<h3>At a Glance</h3>
&bull; Customer: A leading automotive seat supplier (Subject to an NDA). &bull; Problem: The time-consuming and labor-intensive task of removing creases from leather seats. &bull; Solution: Flexiv utilized a Rizon 4 robot coupled with an off-the-shelf steam iron to fully automate the ironing process for leather seats. &bull; Key Features: Real-time data collection, advanced force control capabilities, and customized tooling to attach ironing equipment. &bull; Advantages: Precise real-time force sensing, safe human-robot collaboration, consistent results, and adaptability to various seat models.
&nbsp;
<h3>Overview</h3>
Automotive seats are composed of metal frames, sprung cushioning, and foam padding. Upholstery, in the form of fabric or leather, is then sewn over this base to create a cover. When the cover is leather, the stitching process often leads to wrinkling and creasing due to the seat's curvature and the leather's inflexible nature. Since these wrinkles are unsightly, manufacturers have traditionally used manually operated irons to smooth the surface of the leather. While effective, this manual method introduces the element of human error and, with the irons operating at high temperatures, exposes workers to potential burns or scalding, potentially endangering their health.
<h3><img src="/uploaded/en/PartnerCase/content/2024/04/15/v1ovy482t5.jpg" alt="" width="1080" height="807" /> Customer Profile</h3>
As a leading Asia-based automotive seating provider, the client is renowned within the automotive industry for their dedication to quality and innovation in material and leather seat manufacturing. Seeking to automate the labor-intensive process, the client approached Flexiv to automate their crease removal process while maintaining their trademark superior levels of craftsmanship and customer satisfaction.
<h3> Flexiv's Solution</h3>
Flexiv's automotive seating ironing application leverages a Rizon 4 adaptive robot in combination with a standard steam iron. By utilizing the Rizon 4's precise force control capability, Flexiv's solution can replicate the pressure and sensitivity employed by an experienced worker when ironing. This ensures a consistent yet compliant application of force across various seat models, boosting production efficiency and eliminating the risk of injury or human error.
&nbsp;
<h3>Key Advantages</h3>
1. Contour Tracking
<img src="/uploaded/en/PartnerCase/content/2024/04/15/mvgu6cq8mxm.gif" alt="" /> &bull; The Rizon 4 utilizes a joint force control servo operating at 5000Hz and a 1000Hz whole-arm coordination algorithm for an ultra-high response rate, enabling instantaneous adaptation to seat curvature. &bull; Able to sense and adapt to the resistance of the foam, the robot maintains the exact pressure required for optimal crease removal with a precision level that meets or exceeds human capability.
&nbsp;
2. Rapid Deployment and Debugging
<img src="/uploaded/en/PartnerCase/content/2024/04/15/97v426r18s.gif" alt="" width="640" height="360" /> &bull; Flexiv's graphical programming system, Flexiv Elements, allows engineers to quickly create new programs for different seat models using a library of pre-programmed primitive function blocks. &bull; Rizon's &lsquo;free-float&rsquo; functionality enables engineers to record new ironing trajectories for faster, simpler debugging and deployment. &bull; Whole-body force control ensures that Rizon is inherently safe, allowing operation without cages or barriers in close proximity to human workers.
&nbsp;
3. Mixed-Line Production
<img src="/uploaded/en/PartnerCase/content/2024/04/15/k29ja92ut9k.gif" alt="" /> &bull; Once programmed, the Rizon 4 can operate on multiple seating models in succession, enabling a true mixed-line production process. &bull; With an end-effector force control accuracy of 0.03N, Flexiv's ironing solution can achieve a greater precision than is humanly possible. &bull; Compatible with computer vision solutions, Rizon's integrated AI can enable the robot to detect seat creases and automatically select the most efficient ironing strategy.
&nbsp;
4. Real-time Quality Assurance&nbsp;
<img src="/uploaded/en/PartnerCase/content/2024/04/15/anoh2jhxs4.png" alt="" width="800" height="473" /> &bull; Force control data from every stage of the ironing process is automatically recorded, allowing the full traceability of every seat coving ironed. Real-time data can also be monitored, either manually or automatically, for error detection and metric analysis.
&nbsp;

