Universal Box Build Assembly with Robotic End Effector Changeover
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current automated systems for assembling consumer electronics lack a universal approach, requiring different tooling for various brands and specifications, leading to high changeover times and lack of traceability and adaptability.
Innovation Solution
A Universal Box Build (UBB) system that uses a robotically controlled assembly process with interchangeable end effectors and sensors for precise positioning and data recording, allowing for the assembly of consumer electronics with low changeover time and adaptability to multiple brands and specifications, integrating with a Manufacturing Execution System (MES) for traceability and quality validation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different automated systems are used for different brands and specifications, then assembly precision can be maintained, but device complexity and changeover time increase
Solution Approach 1:
The patent implements a universal automated assembly system that can handle multiple consumer electronic devices of different brands and specifications through a single platform. The system uses programmable robotic arms with interchangeable end effectors, configurable PCB fixtures with adjustable positioning mechanisms, and software that loads different assembly programs for various product types. This multi-functional capability allows the same hardware infrastructure to assemble diverse devices while maintaining precision through program-controlled movements and sensor-guided positioning.
Solution Approach 2:
The system employs dynamic reconfiguration capabilities where robotic end effectors can be quickly swapped between different tool types, PCB fixtures can be adjusted to accommodate various board sizes and component layouts, and assembly parameters can be dynamically modified through software configuration. This dynamic adaptability enables the system to transition between different product specifications without physical retooling, reducing changeover time while maintaining assembly precision through real-time parameter adjustment.
2Adaptability or versatility
If manual assembly with tools is used, then adaptability to different specifications is possible, but productivity and consistency decrease
Solution Approach 1:
The automated system incorporates self-adjustment capabilities where sensors automatically detect PCB positions, component locations, and fixture alignments, then programmatically adjust parameters without human intervention. The system performs self-verification through vision systems and sensors that confirm proper component placement before proceeding, enabling autonomous adaptation to different specifications while maintaining high productivity through continuous automated operation without manual reconfiguration delays.
3Productivity
If specialized automated systems are used for specific products, then assembly speed can be optimized, but flexibility and traceability are reduced
Solution Approach 1:
The system performs preliminary configuration through software programming before physical assembly begins. Different assembly programs containing pre-configured parameters, robotic paths, and fixture settings are loaded into the system's memory in advance. This preliminary digital setup enables the system to maintain optimized assembly speeds for each product type while being flexible enough to switch between products by simply loading different programs, eliminating the need for physical retooling and enabling full traceability through digital record-keeping of assembly parameters.
4Adaptability or versatility
If frequent reconfiguration between specifications is done, then adaptability is improved, but changeover time and productivity are reduced
Solution Approach 1:
The system replaces physical reconfiguration mechanisms with digital programming and software control. Instead of mechanically retooling the assembly system for different products, the control system loads different assembly programs that define robotic paths, positioning parameters, and fixture configurations. This substitution of mechanical retooling with digital reprogramming dramatically reduces changeover time from hours or days to minutes or seconds, while maintaining full adaptability to different specifications through software configuration.
Data Source
AI summary
A method and apparatus for generating consumer electronics using a Universal Box Build (UBB) are disclosed herein. The method may include entering specifications of a product comprised of a printed circuit board (PCB), additional components (such as Central Processing Units (CPUs), memory modules, and heatsinks) into a chassis module, inserting a set of required components in the UBB, and generating the PCB assembly based on the entered specifications, wherein a robot is operatively connected to the interface module to automatically generate a product assembly.