Spline Vision Alignment for Faster Gearbox-to-Motor Assembly
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Solution Overview
Problem
The process of mating a male splined end of a rotor shaft with a female splined end of an input shaft in a gearbox is time-consuming due to the need for multiple attempts to achieve proper phasing, which slows down vehicle assembly.
Innovation Solution
A vision guidance system using cameras with different lenses (anamorphic and conventional) to capture and analyze the splines, a control device to determine phase alignment, and an adjustment mechanism with a servo motor to correct the phase of the female splines, facilitated by gripping devices like robots to position the shafts for imaging and mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual alignment methods are used to mate the male splined end with the female splined end, then the assembly process is simple, but multiple attempts are required to achieve proper phasing, increasing assembly time
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated vision guidance system. Cameras capture images of the splined ends, image processing algorithms automatically determine spline phases, and a control system directs the mating process. This substitution eliminates the need for multiple manual alignment attempts, significantly reducing assembly time while accepting increased system complexity.
Solution Approach 2:
The vision system creates optical copies (images) of the male and female splined ends. These image copies are processed to determine the phase of each spline without physically manipulating the shafts. This copying approach enables precise measurement and alignment planning, reducing the number of physical mating attempts required.
2Manufacturing precision
If multiple attempts are made to align the splines manually, then no additional equipment is needed, but the phasing accuracy decreases due to repeated manipulation
Solution Approach 1:
The patent replaces manual mechanical alignment with an automated vision-based measurement and control system. The system captures images, processes them to determine exact spline phases, and controls the mating process automatically. This eliminates the imprecision introduced by repeated manual manipulation while accepting increased manufacturing complexity.
Solution Approach 2:
The vision guidance system enables the mating process to be self-directed. The system automatically measures the spline phases, calculates the required alignment, and guides the mating operation without requiring skilled operators to manually adjust and retry the alignment. This self-service capability improves phasing accuracy by eliminating human error and repeated manipulation.
3Measurement precision
If a vision guidance system with cameras and image processing is implemented, then phasing accuracy improves, but the device complexity increases
Solution Approach 1:
The system uses cameras to create optical copies (images) of the splined ends, which are then processed to determine spline phases. These image copies allow for precise non-contact measurement without physically disturbing the components, achieving high measurement precision while keeping the physical interaction minimal.
Solution Approach 2:
The patent replaces manual measurement and alignment methods with an automated vision system. The camera-based measurement and image processing algorithms provide precise phase determination, while the control system automates the alignment process, accepting increased system complexity to achieve superior measurement and alignment precision.
Data Source
AI summary
A vision guidance system for mating a first shaft having a male splined end and a second shaft having a female splined end. The vision guidance system may include a control device, a first camera having an anamorphic lens in communication with the control device and configured to generate images of the male splined end, a second camera having a conventional lens in communication with the control device and configured to generate images of the female splined end, and an adjustment device in communication with the control device and configured to modify an orientation of the female splined end.