Automated Ironing Solution for Electric Vehicles

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<h3>At a glance</h3>
&nbsp;
Customer: A leading automotive supplier (Subject to an NDA).
Problem: The calibration and automated testing of turn signal levers.
Solution: Flexiv designed a testing and calibration system utilizing a Rizon 4s adaptive robot which included scheduling, data collection, communication, &nbsp;IPC, and trajectory planning functions.
Key Features: Real-time data collection, data mapping, trajectory planning, and customizable host control systems.
Advantages: Precise real-time force-sensing accuracy, enhanced safety features, scalability, and improved line-changeover speed.
&nbsp;
<h3>Overview</h3>
&nbsp;
The calibration and testing of turn signal levers are critical phases in automobile manufacturing. To ensure the levers operate correctly, Flexiv engineers developed an automotive steering column calibration system. Utilizing the Rizon 4s robot, the system collects data from the TCP (Tool Center Point) and compares it with readings from the steering column's Hall effect sensors. The gathered data is then mapped and confirmed by the steering column sensors to guarantee accurate calibration and functionality.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/lqnb3vvhx0g.JPEG" alt="" />
<h3>Customer Profile&nbsp;</h3>
&nbsp;
The customer is a leading automotive supplier, providing a wide range of OEM products to the automotive industry.&nbsp;
&nbsp;
The customer approached Flexiv to automate the labor-intensive process of manual steering column testing. Due to the proximity of the testing site to staff members, the customer emphasized that the solution must prioritize safety and facilitate seamless human-robot collaboration.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/hzgbz4c7gm8.gif" alt="" />
<h3>Flexiv's Solution</h3>
&nbsp;
Employing the adaptive Rizon 4 robot and the Flexiv Robot Development Kit (RDK), Flexiv engineers developed a comprehensive steering column lever testing and calibration system. This system encompasses modules for scheduling, data collection, communication, memory, IPC (Inter-Process Communication), and trajectory planning.
&nbsp;
During testing, the robot follows a planned trajectory to evaluate the steering column's functions. As each lever is activated, the robot&rsquo;s end position and force data are captured in real-time and synchronized via an SPI (Serial Peripheral Interface). Should the robot identify a fault in the steering column, the event is flagged, and the production manager is automatically notified.
<h3><img src="/uploaded/en/PartnerCase/content/2024/02/01/qv8dplz6wb.gif" alt="" /> Technical Features</h3>
&nbsp;
Real-time Data Collection
The Flexiv RDK gathers and transmits data concerning the robot's end TCP position and the external forces experienced by the robot when it activates a steering column lever function. &nbsp;
Robot Motion Planning
Utilizing standard numerical modeling and kinematic trajectory planning, the system ensures precise end-effector TCP movements. This, combined with a rigid connection between the steering column and the robot, facilitates highly accurate testing.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/uilf71m518q.gif" alt="" width="640" height="401" />
<h3>Solution Advantages</h3>
&nbsp;
Real-time Precision&nbsp; The Rizon 4 robot features a force-sensing accuracy of 0.03N and a response frequency of 1kHz, resulting in a communication delay of just 1ms.
 Easy-to-Deploy Automatic trajectory planning is facilitated by a single point, enabling rapid and efficient testing. The host control system can be fully customized, making the line changeover process both cost-effective and straightforward.
 Safe and Reliable Flexiv&rsquo;s adaptive robots are CE and ETL certified, ensuring the safety of human-robot collaboration while enabling flexible deployment.&nbsp;
</div>
</div>

