Patch PRO (3D)

The challenge

3D patch placement

Typical machines are limited to placing components on a 2D surface or plane. This restricts the use of stiffening and design elements on many products or it may require subsequent manual work to achieve the desired result. Faced with the challenge of stiffening unstable, three dimensional surfaces, OECHSLER developed a material-safe, cost-efficient, and precise automated process for 3D patch placement.

Our target for the process was scalability. To achieve this, we need to reach object, shape, and material independence. Simultaneously, we knew the process must deliver the same level of quality as existing technologies, especially for placement accuracy. A particularly challenging aspect of the process was accurate placement of (larger) elements on curved surfaces, requiring a rolling motion by the robot.

The solution

How does the Patch Pro (3D) work?

It all starts with a computer analysis where critical spots in components can be detected at an early stage. The results of the FEM simulation show at which points and to what extent patches are required to meet the desired performance objectives. This minimizes development time and costs typically resulting from many iterations of sample construction and testing. After determining where and to what extent patches should be applied, the process of the Patch PRO (3D) begins. After positioning the patches on a carrier plate, a smart camera system determines the position of the patches, automatically detects the shape of the patches and confirms their quality. Because of this system the order of the patches on the carrier is irrelevant.The patches are picked up with the help of a specialized vacuum gripper and placed on the surface after being activated by heat briefly. The automation reaches a precise placement of the patches, with an accuracy of about 0.2 mm. The system is capable of applying patches of different thicknesses