<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.

Automated Voice Coil Assembly for Audio Devices

<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
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

https://www.youtube.com/watch?v=Yyu4elBIGbg

Adaptive Robotic Keyboard Testing

Automated Voice Coil Assembly for Audio Devices

Automated Charging Solution for Electric Vehicles

Automated Adhesive Primer Application in Automotive Assembly