Automotive Signal Switch Calibration

<h3>Overview</h3>
&nbsp;
In June 2023, at the Science Centre Singapore, the large-scale STEM performance "The Electrified Show" was organized. The adaptive robot Dawn Rizon 4 played a significant role as an "actor", collaborating with human performers to bring a story that transcends time and space to children and teenagers.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/qfjxif3g8tr.jpg" alt="" width="1280" height="854" />
<h3>Case Introduction</h3>
&nbsp;
Client: Science Centre Singapore
Organized by the Science Centre Singapore, "The Electrified Show" is the first large-scale STEM + special effects performance in Singapore's history. The show aims to allow children of all ages to travel through time, space, and dimensions amidst a spectacular display composed of lights, lasers, robots, drones, dance, flames, and magical effects, experiencing the allure of technology up close.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/w4mp3ys5sy.jpg" alt="" width="1280" height="853" />
According to the script, Rizon Dawn portrays one of the "guardians" of cosmic energy and has some interesting interactions with the main character and supporting characters who accidentally enter this space. The adaptive robot's flexible characteristics make its movements appear very humanoid, providing the audience with a novel and enlightening experience.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/tiafioxxxqr.png" alt="" />
<h3>Technical Features</h3>
&nbsp;
1. With seven degrees of freedom, Dawn possesses advanced industrial-level force control, allowing it to move smoothly and dexterously, much like a human, and to intimately interact with people. When human performers push Dawn's joints or endpoints, this robot "actor" can continue to operate, vividly showcasing a "confrontational" storyline.
&nbsp;
2. By using the graphical programming system Flexiv Elements, staff from the Science Centre Singapore can intuitively and concisely program and control the robot, leveraging the many functions and features of Rizon 4.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/4jg5jbxij4d.gif" alt="" />
As an academic, researcher, and artist, Professor Stavros's work focuses primarily on technological futures with a particular emphasis on architectural augmentation, sensorial interfaces and technological frameworks as extensions of human environments.
 He stated: &lsquo;Collaborating with Flexiv was a great experience. Flexiv's engineers helped optimize various algorithms, allowing me to fully control the robot and make sure its movements were as natural as possible. In terms of design, size, and functionality, Rizon 10 is very suitable, and it can handle the complexity of this project.'

Rizon 4 Performing in STEM Event The Electrified Show

<h3>At a glance</h3>
&nbsp;
Customer
A leading new energy car company.
Problem
Ensuring the quality of car bodywork and worker safety while performing weld grinding tasks.
Solution
Flexiv introduced an adaptive grinding solution using the Rizon 10 robot and standard electric grinding tools.
Key Features
Adaptive polishing, user-friendly operations, and adherence to international human-robot interaction safety standards.
Advantages
Cost-effectiveness, improved polishing quality, user-friendly experience, safe and flexible deployment.
&nbsp;
<h3>Overview</h3>
&nbsp;
Welding is critical to the automobile production process; however, due to the nature of the activity, it is common to encounter slag and enlarged weld seams that will seem unsightly once the car body is painted. Although not safety critical, eliminating these imperfections is vital before the priming and undercoating of paintwork.
<h3> Case Study Customer</h3>
&nbsp;
A Leading New Energy Car Company (Subject to an NDA) A leading electric car manufacturer customer wished to introduce automated weld grinding into their production process so that they could guarantee the quality of their car's bodywork. An essential aspect of this project was that the robots would operate within the same area as human workers. Because of this, safety and efficient space utilization was of paramount importance.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/wyyc77xs33.gif" alt="" width="440" height="248" />
<h3>Flexiv's Solution</h3>
&nbsp;
Harnessing the Rizon 10's full-body force control, in combination with standard electric grinding tools, Flexiv's adaptive grinding solution was created. By utilizing the robot's inbuilt force control capability, the need for costly and less precise force-controlled end-of-arm tooling was removed, along with the need for specialized robotic grinding tools.
&nbsp;
The Rizon 10's force control also enabled the introduction of force-controlled height probing. This groundbreaking approach allows the robot to 'feel'exactly when the welds are ground down to the base level of the bodywork. More precise and consistent than humanly possible, this technique substantially raised the overall grinding quality.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/hes01u9qt8k.jpg" alt="" />
<h3>Technical Features</h3>
 Adaptive Polishing Flexiv's solution automatically employs force-controlled height probing for adaptive polishing to ensure that welds are ground entirely flush with the level of the base material.
&nbsp;
User-Friendly Primitives Common grinding primitives, or pre-sets, are included in the drag-and-drop-based Elements programming system. This significantly reduces robot downtime when creating new polishing tasks while eliminating the skill-based barrier to entry for robotic programming. &nbsp;
&nbsp;
Safe and Reliable Flexiv's Rizon 10 robot meets international human-robot interaction safety standards and holds CE and ETL dual safety certifications. This ensures safe and reliable human-robot interactions in shared workspaces.
<h3> Solution Advantages</h3>
&nbsp;
Straightforward and Cost-Effective Flexiv's grinding solution doesn't require additional floating grinding tools or force control systems. This enables significant savings to be made in both initial outlay and maintenance.
&nbsp;
Improved Polishing Quality Adaptive positioning technology eliminates the problems caused by over or under-grinding, resulting in a superior surface finish compared to manual techniques.
&nbsp;
User-Friendly Experience Deployment is straightforward thanks to the Flexiv Elements graphical programming system. Once a task has been created, modifications can be made on the fly for maximum customizability.
&nbsp;
Flexible Deployment and Safe Collaboration Flexiv's grinding solution can be safely and flexibly deployed in fully automated or hybrid automated/manual production lines without requiring extensive line modifications.

