参考教案讲稿top case tp depth measurement.2-en2

1、J44 Automated Battery Alignment-Installation FixtureV1.2 2014-5-30 BroConcentric Automation 22 BroConcentric AutomationContentsProject Requirements and Machine Functions-P3-P4Machine Structure-P5-P8Main Modules-P9-P14Work Flow-P15-P20Cycle Time-P21Environment Requirements and Safety- P22The fixture

2、will have a location for manually loaded parts.The fixture will measure the Battery Module and determine if it meets dimensional specifications.The fixture will measure the overall X and overall Y in the battery module upon picking it up.The fixture will pick up and place the battery module into the

3、 Top Case.Battery module placement should follow a prescribed flight path to avoid obstacles in the top case.Battery module should hover above the top case just enough to avoid the VHB from contacting the Top Case (this may required determining the z location of the topcase from a sensor).The fixtur

4、e will align the battery module in the TC opening by using the BMU and topcase holes.The fixture will measure the X-gap between the battery and the speakers, both on the left and right side.The fixture will measure the Y-gap between the battery and the topcase mid-wall at specified locations.The fix

5、ture will record these measurements and also calculate rotation.Repeatability performance of 0.1mm at 3 sigma.Fixture will have data server to support and store all alignment and measurement data/images/scans (pre and post alignment measurements in Excel - measurements will be linked to product scan

6、ned serial numbers).Shopfloor tracking - fixture will support and hook into factory SF to track which units have pass/failed alignment and press.Fixture will have a hand held barcode scanner for the operator to scan prior to placement into the fixture.Load Cell: precise load cell with accuracy 10g t

7、o ensure that the automation system does not continue to install a battery module if interference is detected (also review the use of encoder following error).Cycle time: UPH must meet a minimum of 100UPH. BroConcentric Automation31.1 Project requirementsProject Requirements and Machine Functions Br

8、oConcentric Automation41.2 Machine functionsProject Requirements and Machine FunctionsThe fixture have a location for manually loaded parts.The fixture can measure the Battery Module and determine if it meets dimensional specifications.The fixture can measure the overall X and overall Y in the batte

9、ry module upon picking it up.The fixture can pick up and place the battery module into the Top Case.Battery module placement would follow a prescribed flight path to avoid obstacles in the top case.Battery module would hover above the top case just enough to avoid the VHB from contacting the top cas

10、e (this may required determining the z location of the topcase from a sensor).The fixture can align the battery module in the TC opening by using the BMU and topcase holes.The fixture can measure the X-gap between the battery and the speakers, both on the left and right side.The fixture can measure

11、the Y-gap between the battery and the topcase mid-wall at specified locations.The fixture can record these measurements and also calculate rotation.Repeatability performance of 0.1mm at 3 sigma.Fixture have data server to support and store all alignment and measurement data/images/scans (pre and pos

12、t alignment measurements in Excel - measurements will be linked to product scanned serial numbers).Shopfloor tracking - fixture can support and hook into factory SF to track which units have pass/failed alignment and press.Fixture have a hand held barcode scanner for the operator to scan prior to pl

13、acement into the fixture.Load Cell: fixture have a precise load cell with accuracy 10g to ensure that the automation system does not continue to install a battery module if interference is detected (also review the use of encoder following error).Cycle time: UPH can meet a minimum of 100UPH. 5 BroCo

14、ncentric AutomationMachine dimension:1550mm1050mm2000mm2.1 Machine overviewMachine Structure BroConcentric Automation6 Mchiane is composed of :Manualy loaded location fixture for TC and manualy loaded tray for BMU.TC manualy loaded location fixture mounted on a 2 stations turn table to save cycle ti

15、me, and BMU load tray mounted on a Y axis linear motion module for move in and back out.Motion system for BMU automatic loading and alignment composed of a ABB IRB120 6 axis robot and a vacuum board.Vision system for components match composed of a 5M pixels camera, telecentric lens and LED illuminat

16、ion(mounted on the robot). Measurement system for determining thickness of BMU and Z location(height of hovering) composed of 1D laser sensors.Vision system for alignment composed of 2 5M pixels cameras, and fixed on a Z axis linear motion module.The 1D lasers and alignment vision systems were mount

17、ed on a Y axis linear motion module (manualy ajuctive on X axis), flexible for different sizes.Safety curtains for operator safety.Platform composed of marble table.Fixture Dimension:1600mm1200mm1800mm.2.1 Machine overviewMachine Structure BroConcentric AutomationLocating fixture of TC2.2 Machine st

18、ructureMachine StructureLaser system 1 for BMU thickness measurement2 stations rotary tableStation 2Z axis motionFollow-up cameraX axis motionLoad tray of BMUVacuum sucking plateLaser system 2 for Z location confirmationVision system 2 for alignmentStation 1Motion system-6 axis robot7 BroConcentric

