Vacuum Manipulator for Even Component Application
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Solution Overview
Problem
In automotive engineering, manually applying components like foils or pads for structure-borne sound attenuation can lead to deformation of body parts due to excessive contact pressure, air pockets, and separation issues during subsequent processes like lacquering, as existing methods struggle with uniform pressure distribution and air entrapment.
Innovation Solution
A method using a manipulator to apply components by creating a vacuum pressure between a supporting member and the component, which is then displaced towards a construction part, ensuring even contact and adhesion through controlled vacuum pressures, reducing the risk of air pockets and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual application method is used, then ease of operation is improved, but manufacturing precision deteriorates due to uneven pressure distribution and air pocket formation
Solution Approach 1:
The patent replaces manual mechanical application with an automated manipulator system that uses vacuum pressure to hold and position the component, then applies controlled pressing force through a pressing element to achieve uniform contact pressure and eliminate air pockets
Solution Approach 2:
The patent employs vacuum pressure (pneumatics) to secure the component on the manipulator's holding surface and to control the pressing operation, ensuring even pressure distribution across the component-construction part interface
2Manufacturing precision
If excessive contact pressure is applied, then manufacturing precision is improved through better adhesion, but object-generated harmful factors worsen due to deformation of the construction part
Solution Approach 1:
The pressing element is designed to be elastically deformable, allowing it to adapt to the construction part's surface geometry and distribute pressure evenly, preventing localized excessive pressure that would cause deformation while maintaining sufficient overall contact pressure for proper adhesion
3Object-generated harmful factors
If too low contact pressure is applied, then object-generated harmful factors are reduced, but manufacturing precision deteriorates due to air pockets and separation during subsequent processes
Solution Approach 1:
The patent replaces inconsistent manual pressure application with an automated pressing mechanism that delivers controlled, uniform pressure through an elastically deformable pressing element, ensuring complete contact between component and construction part to eliminate air pockets while maintaining appropriate pressure levels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for automatic, even application of components with reduced risk of deformation and air entrapment, ensuring secure adhesion and preventing separation during subsequent processes like lacquering.
Implementation Method 1
Receiving the component to be applied by means of a first vacuum pressure in a first interstice between a supporting member and the component
Implementation Method 2
The manipulator displaces the component to be applied to the construction part, the manipulator disposes the component at least one partial surface of the construction part, wherein, during disposing, a second vacuum pressure is generated
Data Source
AI summary
A method for applying, in particular for evenly pressing across a surface, a component to a construction part by way of a manipulator, by receiving the component to be applied by means of a first vacuum pressure in a first interstice between a supporting member and the component, displacing the manipulator with the component towards the construction part, disposing the component at at least one partial surface of the construction part by way of the manipulator, where, during disposing, a second vacuum pressure is generated in a second interstice between the supporting member and the construction part, and mounting the component at the construction part by increasing the difference between the first and second vacuum pressures, where the manipulator continuously maintains the first vacuum pressure until completion of arrangement and at least partial attachment of the component at the construction part.