Solenoid Bar Zero Flush System for Vehicle Panel Alignment
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Solution Overview
Problem
Existing zero flush systems for vehicle body assembling lines, which use air cylinders or linear actuators to measure and maintain the flush between vehicle body and door panels, face spatial limitations and process delays due to their size and requirement for installation away from conveyor systems, causing interference with robots and prolonging cycle times.
Innovation Solution
A zero flush system employing solenoid bars with permanent magnets and electromagnet pieces, magnetically floated and controlled by solenoids, to precisely measure and adjust the flush between vehicle body and door panels, allowing for non-contact transfer and high-precision control without spatial constraints or process delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If air cylinders or linear actuators are used to fix the door panel and measure flush, then the flush measurement function is achieved, but large volume is occupied causing spatial limitation and teaching interference with robot
Solution Approach 1:
The patent replaces traditional mechanical actuation systems (air cylinders, linear actuators) with a magnetic field-based system. Electromagnet pieces attached to the solenoid bar interact with solenoids mounted on the vehicle body panel to provide contactless actuation and positioning, eliminating the need for large mechanical components and reducing spatial requirements.
Solution Approach 2:
The patent extracts the essential function of mechanical actuation and replaces it with magnetic field interaction. By removing the physical contact and mechanical structure, the system achieves the same positioning and measurement functions with significantly reduced volume and no interference with robot operations.
2Ease of manufacture
If air cylinders or linear actuators are installed far away from conveyor or shuttle transfer line, then installation space is available, but long stroke is required to move door panel which delays process cycle time
Solution Approach 1:
The magnetic actuation system allows the solenoid bar to be positioned close to the conveyor or shuttle transfer line without mechanical interference. The electromagnetic force can effectively actuate the door panel over short distances, eliminating the need for long strokes and reducing process cycle time while maintaining ease of installation.
3Reliability
If air cylinders or linear actuators are used as moving device, then door panel can be fixed and flush can be measured, but spatial limitation and teaching interference with robot occur
Solution Approach 1:
The contactless magnetic actuation system provides reliable door panel fixing through electromagnetic interaction while being highly adaptable to various spatial configurations. The system can be installed in tight spaces near conveyors and shuttles without interfering with robot teaching or operation, combining reliability with spatial versatility.
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 system effectively overcomes spatial limitations and process delays, enabling precise measurement and adjustment of the flush between vehicle body and door panels, improving operational efficiency and reducing interference with robots, while maintaining high precision and accuracy.
Implementation Method 1
a plurality of electromagnet pieces attached to an outer peripheral surface of the solenoid bar, wherein the electromagnet piece interacts with the solenoid to magnetically float and transfer the solenoid bar
Implementation Method 2
The one end of the solenoid bar may be provided with a permanent magnet
Implementation Method 3
The other end of the solenoid bar may be provided with an elastic member providing elastic force
Data Source
AI summary
A zero flush system includes a body provided with a plurality of transfer paths, a plurality of solenoid bars movably inserted into the transfer paths and a solenoid bar in the plurality of solenoid bars having one end closely adhered to a vehicle body panel or a door panel, a plurality of solenoids disposed in the transfer paths and transferring the solenoid bars at a time of applying power to the solenoids and a control device controlling the transferring of the solenoid bars.