Tolerance-Matched Robotic Assembly for Shape-Accurate Components
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Solution Overview
Problem
Existing manufacturing systems face issues where assemblies formed by welding or bolting components within tolerance ranges still result in shape errors outside permissible limits due to unsatisfactory component tolerance matching.
Innovation Solution
A manufacturing system that includes sensors to measure component shapes, a data storage unit, an assembling target component group selection unit, and an assembling state estimation unit to ensure components are selected and assembled such that their shape errors fall within permissible ranges, using robots for precise assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components within tolerance ranges are assembled by conventional methods, then assembly productivity is maintained, but shape errors of the final assembly fall outside permissible ranges due to unsatisfactory tolerance matching
Solution Approach 1:
The system performs preliminary measurement of component shapes and preliminary estimation of assembly states before actual assembly. By calculating and determining suitable component groups in advance based on measured shape data, the system prepares optimal assembly combinations beforehand, ensuring that components with compatible tolerances are selected before the assembly process begins.
Solution Approach 2:
The system compensates for potential shape errors by selecting components whose tolerance variations will cancel each other out. By estimating the assembly state in advance and identifying component groups where positive and negative deviations complement each other, the system cushions against accumulated errors before they affect the final assembly quality.
2Manufacturing precision
If component shapes are precisely measured and tolerance matching is optimized, then assembly shape precision is improved, but measurement and data processing time increases
Solution Approach 1:
The system extracts only the essential shape data necessary for tolerance matching from complete component measurements. By focusing on specific geometric features and dimensions that directly affect assembly fit and function, the system processes only the critical information needed for component selection, rather than analyzing all measurement data.
Solution Approach 2:
The system transforms raw shape measurement data into processed parameters representing tolerance characteristics. By converting complex 3D measurement data into simplified tolerance parameters that capture the essential variation information, the system enables faster comparison and matching of components while maintaining accuracy in tolerance assessment.
Data Source
AI summary
A manufacturing system according to an aspect of the present disclosure includes: at least one measurement sensor configured to measure a shape of each of a plurality of components an assembling target component group selection unit configured to select, from among the plurality of components, a first assembling target component group including at least two components, the at least two components being components of the assembly; an assembling state estimation unit configured to estimate an assembling state of the assembly based on the shape data of the components belonging to the first assembling target component group; and an assembling execution command unit configured to provide, to to an assembling robot, an assembling execution command for instructing the assembling robot to assemble the assembly using the components included in the first assembling target component group based on a result of the estimation by the assembling state estimation unit.