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<h3 class="heading-2 ace-line old-record-id-GCEsdY7jwoYf9jxYoMpczpdSnfd"><strong>At a Glance</strong></h3>
<p>&nbsp;</p>
<div class="ace-line ace-line old-record-id-UpUYdLMWkoykYnxNirzcqgj6ndg"><strong>Customer:</strong> A leading electric vehicle manufacturer (NIO).</div>
<div class="ace-line ace-line old-record-id-ASt3d7jq9oXJqzxaeODczd8ZnLm"><strong>Problem:</strong> Before leaving the factory, every vehicle must undergo a series of rigorous inspections to ensure it is fully functional and ready for delivery to the end customer. Traditionally, this manual process was time-consuming, labour-intensive, and susceptible to human variability.</div>
<div class="ace-line ace-line old-record-id-LUSbdbLILoe0bjxov1McUhiknYd"><strong>Solution:</strong> Flexiv deployed two Rizon 10 adaptive robots, integrated with visible-light and thermal vision modules and an AI-powered self-inspection system, to automate seat inspection, interior trim verification, and charging capacity testing. The result is consistent, high-quality inspection at significantly higher speed.</div>
<div class="ace-line ace-line old-record-id-SdMHdN28zoXatcxsL4EcPRf1nnh"><strong>Key Features:</strong> Advanced force and compliant motion control, thermal imaging inspection, intelligent interior inspection, mixed-model compatibility, and data-driven manufacturing.</div>
<div class="ace-line ace-line old-record-id-QtC7d4gTsoSGMgxWpsxceqgZnGf">&nbsp;</div>
<h3 class="heading-2 ace-line old-record-id-V5jTdb047on1OJxDavVcUcgrnud">Overview</h3>
<p>&nbsp;</p>
<div class="ace-line ace-line old-record-id-Bg1udo0qvoYe3FxENELcbs8Ynod">To enhance production quality, consistency, and efficiency, NIO partnered with Flexiv to fully automate its vehicle quality assurance process. Flexiv&rsquo;s adaptive robots now validate charging functionality, seat operation, and interior components with 100% precision and repeatability. By automating what was once a manual process, inspection efficiency has increased while quality standards have been elevated.</div>
<div class="ace-line ace-line old-record-id-Y9ohd8Cx6ob4plxgKLeceVdPnGb">&nbsp;</div>
<h3 class="heading-2 ace-line old-record-id-QWFBdNohpog3XqxvwNsci2iPnxe"><strong>Flexiv</strong><strong>&rsquo;s Solution </strong></h3>
<div class="image-uploaded gallery old-record-id-WXDNdNx1toXoDjxyMTIcwMrJnah" data-type="image" data-ace-gallery-json="{&quot;items&quot;:[{&quot;uuid&quot;:&quot;13c71c5f-08e2-4288-ac35-604ee8b7c270&quot;,&quot;height&quot;:3142,&quot;width&quot;:3200,&quot;currHeight&quot;:3142,&quot;currWidth&quot;:3200,&quot;natrualHeight&quot;:3142,&quot;natrualWidth&quot;:3200,&quot;pluginName&quot;:&quot;imageUpload&quot;,&quot;scale&quot;:1,&quot;src&quot;:&quot;https%3A%2F%2Finternal-api-drive-stream.feishu.cn%2Fspace%2Fapi%2Fbox%2Fstream%2Fdownload%2Fpreview%2FX7qqbVT3loHqX7xBUxqcpf7BnJd%2F%3Fpreview_type%3D16&quot;,&quot;file_token&quot;:&quot;X7qqbVT3loHqX7xBUxqcpf7BnJd&quot;,&quot;image_type&quot;:&quot;image/jpeg&quot;,&quot;size&quot;:1417335,&quot;comments&quot;:[]}]}"><img