The essence and key of automated assembly

If an automated assembly line is an onion, what lies at the heart of the onion after peeling back the layers?

First, the outermost layer, which is what we see: the layout, various mechanisms, and actuators.

But why choose one layout over another? Why choose one mechanism over another?

This is because of the second layer of the onion: the constraints!

Constraints include cost, space, cycle time, yield, material characteristics, and compatibility requirements. Constraints often conflict with each other, such as cost, cycle time, and compatibility. However, these conflicts often form a stable design triangle.

For example, in a project, the customer requires a conveyor system that is both flexible and capable of handling large loads. Inflexible circular guides and belt lines with insufficient load capacity may not be suitable. A double-speed chain is an ideal choice within these constraints.

But even if the layout and actuators are chosen appropriately, it doesn’t guarantee long-term stability.

At this point, we’ve peeled back the third layer of the onion: defensive design:

If the tachometer at one station in the line is unstable, a buffer mechanism must be installed to balance time with space. For example, when performing high-precision positioning assembly, a secondary positioning mechanism is needed to eliminate accumulated errors. For example, when assembling easily deformable materials, a guiding or shaping mechanism is needed to increase error tolerance. Defensive design is essentially about combating the imperfections and unexpectedness of the real world.

Real-world imperfections arise from both the materials themselves and errors in the workpieces. Furthermore, they arise from various sources, such as electromagnetic interference, mechanical wear, and oxidative corrosion.

This brings us to the core of the onion: the interaction between the digital and analog worlds and the real world.

Industry is essentially a digital and analog world, constructed according to mathematical laws. Reality, however, is a chaotic world, where mathematical ideals are elusive. Automated assembly, in essence, harnesses the human brain to combat reality. The digital-analog world can only operate automatically through human-machine collaboration. If one day artificial intelligence opens the last door and allows the digital-analog world to adapt to the chaos of reality, then the automation industry will enter a new era!