Automated Engine Piston Installation Using Industrial Robots
ABSTRACT This paper presents engine piston installation using industrial robots. Because the current manual and hard automation engine piston installation systems are either labour intensive or inflexible and costly, the three-robot and two-robot piston installation systems are developed and investigated. The robotic piston installation process is simulated. A robotic piston stuffing gripper with ring detection is designed to perform the sophisticated stuffing process. Robot force control is used in the cylinder bore finding. The piston stuffing is implemented using a search-finding method based on the force control. The searching method and parameters are discussed. Related future research and development are proposed.
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ABSTRACT: This paper presents a study on the Design Of Experiments (DOE)-based parameter optimization technique to adapt to the manufacturing environment changes in robotic force control assembly. Based on a real-world transmission torque converter assembly production process, investigation and analysis are performed in production. An on-pendant robotic assembly parameter optimization tool is introduced. When manufacturing environment changes such as the changes of geometrical dimension of part and tool (the location of feature on part, the size of the feature, the dimension of the tool, etc.), the changes of position and orientation of part, fixture or robot; the changes of properties of part (weight, spring constant, etc.), the performance metrics such as mean of the cycle time, mean plus 3 sigma of the cycle time, first time through (FTT) rate are degraded. The on-pendant optimization tool applies full factorial experiments on the most influential parameters. Then the results are subjected to statistical analysis to find the optimal parameter set. Finally verifying the optimized parameter set through running a number of experiments and checking on performance of the force control assembly to adapt the changes. The efficiency of proposed method is proved in the Ford Powertrain assembly production. The program continues running in production and adjusting the process parameters to adapt the manufacturing variations. The real factory acceptance testing results are presented and analyzed. Finally, conclusions are drawn and discussion and further investigation is proposed.IEEE International Conference on Robotics and Automation, ICRA 2011, Shanghai, China, 9-13 May 2011; 01/2011
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ABSTRACT: This paper presents the objective metric study on design of experiments (DOE)-based robotic force control parameter optimization in transmission torque converter assembly. Based on a real-world assembly production process, investigation and analysis are performed on the optimization metrics of assembly cycle time mean (MEAN), its mean plus three times of standard deviation (MEAN+3*STDEV), and first time through (FTT) rate. Simulations have been conducted to illustrate and explain the findings in the parameter optimization practice. Practical metric criteria have been proposed and discussed. An on-pendant robotic assembly parameter optimization tool with the objective metric concept is introduced. And automatic parameter optimization or online robot learning feature is also mentioned in terms of the objective metrics for the particular robot assembly parameter optimization tasks. Finally conclusions are drawn and discussion and further investigation is proposed.2009 IEEE/RSJ International Conference on Intelligent Robots and Systems, October 11-15, 2009, St. Louis, MO, USA; 01/2009
Conference Paper: Toward robotizing powertrain assembly[Show abstract] [Hide abstract]
ABSTRACT: This paper presents the recent progress of using robotics in automotive powertain assembly manufacturing processes. After briefly describing force control and vision-guided robot (VGR), we introduce successful implementation of robotic assembly for transmission torque converters, VGR-based engine head assembly, transmission valve body assembly and engine piston installation. Then we discuss other robotic assembly related technologies such as visual servoing and assembly parameter optimization and followed by discussing assembly production line evolution such as the merging of automated-guided vehicle (AGV). The successful model of collaborative development between Ford Advanced Manufacturing Technology Development (AMTD) and ABB Robotics is also mentioned and reviewed.Intelligent Control and Automation, 2008. WCICA 2008. 7th World Congress on; 07/2008