477 research outputs found

    Automated freeform assembly of threaded fasteners

    Get PDF
    Over the past two decades, a major part of the manufacturing and assembly market has been driven by its customer requirements. Increasing customer demand for personalised products create the demand for smaller batch sizes, shorter production times, lower costs, and the flexibility to produce families of products - or different parts - with the same sets of equipment. Consequently, manufacturing companies have deployed various automation systems and production strategies to improve their resource efficiency and move towards right-first-time production. However, many of these automated systems, which are involved with robot-based, repeatable assembly automation, require component- specific fixtures for accurate positioning and extensive robot programming, to achieve flexibility in their production. Threaded fastening operations are widely used in assembly. In high-volume production, the fastening processes are commonly automated using jigs, fixtures, and semi-automated tools. This form of automation delivers reliable assembly results at the expense of flexibility and requires component variability to be adequately controlled. On the other hand, in low- volume, high- value manufacturing, fastening processes are typically carried out manually by skilled workers. This research is aimed at addressing the aforementioned issues by developing a freeform automated threaded fastener assembly system that uses 3D visual guidance. The proof-of-concept system developed focuses on picking up fasteners from clutter, identifying a hole feature in an imprecisely positioned target component and carry out torque-controlled fastening. This approach has achieved flexibility and adaptability without the use of dedicated fixtures and robot programming. This research also investigates and evaluates different 3D imaging technology to identify the suitable technology required for fastener assembly in a non-structured industrial environment. The proposed solution utilises the commercially available technologies to enhance the precision and speed of identification of components for assembly processes, thereby improving and validating the possibility of reliably implementing this solution for industrial applications. As a part of this research, a number of novel algorithms are developed to robustly identify assembly components located in a random environment by enhancing the existing methods and technologies within the domain of the fastening processes. A bolt identification algorithm was developed to identify bolts located in a random clutter by enhancing the existing surface-based matching algorithm. A novel hole feature identification algorithm was developed to detect threaded holes and identify its size and location in 3D. The developed bolt and feature identification algorithms are robust and has sub-millimetre accuracy required to perform successful fastener assembly in industrial conditions. In addition, the processing time required for these identification algorithms - to identify and localise bolts and hole features - is less than a second, thereby increasing the speed of fastener assembly

    Screw torque traceability control: industrial application

    Get PDF
    This paper analyses a new screw torque traceability control procedure designed for an operation in a car audio workstation. First the detection score at a Failure Mode and Effects Analysis (FMEA) indicated which process improvement were needed. On the sequence, data was collected to evaluate performance indicators. Finally, specific actions were executed based on the improvement plan. As result, the FMEA detection score improved from 7 to 3, the run rate increased from 12 to 16 products/h and defects caused by improper screwing were eliminated. This research contributes to disseminate a practical application of a screw torque traceability control

    Accurate Bolt Tightening using Model-Free Fuzzy Control for Wind Turbine Hub Bearing Assembly

    Get PDF
    "In the modern wind turbine industry, one of the core processes is the assembly of the bolt-nut connections of the hub, which requires tightening bolts and nuts to obtain well-distributed clamping force all over the hub. This force deals with nonlinear uncertainties due to the mechanical properties and it depends on the final torque and relative angular position of the bolt/nut connection. This paper handles the control problem of automated bolt tightening processes. To develop a controller, the process is divided into four stages, according to the mechanical characteristics of the bolt/nut connection: a Fuzzy Logic Controller (FLC) with expert knowledge of tightening process and error detection capability is proposed. For each one of the four stages, an individual FLC is designed to address the highly non-linearity of the system and the error scenarios related to that stage, to promptly prevent and avoid mechanical damage. The FLC is implemented and real time executed on an industrial PC and finally validated. Experimental results show the performance of the controller to reach precise torque and angle levels as well as desired clamping force. The capability of error detection is also validated.

