Vehicle Body Gap Step Adjustment Using Image Feedback Control
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Solution Overview
Problem
Existing vehicle body assembly processes face challenges in maintaining consistent gap steps between moving parts due to part and process distribution, leading to quality issues that are not addressed until the final painting process, requiring time-consuming adjustments.
Innovation Solution
A system and method for adjusting gap steps using a process device, information obtaining devices, and a control device to monitor and adjust the mounting of moving parts on a vehicle body, incorporating cameras for image analysis and control algorithms to ensure accurate gap and step differences are maintained throughout the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gap step is adjusted during each mounting process, then gap step quality is maintained at each stage, but time and cost increase due to repeated measurements and adjustments
Solution Approach 1:
The system performs preliminary gap step measurement and adjustment after the vehicle body assembly process is completed, rather than waiting until the final painting process. This preliminary action allows gap step issues to be identified and corrected earlier in the production flow, reducing the need for repeated adjustments later while maintaining quality standards.
Solution Approach 2:
The system implements a feedback mechanism where gap step is measured after assembly completion, and adjustment information is fed back to the mounting process. This feedback loop enables continuous improvement and reduces the need for multiple adjustment cycles by providing real-time correction data.
2Productivity
If gap step adjustment is delayed until after painting process, then assembly process efficiency is maintained, but quality management cost and time increase
Solution Approach 1:
The system performs gap step measurement and adjustment as a preliminary action before the painting process begins. By completing quality management tasks earlier in the production sequence, the system eliminates the need for post-painting adjustments, thereby reducing total quality management time while maintaining assembly efficiency.
3Manufacturing precision
If multiple adjustments are performed to achieve consistent gap step, then quality is improved, but device complexity and operation difficulty increase
Solution Approach 1:
The system replaces complex mechanical adjustment operations with an automated control system that uses image processing and algorithmic calculation. The control device automatically determines adjustment amounts based on measured gap step data, eliminating the need for manual measurement and repeated mechanical adjustments, thereby reducing operational complexity while maintaining precision.
4Reliability
If gap step is measured and adjusted at each process stage, then quality control is thorough, but productivity decreases due to repeated operations
Solution Approach 1:
The system performs a comprehensive gap step measurement and adjustment as a preliminary action after assembly completion but before painting. This single thorough measurement and adjustment operation replaces multiple smaller adjustments that would otherwise be needed at intermediate stages, maintaining quality control thoroughness while improving production efficiency.
Data Source
AI summary
An embodiment system for adjusting a gap step includes a process device configured to mount a first moving part and a second moving part, a first information obtaining device including a camera, and a control device configured to control the process device based on a first driving control value such that the first moving part and the second moving part are mounted on a first vehicle body, obtain a first image of the first vehicle body on which the first moving part and the second moving part are mounted, obtain the gap step for the first moving part, the second moving part, or both through the first image, and mount the first moving part and the second moving part on a second vehicle body by controlling the process device based on a second driving control value corresponding to the gap step.