Terminal Insertion Assembly Using a Lockable Parallel Robot
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Solution Overview
Problem
Existing serial robot systems face challenges in maintaining assembly precision when inserting terminals into housings that require large insertion forces due to their low rigidity, which affects the relative position accuracy between the terminal and the housing.
Innovation Solution
An assembly system utilizing a parallel robot mechanism with a support platform and a serial robot mechanism, where the parallel robot mechanism is locked during insertion to bear the large insertion force, ensuring high rigidity and maintaining position accuracy, while the serial robot mechanism drives the parallel robot to align the terminal with the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a serial robot mechanism is used to hold both the terminal and the housing during insertion, then the assembly can be performed with a simple system structure, but the position accuracy deteriorates when large insertion forces are required due to the low rigidity of the serial robot
Solution Approach 1:
The system divides the robot mechanism into two separate parts: a parallel robot mechanism dedicated to holding the housing and an insertion mechanism for inserting the terminal. This segmentation allows each component to be optimized for its specific function, with the parallel robot providing high rigidity for position accuracy and the insertion mechanism handling the insertion force independently.
Solution Approach 2:
The parallel robot mechanism acts as an intermediary between the serial robot mechanism and the housing. It receives positioning commands from the serial robot, moves to align the insertion hole, and then locks to provide a rigid platform that can withstand the insertion force without compromising position accuracy.
2Manufacturing precision
If a parallel robot mechanism is used to hold the housing and provide high rigidity, then the position accuracy is maintained under large insertion forces, but the system complexity increases due to the need for coordination between multiple robot mechanisms
Solution Approach 1:
The system merges the positioning function of the serial robot with the rigid support function of the parallel robot into a coordinated workflow. The serial robot positions the terminal, the parallel robot positions the housing and then locks, and the insertion mechanism performs the insertion. This combination leverages the strengths of both robot types while managing complexity through functional integration.
Solution Approach 2:
The parallel robot mechanism performs preliminary positioning of the housing and then locks before the insertion force is applied. This preliminary action establishes a stable, rigid platform that prevents position accuracy loss during the subsequent insertion operation, separating the positioning phase from the force application phase.
3Ease of operation
If the parallel robot mechanism remains movable during insertion, then the system is more flexible and easier to operate, but the position accuracy is lost when large insertion forces are applied
Solution Approach 1:
The parallel robot mechanism transitions from a dynamic, movable state during positioning to a static, locked state during insertion. This dynamic adjustment allows the system to maintain flexibility during the positioning phase while providing the rigidity needed for accurate insertion, optimizing both ease of operation and position accuracy at different stages of the process.
Solution Approach 2:
The parallel robot mechanism performs preliminary positioning while movable, then locks to maintain position accuracy during insertion. This preliminary positioning action allows the system to benefit from the flexibility and ease of operation of a movable mechanism, while the subsequent locking ensures position accuracy is maintained when large insertion forces are applied.
Data Source
Figure 1
AI summary
An assembly system, adapted to insert a terminal into a housing, comprises: a parallel robot mechanism having a support platform on which the housing is held; a serial robot mechanism having an end effector mounted thereon, the end effector being connected to the support platform, so as to drive the parallel robot mechanism to move; and an insertion mechanism configured to insert the terminal into the housing held on the support platform. The parallel robot mechanism is moved by the serial robot mechanism until an insertion hole in the housing is aligned to the terminal to be inserted before inserting the terminal into the housing. The parallel robot mechanism and the support platform are kept stationary by locking at least a part of joints of the parallel robot mechanism during inserting the terminal into the housing. Since insertion force required for inserting the terminal into the housing is completely exerted on and born by the parallel robot mechanism with high rigid, other than exerted on the serial robot mechanism with low rigid, it ensures the position accuracy of the serial robot mechanism, improving the assembly precision of the terminal in the housing.