19、Automation82.2 Machine structureMachine StructureLocating fixture of TCLaser system 1 for BMU thickness measurement2 stations rotary tableZ axis motionFollow-up cameraX axis motionLoad tray of BMUVacuum sucking plateLaser system 2 for Z location confirmationVision system 2 for alignmentMotion system

20、-6 axis robot BroConcentric Automation9Work Flow3.1 X-Y linear motor modules BroConcentric Automation104.1 Initial StateWork FlowAll the mechanism are in the initial stateWaiting for load. BroConcentric Automation113.2 Manual LoadOperator loads TC into locating fixture and loads packaging tray into

21、locating fixture after barcode scan, then presses the start button.Locating cylinders push TC into a fixed position.packaging tray is fixed by a locating fixture with 2 locating pins. BroConcentric Automation123.2 Manual LoadOperator loads TC into locating fixture and loads packaging tray into locat

22、ing fixture after barcode scan, then presses the start button.Locating cylinders push TC into a fixed position.packaging tray is fixed by a locating fixture with 2 locating pins.Positioning pinMistake-proof sensor BroConcentric Automation133.1 Thickness MeasurementLinear motion module 1 bring packag

23、ing tray into thickness measuring position. 2 1D laser sensor measure the thickness and submit to upper computer. BroConcentric Automation143.1 Automatic LoadLinear motion module 1 bring packaging tray into automatic load pisition. Rotary table rotate and take TC from station 1 to station 2.Operator

24、 could load next TC BroConcentric Automation153.1 Automatic LoadLinear motion module 1 bring packaging tray into automatic load pisition. Rotary table rotate and take TC from station 1 to station 2.Operator could load next TC BroConcentric Automation163.1 Automatic LoadLinear motion module 1 bring p

25、ackaging tray into automatic load pisition. Rotary table rotate and take TC from station 1 to station 2.Operator could load next TC BroConcentric Automation173.1 Automatic LoadLinear motion module 1 bring packaging tray into automatic load pisition. Rotary table rotate and take TC from station 1 to

26、station 2.Operator could load next TC BroConcentric Automation183.1 Automatic LoadLinear motion module 1 bring packaging tray into automatic load pisition. Rotary table rotate and take TC from station 1 to station 2.Operator could load next TC BroConcentric Automation193.1 Pre-measurement/alignment

27、of BMURobot take vision system1 move to muti-position of BMU to measure the demension and confirm whether it is OK for installation(go/no-go). BroConcentric Automation203.1 Pre-measurement/alignment of TCRobot bring laser system 2 to the top of TC and measure the height of TC. Vision system 2 measur

28、e the X-Y of the topcase mounting holes and submit the data to robot.Robot get the primary XOY target position and the hover height. BroConcentric Automation213.1 Pre-measurement/alignment of TCRobot bring laser system 2 to the top of TC and measure the height of TC. Vision system 2 measure the X-Y

29、of the topcase mounting holes and submit the data to robot.Robot get the primary XOY target position and the hover height. BroConcentric Automation22Robot bring laser system 2 to the top of TC and measure the height of TC. Vision system 2 measure the X-Y of the topcase mounting holes and submit the

30、data to robot.Robot get the primary XOY target position and the hover height. 3.1 Pre-measurement/alignment of TC BroConcentric Automation23Robot take BMU approach the TC at a 12 degree angleOnce the rear of battery is in the correct Y position, it needs to rotate to horizontal around the rear of th

31、e batteryThe battery module should Hover at 0.75mm above the TC according to the pre-measurement resultsThe module is now ready for alignment3.1 Pre-installation of BMU12 degree angle BroConcentric Automation24Robot take BMU approach the TC at a 12 degree angleOnce the rear of battery is in the corr

32、ect Y position, it needs to rotate to horizontal around the rear of the batteryThe battery module should Hover at 0.75mm above the TC according to the pre-measurement resultsThe module is now ready for alignment3.1 Pre-installation of BMU BroConcentric Automation253.1 Alignment and AjustmentRobot ta

33、ke BMU hover on the top of TC Vision system 2 measure both center of BMU and TC mounting holes, and feed it back to robotRobot ajust the position of BMU according to the vision system alignmentThere are 3 chances for alignment and ajustment, the system will alarm and abort the installation if the BM

34、U still could not arrive the right position after 3 times of ajustment. BroConcentric Automation263.1 Alignment and AjustmentRobot take BMU hover on the top of TC Vision system 2 measure both center of BMU and TC mounting holes, and feed it back to robotRobot ajust the position of BMU according to t

35、he vision system alignmentThere are 3 chances for alignment and ajustment, the system will alarm and abort the installation if the BMU still could not arrive the right position after 3 times of ajustment. BroConcentric Automation273.1 installation and remeasurementRobot install BMU in to TC opening

