Spring Carrier Arm Rolling via Articulated Robot Gripper
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing processes for spring carrier arms in vehicle wheel axle suspensions are laborious and time-consuming due to the need for precise setup of handling devices in rolling machines, and manipulators with linearly guided carriages are prone to wear, affecting process reliability.
Innovation Solution
An articulated robot with a gripper directly mounted on its head holds the workpiece during rolling, allowing free movement in the longitudinal direction and using the gripper position to control the roll gap and rotational velocity, preventing sagging or curving of the spring carrier arm, and allowing different portions to be rolled at various locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If handling devices are precisely adjusted to the position of the working region of the rolling machine, then manufacturing precision is improved, but setup time and device complexity increase
Solution Approach 1:
The robot system automatically determines its own position relative to the rolling machine through sensors and control systems, eliminating the need for manual setup and adjustment by operators. The system self-calibrates and adapts to the working region position, making the setup process autonomous and significantly reducing setup time while maintaining precision.
Solution Approach 2:
The robot is designed with multi-functionality to perform both gripping/holding operations and positioning tasks. By integrating positioning capabilities directly into the robot system rather than requiring separate adjustment mechanisms, the setup process is simplified and time is reduced while maintaining the required manufacturing precision.
2Ease of operation
If manipulators with linearly guided carriages are used to hold the workpiece during rolling, then ease of operation is improved, but reliability deteriorates due to wear
Solution Approach 1:
The patent replaces the mechanical linearly guided carriage system with a robot-based holding system. The robot uses its gripper to hold the workpiece while allowing free movement in the rolling direction, eliminating the mechanical contacts and sliding surfaces that cause wear in traditional carriages. This substitution maintains ease of operation while significantly improving reliability by removing wear-prone components.
3Manufacturing precision
If the workpiece is constrained in all directions during rolling, then manufacturing precision is improved, but the workpiece may sag or curve due to excessive constraint
Solution Approach 1:
The robot holding system is designed to be dynamic rather than rigidly fixed. It provides adaptive constraint forces that prevent sagging and curving while allowing the workpiece to move freely in the rolling direction. The robot can adjust its gripping force and position dynamically during the rolling process, maintaining the necessary constraints for precision without over-constraining the workpiece and causing deformation.
Data Source
AI summary
In a method for manufacturing a spring carrier arm for a wheel axle suspension of a vehicle by rolling, the work piece is picked up by a robot (2), in particular an articulated robot, with a head (3) and a gripper (4) directly mounted at the head (3). The robot gripper (4) holds the workpiece (1) while it is passed between the rolls (5) of the rolling device. The robot (2) allows a free movement of the workpiece (1) in a longitudinal direction of the spring carrier arm to be formed.