Vehicle Frame Assembly Cell With Vertical Positioning and Robot Lift
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Solution Overview
Problem
Current manufacturing systems for vehicles are inflexible, labor-intensive, and costly, particularly for producing a variety of vehicle types, with long R&D cycles and high costs due to the need for extensive retooling and complex assembly processes.
Innovation Solution
A modular manufacturing cell system comprising a positioner, robot carrier, and robot, with a vertical lift and controller, enabling flexible assembly of vehicle frames with high robot utilization and automatic processes, reducing the need for extensive retooling and minimizing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional space frame chassis manufacturing is used, then better torsional rigidity is achieved, but the manufacturing process becomes very time consuming and labor intensive
Solution Approach 1:
The manufacturing system is divided into modular functional units: positioner for frame positioning, robot carrier for mobile robot deployment, and interchangeable end effectors for different assembly operations. This segmentation enables independent optimization of each module while maintaining overall system productivity for space frame assembly
Solution Approach 2:
Manual welding and assembly operations are replaced with automated robotic systems. The robot carrier enables mobile robots to access different positions of the space frame structure, performing automated welding and assembly operations that maintain quality while dramatically reducing labor intensity and manufacturing time
2Weight of moving object
If unibody design is used, then weight is reduced and fuel economy is improved, but the R&D cycle becomes very long and retooling costs are high
Solution Approach 1:
The robot carrier provides dynamic positioning capabilities, allowing robots to move to different locations around the vehicle body. This dynamic system can be reconfigured for different vehicle models and body styles, enabling production flexibility without extensive retooling while maintaining weight reduction benefits of unibody construction
Solution Approach 2:
The manufacturing system uses universal robot carriers and interchangeable end effectors that can perform multiple assembly operations on different vehicle types. This multi-functionality allows the same equipment to produce various unibody vehicle configurations, reducing R&D cycle time and retooling costs while maintaining weight efficiency
3Strength
If body-on-frame construction is used, then vehicle strength is improved, but the vehicle becomes heavier and fuel efficiency worsens
Solution Approach 1:
The system enables precise control of frame component positioning and assembly parameters through automated robots. This precision allows optimization of frame structure design, using minimal material where needed while maintaining required strength, thereby reducing overall weight compared to traditional conservative body-on-frame constructions
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
Manufacturing cell based vehicle manufacturing systems and methods for a wide variety of vehicles are disclosed. In one aspect, a manufacturing cell configured for assembling a frame of a vehicle is disclosed. The manufacturing cell includes a positioner, a robot carrier and a robot. The positioner is configured to receive a fixture table configured to hold the frame. The robot carrier includes a vertical lift. The robot is configured to assemble the frame. The positioner is configured to support the frame in a vertical position during an assembling process. In another aspect of the disclosure, a system for manufacturing a vehicle based on a manufacturing cell is disclosed. In another aspect of the disclosure, a method for manufacturing a vehicle based on a manufacturing cell is disclosed.