3D-Printed Underbody Validation Body for Robotic Equipment Checks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing validation systems for manufacturing equipment in motor vehicle production are limited in their ability to accurately validate vehicle data, including surface information, component positions, and weight distribution, prior to prototyping.
Innovation Solution
A 3D printed validation body comprising a base, tubular frame, and vehicle panels, reinforced with ABS and carbon fiber, which includes machined sealant lines and break-away features, is used to accurately represent vehicle design and facilitate robot interaction, enabling precise validation of manufacturing equipment before production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional foam-based validation systems are used, then general size and weight validation is possible, but surface information accuracy, component position accuracy, and weight distribution accuracy are insufficient
Solution Approach 1:
The validation body uses composite construction combining 3D printed base (foam or plastic) with attached tubular frame members (metal or rigid material) and panel sections. This composite approach provides both the weight characteristics of foam and the structural integrity and precision of rigid materials, enabling accurate surface information, component position, and weight distribution validation.
Solution Approach 2:
Different portions of the validation body have different properties optimized for their specific functions. The base provides weight and general shape, the tubular frame provides structural integrity and precise positioning, and the panels provide accurate surface information. This local optimization allows each component to contribute its strengths to overall validation accuracy.
2Measurement precision
If rigid validation structures are used for accurate validation, then validation precision is improved, but damage from robot contact becomes more severe
Solution Approach 1:
The validation body incorporates break-away features and removable panel sections that are designed to detach or deform under impact forces from robot contact. This beforehand cushioning protects the critical tubular frame structure and base from damage while still allowing accurate validation of robot positioning and motion paths.
Solution Approach 2:
The validation body is divided into separate components: a durable tubular frame, a base structure, and removable panel sections. This segmentation allows the critical structural elements to remain protected while sacrificial panels absorb impact damage, enabling the validation system to withstand repeated robot interactions.
3Measurement precision
If detailed surface features are added to validation body, then computer vision system training accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
The validation body accurately copies critical surface features, sealant lines, and geometric characteristics from the actual vehicle design using 3D printing technology. This copying approach provides sufficient detail for computer vision system training while avoiding the manufacturing complexity of creating entirely new detailed surfaces, as the features are directly derived from existing digital models.
Data Source
AI summary
The systems, devices, and methods described herein relate to validation of vehicle data using a validation body. This validation body may include 3D printed portions including a 3D printed base formed using vehicle data representing the underside of the vehicle, a tubular frame, and vehicle panels removably mounted on the tubular frame. The validation body may be used to validate vehicle data before a prototype vehicle is available. In some implementations, the validation body is formed from ABS reinforced with carbon fiber. Sealant lines may be machined into the validation body representing the sealant lines between parts on the vehicle.