a gas cylinder in which a gas is filled at a predetermined pressure
Implementation Method 2
a force and torque (FT) sensor installed at a portion at which the articulated arm and the transfer gripper are connected for sensing a direction of a force applied to the transfer gripper or the trunk lid hinge
Data Source
AI summary
A smart loader apparatus for a trunk lid hinge includes a hinge alignment jig at which a trunk lid hinge is aligned and disposed at a predetermined position, a smart loader of which a transfer gripper for gripping the trunk lid hinge aligned at the hinge alignment jig is disposed at a front end portion, and the smart loader includes an articulated arm for transferring the trunk lid hinge gripped by the transfer gripper to a predetermined position of a vehicle body, a driving portion that drives the transfer gripper and the articulated arm to change a position of the transfer gripper, a force and torque (FT) sensor installed at a portion at which the articulated arm and the transfer gripper are connected, and a controller that controls the driving portion to move the transfer gripper in the direction of the force sensed by the FT sensor.