Automated Weld Grinding for Automotive Manufacturing

<h3>At a glance</h3>
&nbsp;
Customer
A leading automobile manufacturer (Subject to an NDA).
Problem
High costs, human error, and inconsistencies associated with manually removing welding debris.
Solution
Flexiv introduced an automated grinding solution using the Rizon 10 robot with off-the-shelf electric grinding tools.
Key Features
Simplified operations, human-inspired adaptability, safe and efficient human-robot interaction.
Advantages
Consistent, high-quality results, cost-effectiveness, and ease of deployment.
&nbsp;
<h3>Overview&nbsp;</h3>
&nbsp;
Welding is a vital element of the automobile manufacturing process. However, it frequently leaves various surface defects, such as welding spatter, slag, and uneven surfaces. These defects can significantly impact the later stages of assembly, especially if the affected surface is to be mated to another or if it is going to be painted.&nbsp;
&nbsp;
Complex shapes, large sizes, tolerance variations, and throughput demands of the workpieces make automated grinding and polishing a significant challenge.&nbsp;
&nbsp;
Most automobile manufacturers rely on manual labor to perform body surface grinding and polishing tasks. However, this approach dramatically increases the production cost while inserting the possibility of human error.&nbsp;
<h3>&nbsp; Case Study Customer</h3>
&nbsp;
(Subject to an NDA)
The customer's previous strategy for welding spatter involved applying an anti-spatter compound to the surrounding surfaces before welding. Given the limited effectiveness of the anti-spatter compound, manual labor was used to remove the compound and the spatter. This resulted in a laborious and expensive process, which made it difficult to maintain a consistent level of quality.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/o7h1kucub.gif" alt="" width="440" height="248" />
<h3>Flexiv's Solution&nbsp;</h3>
&nbsp;
Leveraging its full-body force control capability, Flexiv's Rizon 10, equipped with standard off-the-shelf electric grinding tools, provided the customer with a fully automated grinding solution.
&nbsp;
Thanks to its state-of-the-art hybrid motion and force control technology, the Rizon 10 can adapt to complex curved surfaces to deliver superior polishing results without requiring additional force control tools or specialized grinding equipment.
&nbsp;
By packaging the polishing process into meta-operation primitives, and using straightforward trajectory dragging/teaching, in combination with a graphical programming interface, the skill-based barrier to entry is removed, and the deployment time is massively decreased.&nbsp; &nbsp;<img src="/uploaded/en/PartnerCase/content/2024/02/01/gp4ag4pw1pv.gif" alt="" width="440" height="248" />
<h3>Technical Features</h3>
&nbsp;
1. Flexiv simplifies the programming of the material removal process by including multiple user-friendly meta-operations into the Flexiv Elements system to ensure ease of use, even for those new to the technology.
&nbsp;
2. Inspired by human adaptability, advanced force control, and precise movement control enable the robot to modify its actions to conform and maintain stable pressure on complex or irregular surfaces.&nbsp;
&nbsp;
3. Designed for safe and efficient human-robot interaction, Flexiv's material removal solution can work next to or fully replace manual workstations. With a compact footprint, the debris removal process is streamlined while efficiency and workpiece quality are increased.&nbsp;
<img src="/uploaded/en/PartnerCase/content/2024/02/01/gapstc28mg.gif" alt="" width="640" height="360" />