    Safety Design and Development of a Human-Robot Collaboration Assembly Process in the Automotive Industry

    Get PDF
    Human-robot collaboration (HRC) is a complex procedure in manufacturing due to the problems posed by compatibility and operational safety among humans and robots, and by task definitions among them in a collaborative order. In this paper, the research results of the human-robot collaboration study for the case of an automotive brake disc assembly is presented. The analytic hierarchy process (AHP) is proposed as a decision-making method for the human-robot collaboration system, and detailed hierarchical task analysis (HTA) is applied to allocate operational tasks to humans and robots, thus reducing the chance of duty interference. Additionally, a virtual environment software (Tecnomatix Process Simulate, version 11.1,80, Siemens, Munich, BY, Germany, 2012) is used to model the assembly workstation, providing an opportunity to evaluate the feasibility of the process through different scenarios. Finally, an experimental test is conducted to evaluate the performance of the assembly procedure. This research proves that, although human-robot collaboration increases the total process time slightly, this collaboration improves human ergonomics considerably and reduces the operator injury risk

    Intelligent Assembly of Wind Turbine Hubs

    Get PDF

    Robotic assembly of threaded fasteners in a non-structured environment

    Get PDF
    Over the past two decades, a major part of the manufacturing and assembly market has been driven by the increasing demand for customised products. This has created the need for smaller batch sizes, shorter production times, lower costs, and the flexibility to produce families of products—or to assemble different parts—with the same sets of equipment. Consequently, manufacturing companies have deployed various automation systems and production strategies to improve their resource efficiency and move towards right-first-time production. Threaded fastening operations are widely used in assembly and are typically time-consuming and costly. In high-volume production, fastening operations are commonly automated using jigs, fixtures, and semi-automated tools. However, in low-volume, high-value manufacturing, fastening operations are carried out manually by skilled workers. The existing approaches are found to be less flexible and robust for performing assembly in a less structured industrial environment. This motivated the development of a flexible solution, which does not require fixtures and is adaptable to variation in part locations and lighting conditions. As a part of this research, a novel 3D threaded hole detection and a fast bolt detection algorithms are proposed and reported in this article, which offer substantial enhancement to the accuracy, repeatability, and the speed of the processes in comparison with the existing methods. Hence, the proposed method is more suitable for industrial applications. The development of an automated bolt fastening demonstrator is also described in this article to test and validate the proposed identification algorithms on complex components located in 3D space

    Behavior-specific proprioception models for robotic force estimation: a machine learning approach

    Get PDF
    Robots that support humans in physically demanding tasks require accurate force sensing capabilities. A common way to achieve this is by monitoring the interaction with the environment directly with dedicated force sensors. Major drawbacks of such special purpose sensors are the increased costs and the reduced payload of the robot platform. Instead, this thesis investigates how the functionality of such sensors can be approximated by utilizing force estimation approaches. Most of today’s robots are equipped with rich proprioceptive sensing capabilities where even a robotic arm, e.g., the UR5, provides access to more than hundred sensor readings. Following this trend, it is getting feasible to utilize a wide variety of sensors for force estimation purposes. Human proprioception allows estimating forces such as the weight of an object by prior experience about sensory-motor patterns. Applying a similar approach to robots enables them to learn from previous demonstrations without the need of dedicated force sensors. This thesis introduces Behavior-Specific Proprioception Models (BSPMs), a novel concept for enhancing robotic behavior with estimates of the expected proprioceptive feedback. A main methodological contribution is the operationalization of the BSPM approach using data-driven machine learning techniques. During a training phase, the behavior is continuously executed while recording proprioceptive sensor readings. The training data acquired from these demonstrations represents ground truth about behavior-specific sensory-motor experiences, i.e., the influence of performed actions and environmental conditions on the proprioceptive feedback. This data acquisition procedure does not require expert knowledge about the particular robot platform, e.g., kinematic chains or mass distribution, which is a major advantage over analytical approaches. The training data is then used to learn BSPMs, e.g. using lazy learning techniques or artificial neural networks. At runtime, the BSPMs provide estimates of the proprioceptive feedback that can be compared to actual sensations. The BSPM approach thus extends classical programming by demonstrations methods where only movement data is learned and enables robots to accurately estimate forces during behavior execution
    • …
    corecore