Stacked Component Assembly With Dual Imaging Alignment Validation
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Solution Overview
Problem
Existing automated assembly systems for disc-shaped objects, such as electrochemical cells, face challenges in precise alignment and validation of components, leading to misalignment and premature failure, especially when dealing with non-planar or deformed components, resulting in poor performance and misleading test results.
Innovation Solution
An apparatus equipped with upward- and downward-facing imaging devices and a controller that coordinates the component holder and imaging devices for precise position alignment and validation, applying image processing techniques to identify reference alignment features and detect defects, ensuring accurate placement and quality control without operator supervision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated assembly systems are used for disc-shaped objects, then productivity is improved, but manufacturing precision deteriorates due to misalignment of components
Solution Approach 1:
The patent replaces mechanical alignment systems with optical imaging devices (cameras) that capture images of components from above and below. The controller processes these images to identify alignment features and calculate precise positions, substituting mechanical positioning with optical-mechanical coordination for sub-20 μm alignment precision
Solution Approach 2:
The patent creates optical copies (images) of the physical components using imaging devices. These digital representations are processed by the controller to determine alignment features and guide component placement, allowing virtual measurement and positioning before physical assembly occurs
2Measurement precision
If conventional imaging systems are used, then device complexity is reduced, but measurement precision deteriorates due to inability to detect alignment features accurately
Solution Approach 1:
The patent divides the imaging function into two separate devices: an upward-facing imaging device for capturing images of the top surface of components, and a downward-facing imaging device for capturing images of the bottom surface. This segmentation allows each device to specialize in capturing specific alignment features that would be invisible from a single viewpoint
Solution Approach 2:
The patent transitions from single-plane imaging to multi-plane imaging by positioning imaging devices on opposite sides of the component stack. The upward-facing device captures features on the top surface while the downward-facing device captures features on the bottom surface, adding a vertical dimension to the imaging system for comprehensive alignment detection
3Manufacturing precision
If manual alignment methods are used, then manufacturing precision is maintained, but productivity deteriorates due to operator supervision requirement
Solution Approach 1:
The system performs self-alignment through automated image capture, processing, and position calculation. The controller automatically identifies alignment features from captured images, calculates precise component positions, and guides the component holder for accurate placement without requiring operator intervention or supervision
Solution Approach 2:
The system implements closed-loop feedback by capturing images of components, processing these images to determine actual positions and alignment features, comparing these with target positions, and using this information to guide precise component placement. This feedback mechanism ensures sub-20 μm alignment precision while maintaining high automated assembly speed
Data Source
AI summary
There is provided an apparatus for assembling an object having a stacked construction of a plurality of components. The apparatus comprises:a component holder for selectively holding and placing a component;an assembly zone in which the object may be assembled;first and second imaging devices, the first imaging device positioned to face in an upward direction, the second imaging device positioned to face in a downward direction; anda controller programmed to selectively coordinate the component holder and the first and second imaging devices to carry out an assembly operation for assembling components of the object in which:the component holder holds a component over the first imaging device;the first imaging device captures an image of the component;the controller identifies a first reference alignment feature of the component from the image captured by the first imaging device;the component holder places the component on top of another component in the assembly zone based on the identified first reference alignment feature of the component;the second imaging device captures an overhead image of the component on top of the other component;the controller identifies a second reference alignment feature of the component from the image captured by the second imaging device;the controller validates a position of the component in the assembly zone based on the identified second reference alignment feature of the component.A clean copy of the amended Abstract is submitted herewith on a separate sheet in the Appendix to this Preliminary Amendment.