US 11,034,024 B2Granted

Fixtureless component assembly

AssigneeGM Global Technology Operations LLC

InventorsMiguel A. Saez, John P. Spicer, Richard Skurkis

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Abstract

A method of assembling a plurality of subcomponents to form a finished component comprises gripping a first subcomponent with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm and grasping a second subcomponent with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm. Moving the first and second end-of-arm tools to position the first subcomponent relative to the second subcomponent in a pre-assembly position and then moving the first and second end-of-arm tools to engage interface surfaces of the first and second subcomponents. Forming a joint between the first subcomponent and the second subcomponent with a joining tool attached to a joining robot arm to thereby assemble the finished component.

Claims19

Dependent claims

A method of assembling a plurality of subcomponents to form a finished component, the method comprising:

grasping a first subcomponent with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm;
grasping a second subcomponent with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm;
grasping a third subcomponent with a third end-of-arm tool, wherein the third end-of-arm tool is attached to a third robot arm;
moving the first, second and third end-of-arm tools with a system controller adapted to control the first, second and third robot arms and first, second and third end-of-arm tools;
positioning the first subcomponent, the second subcomponent and the third subcomponent relative to one another in a pre-assembly position;
using an inspection camera that is in communication with the system controller to visually locate interface surfaces on the first, second and third subcomponents;
using the system controller and estimating an off-set between the pre-assembly position and a required assembly position;
actuating the first, second and third robot arms and moving the first, second and third end-of-arm tools to engage the interface surfaces of the first, second and third subcomponents;
actuating the first, second and third robot arms and moving the first, second and third subcomponents to the required assembly position,
measuring torque forces and lateral forces placed on the first, second and third subcomponents by the first, second and third end-of-arm tools with sensors mounted on the first, second and third end-of-arm tools, and establishing when the first, second and third subcomponents are in the required assembly position based on the torque forces and lateral forces;
scanning the first, second and third subcomponents and locating assembly datums with a non-contact measuring device;
comparing the position of the first, second and third subcomponents to the required assembly position;
actuating the first, second and third robot arms and moving the first, second and third subcomponents to the required assembly position within established tolerances;
actuating a joining tool attached to a joining robot arm and forming a joint between the first subcomponent and the second subcomponent, and actuating the joining tool and forming a joint between the second subcomponent and the third subcomponent to thereby assemble a finished component;
and
using the inspection camera and the system controller and scanning the finished component to verify geometry.

13 more elements

A fixtureless component assembly system comprising:

a first robot arm having a first end-of-arm tool mounted thereon and adapted to grasp a first subcomponent;
a second robot arm having a second end of arm tool mounted thereon and adapted to grasp a second subcomponent;
a third robot arm having a third end-of-arm tool mounted thereon and adapted to grasp a third subcomponent;
a system controller adapted to control the first, second and third robot arms and the first, second and third end-of-arm tools to position the first, second and third subcomponents relative to one another;
an inspection camera in communication with the system controller and adapted to visually locate interface surfaces on the first, second and third subcomponents, wherein the system controller estimates an off-set between a pre-assembly position and a required assembly position;
and
sensors mounted on the first, second and third end-of-arm tools and adapted to measure torque forces and lateral forces placed on the first, second and third subcomponents by the first, second and third end-of-arm tools as the first, second and third end-of-arm tools move the first, second and third subcomponents to the required assembly position.

4 more elements

A fixtureless component assembly system comprising:

a first robot arm having a first end-of-arm tool mounted thereon and adapted to grasp a first subcomponent;
a second robot arm having a second end of arm tool mounted thereon and adapted to grasp a second subcomponent;
a system controller adapted to control the first and second robot arms and first and second end-of-arm tools to position the first and second subcomponents relative to one another;
an inspection camera in communication with the system controller and adapted to visually locate interface surfaces on the first and second subcomponents, wherein the system controller estimates an off-set between a pre-assembly position and a required assembly position;
sensors mounted on the first and second end-of-arm tools and adapted to measure torque forces and lateral forces placed on the first and second subcomponents by the first and second end-of-arm tools as the first and second end-of-arm tools move the first and second subcomponents to the required assembly position;
and
a joining robot arm having a joining tool mounted thereon, wherein the system controller controls the joining robot arm to bring the joining tool into engagement with the first and second subcomponents and join the first and second subcomponents to one another and the first and second robot arms are adapted to exert forces onto the first and second subcomponents to distort the first and second subcomponents to a thermal distortion compensation position prior to joining the first, second and third subcomponents, and to exert forces onto the first and second subcomponents to plastically deform the finished component after the first and second subcomponents are joined.

4 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/277,374Filed 15 Feb 2019
Published: US 2020/0262078 A120 Aug 2020
Granted: 15 Jun 2021
Term ends: Not estimatedThe source records don’t support an estimate.

Classification16 codes

B25J 9/1682
Characterised by the tasks executed: dual arm manipulator; Coordination of several manipulators
B23K 26/032
Observing, e.g. monitoring, the workpiece: using optical means
B23K 31/02
Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups…:…
B23K 37/0452
Fixtures for other work: orientable fixtures