Automated Welding Debris Removal in Automobile Manufacturing

<h3>Overview</h3>
 In the avant-garde art installation "Xenoforms" exhibited in 2022, Professor Stavros Didakis of New York University employed the adaptive robot Rizon 10 as the "protagonist" to demonstrate how robots autonomously observe and explore inorganic entities generated by artificial intelligence. The work depicts how cutting-edge technology, especially computer technology, follows its strategies to colonize architectural spaces and evolve into a symbiotic entity with humans.
<h3> Case Introduction</h3>
 Case Study Customer
Stavros Didakis, Greek Media Artist, and Professor at New York University
 "Xeno" originates from the Greek word &xi; &nu;&omicron;, meaning "foreign, alien", referring to organisms or artificial organisms that invade the local host's ecological environment. In "Xenoforms", they are entities generated through 3D printing with randomly AI-generated models.&nbsp;
<img src="/uploaded/en/PartnerCase/content/2024/02/02/y8k33vcm8j.gif" alt="" />
Rizon 10 randomly patrols these Xenos, then selects, grasps and places them, observing them like a laboratory researcher. After the observation, the Xeno is returned to its original position, and Rizon 10 continues the next round of search.
&nbsp;
<h3>Technical Features</h3>
 1. "Xenoforms" fully utilizes the design features and technical capabilities of the adaptive robot Rizon 10. The deep gray aluminum alloy surface creates a futuristic feeling that matches the installation theme, while its rigorous and modern design language provokes more thoughts on the fusion of humanities and technology.
&nbsp;
2. With seven degrees of freedom, Rizon 10 can achieve a patrol range as wide as a human arm, while advanced force control ensures the arm's smooth movement and flexible grasping motions, which makes the robot more 'human-like' without damaging objects.&nbsp;
<img src="/uploaded/en/PartnerCase/content/2024/02/02/p184smb09v.gif" alt="" />
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As an academic, researcher, and artist, Professor Stavros's work focuses primarily on technological futures with a particular emphasis on architectural augmentation, sensorial interfaces and technological frameworks as extensions of human environments.
He stated: &lsquo;Collaborating with Flexiv was a great experience. Flexiv's engineers helped optimize various algorithms, allowing me to fully control the robot and make sure its movements were as natural as possible. In terms of design, size, and functionality, Rizon 10 is very suitable, and it can handle the complexity of this project.'
</div>
</div>

Avant Garde Art Installation Xenoforms

<h3>At a glance</h3>
&nbsp;
Customer
A renowned new energy car company (Subject to an NDA).
Problem
Reliance on manual labor for potentially harmful primer application tasks in automotive manufacturing.
Solution
Flexiv&rsquo;s adhesive primer application system uses the Rizon 4 adaptive robot and a customized brush in conjunction with a standard adhesive supply system.
Key Features
High-response force control, force-controlled application.
Advantages
Tolerance to workpiece positional errors, consistent results, easy deployment, and scalability.
&nbsp;
<h3>Overview&nbsp;</h3>
&nbsp;
Adhesive primer is applied to work surfaces to maximize the bond that forms between the work surface, primer, and adhesive. The primer application process is commonly employed for pre-treating different materials such as metals, non-metals, and polymers before adhesive bonding, and it&rsquo;s essential in the installation of automotive glass.
&nbsp;
Primers are often made from volatile solvents, which are potentially harmful to human health. Despite this, most automotive priming processes are currently performed manually.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/x9k8syejs5o.png" alt="" width="1970" height="1182" />
<h3>Case Study Customer</h3>
&nbsp;
A Renowned New Energy Car Company (Subject to an NDA)
The customer had previously heavily depended on manual labor during their production process. Faced with challenges such as high labor turnover, recruitment costs, and the desire to enhance production quality and overall automation, they sought an automated solution to apply adhesive primer. They aimed to implement an automatic cleaning and priming station, bolstering their production quality and throughput.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/4rjv2u7t9qt.png" alt="" />
<h3>Flexiv&rsquo;s Solution</h3>
&nbsp;
Flexiv&rsquo;s automotive adhesive primer application employs a Rizon 4 adaptive robot, a customized brush, a standard adhesive supply system, and a gluing software package.
&nbsp;
This solution does not require computer vision, as the Rizon 4&rsquo;s hybrid motion and force control maintains a consistent force between the brush and the workpiece, enabling even curved or uneven surfaces to be treated without specialized programming. The solution exhibits high tolerance to workpiece misalignment and can be rapidly deployed into any installation, regardless of size or shape.
<h3><img src="/uploaded/en/PartnerCase/content/2024/02/01/acc8p9z9h4h.gif" alt="" width="640" height="360" /> &nbsp; Technical Features</h3>
&nbsp;
Responsive Force Control With a 0.1N force sensing accuracy and a 1KHz high-response control frequency, Flexiv&rsquo;s application solution ensures a constant contact pressure, resulting in a uniform and stable primer quality.
 Force-Controlled Application Real-time feedback and force control from the contact between the robot&rsquo;s end-of-arm tool and the workpiece enables the surface to be tracked exactly. This allows complex curvatures to be followed and reduces coating breakage and trajectory issues. <img src="/uploaded/en/PartnerCase/content/2024/02/01/2zvxt1ljg9q.gif" alt="" />
<h3>Solution Advantages</h3>
&nbsp;
High Trajectory Error Tolerance Rizon&rsquo;s hybrid motion force control counters position disturbances from workpiece misalignment or imperfections, ensuring comprehensive surface coverage and no coating breaks.
&nbsp;
Consistent Results The application has demonstrated a coverage and accuracy rate exceeding 99% in rigorous real-world testing.
&nbsp;
Easy Deployment Users can create gluing paths easily with Flexiv Elements, our drag-and-drop programming interface. This easy-to-use yet powerful software provides operators with unparalleled command and control capability.
&nbsp;
Scalability Fully customizable and infinitely adaptable, Flexiv's adhesive application solution can be seamlessly integrated into any production environment.