36、after successful alignment and adjustmentPrecise load cell will stop the robot when the pressure is reaches the standardRobot take vision system 1 to muti-position to remeasure the X/Y gap between BMU and TCAll alignment and measurement data will be stored and linked to product scanned serial number

37、s BroConcentric Automation283.1 installation and remeasurementRobot install BMU in to TC opening after successful alignment and adjustmentPrecise load cell will stop the robot when the pressure is reaches the standardRobot take vision system 1 to muti-position to remeasure the X/Y gap between BMU an

38、d TCAll alignment and measurement data will be stored and linked to product scanned serial numbers BroConcentric Automation293.1 Unload And ReloadRotary table rotate the TC back to station 1 and take next TC to station 2Operator unload TC , load another one and wait for next cycleLoad okStep in next

39、 cycleassemble okLoad ok BroConcentric Automation303.1 Location FixtureMachine Main Structure IntroductionThere are maualy loaded locating fixtures for TC and BMU. Locating cylinders will push units into fixed position.Locating fixture for BMU BroConcentric Automation31Machine Main Structure Introdu

40、ction3.1 Location FixtureThere are maualy loaded locating fixtures for TC and BMU. Locating cylinders will push units into fixed position.Locating fixture for BMU BroConcentric Automation323.1 X-Y linear motor modulesMachine Main Structure IntroductionThere are maualy loaded locating fixtures for TC

41、 and BMU. Locating cylinders will push units into fixed position.Positioning pinGuide pillarspringLinear bearingPositioning pinMistake-proof sensor BroConcentric Automation333.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation343.1 X-Y linear motor modulesMachine

42、Main Structure Introduction BroConcentric Automation353.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation363.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation373.1 X-Y linear motor modulesMachine Main Structure Introduction Br

43、oConcentric Automation383.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation393.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation403.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation413.1 X-

44、Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation423.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation433.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation443.1 X-Y linear motor modulesMachine

45、Main Structure Introduction BroConcentric Automation453.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation463.1 X-Y linear motor modulesMachine Main Structure Introduction BroConcentric Automation473.1 X-Y linear motor modulesMachine Main Structure Introduction Br

46、oConcentric Automation48Machine Main Structure Introduction3.1 X-Y linear motor modules BroConcentric Automation49Y direction servo motor module: To carry UUT from the loading position to the measured position and vice versa.It will be convenient for the operator to load and unload UUT.Y direction s

47、ervo motion moduleMain Modules3.2 Y direction servo motor module BroConcentric Automation50Gocator2020Data Points/Profile: 640Z resolution: 6 micons at 19mm FOVMeasurement Range: 3-25mmFOV: 19-26mm Linearity:0.02% MR = 0.005mm at 25mm MROver all precision: 0.006mmScan rate: upto 5K HZTwo 2D lasers:T

48、he two 2D lasers will be calibrated (to get the relative installing distance of Z axis) using calibration blocks with the certain thickness.The 3D image acquired by 2D laser system contains X-Y coordinates information. The software will collect Z-height at any specified positions.Main Modules3.3 Las

49、er system BroConcentric Automation51The intersection point of TPs two edges could be used as the reference point to locate 16 measurement locations. The Z-height information at a specified location can be extracted by the software in this image according to the X-Y coordinates in the SPEC. The Z-hei

50、ght information acquiredby the 2D laser after scanning forms this image.Main Modules3.3 Laser systemA sample of TP image acquired by a 2D lasers sensor. BroConcentric Automation52Location cylinderPOM location PinThe reference plate: It could be changed according to the products of different sizes, s

51、uch as 11 inch, 13 inch, 15 inch. The pushing head of the cylinder equips with the spring to guarantee the pushing strength is certain. It will not make UUT out of shape to avoid the influence on the measurement results.POM supporting blocks: They contact UUT and will not damage the UUT surface. Its

52、 easy for change to keep level accuracy after a period of time of use.Main Modules3.4 Location fixture 53Vibration-proof system is composed of customized marble platform and air spring suspension module.Granite Table: heavy weight, high flatness, would not affected by temperature and humidity change

53、sVibration-proof system: automatic adjust levels, maintain the levelness of the whole platformGas spring system: the vibration efficiency more than 90%, can reduce the vibration coming from the floor and equipment itself.Granite TableGas spring suspension system3.5 Granite table and gas spring suspe

54、nsion system BroConcentric AutomationMain Modules BroConcentric Automation54Work Flow BroConcentric Automation55Automation is homed.Machine(HMI) notifies the operator that it is safe to load.Work Flow4.1 Initial state BroConcentric Automation56Operator puts the UUT into the nest and presses start buttons. Work Flow4.2 Load BroConcentric Automation57Mistake-proofThe machine senses that the UUT is placed co