Vacuum Manipulator for Uniform Component Attachment
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Solution Overview
Problem
In vehicle construction, attaching components like foils or pads for damping structure-borne noise is challenging due to issues with contact pressure, air pockets, and separation during subsequent processes like painting, as existing methods either deform the body part or allow air to enter between the component and the body part.
Innovation Solution
A method using a manipulator with a support element and membrane that generates negative pressure to attach components automatically, eliminating the need for additional sealing elements by having the membrane seal directly between the support element and the component, ensuring even contact and preventing air pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot is used to apply components to a body panel, then productivity is improved, but manufacturing precision deteriorates due to excessive or uneven contact pressure causing deformation or air pockets
Solution Approach 1:
The patent uses a vacuum system with suction openings distributed across the support element to create uniform negative pressure that evenly holds the component against the body panel. This pneumatic approach replaces mechanical pressing, ensuring uniform contact pressure without deformation while maintaining high productivity through automated robot operation.
2Adaptability or versatility
If the manipulator is swiveled to apply films vertically, then adaptability is improved, but reliability deteriorates because the film falls off the support
Solution Approach 1:
The vacuum system provides continuous suction force that secures the film to the support element regardless of the manipulator's orientation. The negative pressure acts perpendicular to the film surface, maintaining reliable attachment whether the application is horizontal, vertical, or at any intermediate angle, thus enabling full adaptability without sacrificing reliability.
Solution Approach 2:
The system changes the physical state of the film-support interaction from gravitational dependence to pressure-dependent adhesion. By controlling the vacuum pressure parameter, the system maintains film retention across all orientations, transforming the retention mechanism from passive (relying on gravity) to active (controlled by pressure differential).
3Manufacturing precision
If additional sealing elements are added to prevent air pockets, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the sealing function from separate additional sealing elements and integrates it into the vacuum system itself. The vacuum pressure creates a pressure differential that naturally prevents air from entering between the component and body panel, eliminating the need for separate sealing components while maintaining manufacturing precision.
Solution Approach 2:
The vacuum system performs multiple functions simultaneously: it holds the component in position, applies uniform contact pressure, and prevents air pocket formation. The negative pressure self-regulates to maintain these functions without requiring additional sealing elements, making the system self-sufficient and reducing overall complexity.
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
This method allows for secure, even attachment of components without deformation or air pockets, ensuring reliable bonding and preventing separation during subsequent manufacturing steps like painting.
Implementation Method 1
a first vacuum is generated in a first space between a support element and the component, by means of a vacuum pump
Implementation Method 2
a second vacuum is generated in a second space between the support element and the component, by means of a vacuum pump
Data Source
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AI summary
The present invention relates to a method for applying, in particular for uniformly pressing over a surface, a component (14) to a component (40) by means of a manipulator (10), by picking up the component (14) to be applied by means of a first vacuum in a first space (20) between a support element (11) and the component (14), moving the manipulator (10) with component (14) to the component (40), arranging the component (14) on at least a partial surface of the component (40) by means of the manipulator (10), wherein during the arranging a second vacuum is generated in a second space (46) between the support element (11) and the component (40), and fixing the component (14) to the component (40) by increasing the difference between the first and second vacuum.The process is also characterized by the fact that the manipulator (10) continuously maintains the initial vacuum until after the component (14) has been arranged and at least partially attached to the component (40).