Automated Adhesive Primer Application in Automotive Assembly

<h3>At a glance</h3>
&nbsp;
Customer
Hycan, a Mobility Power Supply (MPS) product designer.
Problem
Inefficiencies and high costs associated with electric vehicle charging in parking lots.
Solution
Flexiv devised an innovative mobile automatic charging system comprising of an Autonomous Mobile Robot (AMR) with an adaptive robot. This system leverages artificial intelligence, computer vision, and force control to automate car charging.
Key Features
Seven degrees of freedom, precision-based control, artificial intelligence, machine vision, dual safety certifications, and the adaptability to charge any electric car model.
Advantages
Enhanced safety, optimized operation, universality, and flexibility in handling different car models. 
<h3>Overview&nbsp;</h3>
&nbsp;
With the rapid adoption of electric cars, parking lots are increasingly looking to offer car charging solutions to their customers. Installing a dedicated car charger per parking space is often impossible or cost-prohibitive though. Flexiv developed a solution to this problem by mounting an adaptive robot to a mobile platform that can navigate the car park and automatically insert the charging connector in the car charging port.
<h3> Case Study Customer</h3>
&nbsp;
Hycan
Hycan is committed to designing secure and efficient Mobility Power Supply (MPS) products. Their mission is to deliver dependable and convenient charging services while tackling the issues prevalent in parking lot charging scenarios. These include inefficient use of charging stations, underutilization of parking spaces, and time constraints for vehicle owners.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/01hfbbcqpos3.jpg" alt="" />
<h3>Flexiv&rsquo;s Solution</h3>
&nbsp;
Flexiv&rsquo;s adaptive mobile charging solution revolutionizes parking lot charging by combining an AMR (automounts mobile robot) with an adaptive robot that uses artificial intelligence, computer vision, and force control.
&nbsp;
Mirroring how a human would manipulate the charging plug, Flexiv&rsquo;s robot can use a combination of vision and force control to ensure that the plug is always correctly inserted into the car&rsquo;s socket. Featuring seven degrees of freedom, and the ability to navigate in a car park safely and reliably independently, Flexiv&rsquo;s charging solution can calculate an optimized pathway to ensure its charging task is completed quickly and efficiently.
&nbsp;
This focus on safety is further reinforced through the solution of dual CE and ETL certification and its AI engine, which prioritizes the protection of individuals and vehicles at all times.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/r6d4uz7gxc.gif" alt="" /> &nbsp;
<h3>Technical Features</h3>
&nbsp;
Complete with seven degrees of freedom, a whole-body control algorithm, computer vision integration, industry-leading force control, and artificial intelligence Flexiv&rsquo;s charging solution can utilize adaptive control strategies to perform actions like a human.
 1. The solution&rsquo;s high-speed, precision-based control ensures accurate and reliable task completion.
2. Dual CE and ETL safety certifications provide peace of mind that the robot meets or exceeds international safety and quality standards.&nbsp;
3. A reliable and adaptable AI vision algorithm provides exceptional tolerance to lighting changes, and secondary camera angles are used to enhance object recognition accuracy.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/789y0ducnb4.gif" alt="" />
<h3>Solution Advantages</h3>
&nbsp;
Safety and Reliability Leveraging high-precision force control and inbuilt safety features, Flexiv&rsquo;s automatic charging solution guarantees the safety of personnel, vehicles, and charging devices during the charging process. &nbsp;
Compliant Operation A human-inspired approach to object manipulation, supported by multiple force control strategies and compliance control, enables the charging solution to eliminate port damage caused by posture, position, trajectory accuracy, and other variables. &nbsp;
Universality and Flexibility Due to an adaptive robot&rsquo;s unique force control ability and a highly adaptable AI vision algorithm, it can adapt itself to any make and model of the electric car. This means that the robot can complete the charging task regardless of body styling, port location, or charging port height.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/7jhv3a7edtk.gif" alt="" />

