Suspended Sub-Assembly Joining for Compact Robotic Assembly Lines
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Solution Overview
Problem
Existing assembly lines for multicomponent items, such as hinges, are limited in productivity and require excessive resources due to stationary components, leading to longer production times and increased plant volumes.
Innovation Solution
A method and assembly station that utilizes manipulator arms to suspend and assemble sub-assemblies in mid-air, followed by transferring the completed joint assembly to a receiving component on a pallet or rotary table, allowing simultaneous operations at a single station, thereby reducing the need for multiple stations and optimizing assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple series of individual assembly stations are used for each stationary status, then each component can receive one assembly operation at a time, but the assembly line length increases and excessive resources are required
Solution Approach 1:
The patent combines multiple assembly operations that were previously performed at separate stationary stations into a single mobile assembly station. The station integrates multiple manipulator arms that can perform different assembly operations simultaneously or sequentially on the same component, merging the functions of what were previously multiple separate stations into one unified mobile unit.
Solution Approach 2:
The assembly station is designed to be mobile rather than stationary, allowing it to move between different component locations. This dynamic capability enables the station to service multiple components without requiring multiple fixed stations, thereby reducing the overall assembly line length while maintaining complete assembly coverage.
2Reliability
If multiple series of individual assembly stations are used for each stationary status, then each component can receive one assembly operation at a time, but excessive resources are required to create each station
Solution Approach 1:
The mobile assembly station is designed with multiple manipulator arms that can perform various assembly operations on different components. This multi-functional design allows a single station to replace multiple specialized stationary stations, reducing the total number of stations required while maintaining comprehensive assembly capability across all component types.
Solution Approach 2:
The patent merges the functions of multiple individual assembly stations into one integrated mobile station. By combining multiple manipulator arms and assembly capabilities into a single unit, the system reduces the total number of stations needed while maintaining the ability to perform all necessary assembly operations.
3Ease of manufacture
If components remain stationary at each assembly station, then assembly operations can be performed, but production time increases and productivity decreases
Solution Approach 1:
The assembly station is designed to be mobile, moving between stationary components rather than requiring components to move between stationary stations. This dynamic approach allows the station to efficiently service multiple components in sequence, reducing overall production time while maintaining assembly precision through controlled movement and positioning.
Solution Approach 2:
The system prepares multiple components in advance at different stationary positions, and the mobile assembly station visits them in an optimized sequence. This preliminary positioning of components allows the assembly station to perform operations efficiently without idle waiting time, thereby increasing productivity while maintaining assembly simplicity.
4Productivity
If several series of assembly stations are used to meet production volume requirements, then increased volumes can be achieved, but the plant volume and production site area increase
Solution Approach 1:
The patent consolidates multiple assembly station series into a single mobile assembly station that can service multiple components. This merging approach maintains high production volumes by enabling the station to work on multiple components sequentially or in parallel, while significantly reducing the physical space required compared to having multiple separate stationary station series.
Solution Approach 2:
The mobile assembly station can move between and service multiple components located in a compact arrangement, allowing high production volumes to be achieved within a smaller plant footprint. The dynamic positioning capability enables efficient utilization of space while maintaining the throughput required for increased production volumes.
Data Source
AI summary
A method for assembling two sub-assemblies involves providing a first sub-assembly and a second sub-assembly, by a first manipulator arm and a second manipulator arm, picking the first sub-assembly and the second sub-assembly, keeping the first and second sub-assemblies suspended, bringing the first and second sub-assemblies to a mutual assembly position and assembling the first and second sub-assemblies in a suspended-in-air position to form a joint assembly, avoiding all contact with any support other than the first and second manipulator arms. A method for assembling multicomponent items including the method for assembling the two sub-assemblies is provided. An assembly station and an assembly line including the assembly station are also provided.