Assembly 4.0 - Flexibly Picked Up, Precisely Mounted
2019
Component deviations between as-designed and as-built as a result of deformations in the production process lead to significant cost increasing during
assembly. After quality inspection, components are provisionally preassembled to determine their matching accuracy.
Components with an acceptable tolerance range are then
assembled. Otherwise costly reworks are required.
Subsequently, the preassembly process is repeated until
acceptable assembly tolerances are achieved. To avoid this
time-consuming and costly process loop, a flexible mounting
frame coupled with a real-time measuring system is used to
optimize the assembly process. The flexible mounting frame
can be applied for many applications where components are
to be aligned and mounted. This flexible mounting frame
allows the realization of exact shape and acceptable position
tolerances.
The mounting frame consists of telescopic carbon fiber
reinforced polymer (CFRP) tubes, linear actuators and
suctions grippers. Linear actuators deform the component in
the elastic range. Connected vacuum suction grippers hold
the component securely to the mounting frame. The individually configurable joining device compensates manufacturing
deviations during assembly in the elastic range. This is realized
through a real time 3-D surface measuring system that assists
in controlling a variable number of actuators. The geometric
deviations are detected contactless by an external measuring
system. This system provides the required measurements to
control the actuators. By decoupling the measuring method
from the manipulator, the system design can be kept very
simple without compromising accuracy.
Furthermore, the frame is mounted on a mobile robot
platform. The applied mobile robot platform consists of the
mobile platform (KUKA omniMove) and an industrial robot
(KR QUANTEC 150 R3300 prime K). By using such mobile
robot, the system can be universally used. Moreover, components can be brought into the assembly position by contour
optimized elastic deformation. This novel implementation of
flexibly pick up and precisely mounting system results in a
more efficient and faster assembly.
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