Automated Charging Solution for Electric Vehicles

<h3>At a glance</h3>
&nbsp;
Customer&nbsp;
An undisclosed leading audio device manufacturer.
Problem
The complex, time-consuming, and manual process of voice coil assembly in audio devices.
Solution
Flexiv provided a unique interference-fit assembly solution leveraging advanced computer vision and industry-leading force control technology.
Key Features
Adaptive grasping, force-controlled searching, and component insertion.
Advantages
Enhanced assembly quality, improved operational efficiency, flexibility, and the universality of the assembly process.
<h3> Overview&nbsp;</h3>
&nbsp;
With the ever-increasing demand for smartphones, tablets, and wireless earphones, the audio device industry has, in turn, seen increased demand. As the audio devices become smaller and more complex, the audio component assembly process becomes more challenging to automate. This, in turn, leads to lower automation rates and higher production costs. To combat this, Flexiv created a solution to automate the installation of the minute and delicate components that form the 'voice coil', a core element found in all speakers, earphones, and other audio-based devices. &nbsp;
<h3>Case Study Customer</h3>
&nbsp;
(Subject to an NDA)&nbsp;
Voice coil assembly is a difficult and time-consuming process that the customer sought to automate. A challenging task due to the irregular shape and deformable nature of the wires that form the coils, the client clarified that they wished for a coil assembly yield of over 99% and a reduction in installation angle deviations by at least 25% compared to manual processing.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/6p703bkdgen.png" alt="" />
<h3>Flexiv's Solution</h3>
&nbsp;
Flexiv provided a unique solution for the interference-fit assembly of voice coils, which leveraged advanced computer vision and Flexiv's industry-leading force control technology.
&nbsp;
Our solution achieved pinpoint accuracy in coil positioning and rotation using standardized components and AI-powered vision.
&nbsp;
With force-controlled handling eliminating coil deformation during manipulation and assembly phases, workpiece damage was negligible. This damage reduction was also empowered via the implementation of the vision-guided insertion, which ensured accurate coil insertion. &nbsp;<img src="/uploaded/en/PartnerCase/content/2024/02/01/djg8d8tdif8.jpg" alt="" />
<h3>Technical Features</h3>
&nbsp;
Adaptive Grasping
Flexiv's proprietary force-control technology adapts to positional errors, ensuring accurate and non-deformable grasping.
Force-Controlled Searching
Precise placement into installation grooves is enabled using a fine force-controlled -searching algorithm.&nbsp;&nbsp;
Force-Controlled Insertion
Specific pressure is applied by the robot in conjunction with a slight oscillation until a designated force value is reached and the force-controlled insertion process is complete.
<img src="/uploaded/en/PartnerCase/content/2024/02/01/m45wylujkqo.png" alt="" width="1826" height="1028" />
<h3>Solution Advantages</h3>
&nbsp;
Enhanced Quality
Flexiv's voice coil assembly process has a yield rate greater than 99% and an angle deviation rate below 25%.
Automated Efficiency
Able to fully replace the manual processing of voice coils, Flexiv's solution provides an improved throughput rate and the ability to operate in a 'lights out' manufacturing environment.&nbsp;
Flexibility and Universality
Leveraging the robot's inherent force control capabilities and ease of programming, a user can re-task the robot quickly and efficiently with minimal downtime.

Case Study