src="/uploaded/en/PartnerCase/content/20260115-164400.jpg" width="880" height="3142" data-single-block="true" data-snapshot="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" data-suite="eyJmaWxlVG9rZW4iOiJYN3FxYlZUM2xvSHFYN3hCVXhxY3BmN0JuSmQiLCJvYmpUeXBlIjoiZG9jeCIsIm9ialRva2VuIjoiV1hETmROeDF0b1hvRGp4eU1USWN3TXJKbmFoIiwib3JpZ2luU3JjIjoiaHR0cHM6Ly9pbnRlcm5hbC1hcGktZHJpdmUtc3RyZWFtLmZlaXNodS5jbi9zcGFjZS9hcGkvYm94L3N0cmVhbS9kb3dubG9hZC9wcmV2aWV3L1g3cXFiVlQzbG9IcVg3eEJVeHFjcGY3Qm5KZC8/cHJldmlld190eXBlPTE2In0=" data-src="https://internal-api-drive-stream.feishu.cn/space/api/box/stream/download/all/X7qqbVT3loHqX7xBUxqcpf7BnJd/?mount_node_token=WXDNdNx1toXoDjxyMTIcwMrJnah&amp;mount_point=docx_image" data-width="3200" data-height="3142" data-lark-image-uri="drivetoken://X7qqbVT3loHqX7xBUxqcpf7BnJd" data-lark-image-width="3200" data-lark-image-height="3142" /></div>
<h3 class="heading-2 ace-line old-record-id-U1UFdSzpkoDZCuxSQ2GcBjoQnkb"><strong>HOW IT WORKS</strong></h3>
<p>&nbsp;</p>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-ZnDRd5pppoPKh7x8zjXcNXlNnfh" data-list="bullet">
<div><strong>Tool Selection &amp; Coarse Visual Positioning</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-BK5Mdp0PZo3bYjx9Rf9cn47jnzc">The EV model is automatically identified, and the appropriate charging plug is selected. Using coarse visual positioning, the robot moves the plug to the vicinity of the charging port.</div>
<div class="ace-line ace-line old-record-id-FuFZd0mrDoZZawx0mikcZqXJnSZ"><img src="/uploaded/en/PartnerCase/content/选择工具_01.gif" alt="" width="880" height="472" /></div>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-FcsHdzpwaoewhqxDmeocSXLJn88" data-list="bullet">
<div><strong>Compliant Insertion &amp; Charging</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-S43BdLY1io5nv9xEO6dc5ZSmnne">Through a combination of force control strategies and compliant motion, the robot inserts the charging plug in a manner that closely replicates human handling. Once connected, the charging current test is initiated and evaluated.</div>
<div class="ace-line ace-line old-record-id-WUVadVSjno0VAJxYNH7cqiZUneZ"><img src="/uploaded/en/PartnerCase/content/柔顺插拔_01.gif" alt="" width="880" height="464" /></div>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-IBCAdS8xcoDqBVxVuL7c6tDonKe" data-list="bullet">
<div><strong>Thermal Imaging Verification</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-A81Mdeow9ooW6wx3dPWcFKkPn1d">A robot-mounted thermal camera verifies the performance of heated comfort features installed in the vehicle. Any abnormality or failure is automatically detected and flagged by the AI inspection system.</div>
<div class="ace-line ace-line old-record-id-OVNLdMu78oTWCqxkcJbcIv5Pnqe"><img src="/uploaded/en/PartnerCase/content/热成像.mp4.gif" alt="" width="880" /></div>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-P7g4dqj0NoIvgrxmgXrczDtnnpb" data-list="bullet">
<div><strong>Intelligent Interior Inspection</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-KprNdxNjSofAlPx0WG3cRpesnBg">By combining computer vision with smart inspection algorithms, the system evaluates seat leather quality, colour consistency, stitching accuracy, and infotainment system configuration to ensure compliance with customer requirements.</div>
<div class="ace-line ace-line old-record-id-VsAVdrhx3or9WwxCzgbcOBb8njB"><img src="/uploaded/en/PartnerCase/content/内饰检测_batch.gif" alt="" width="880" /></div>
<h3 class="heading-2 ace-line old-record-id-VjNWdSJQVoEX04xjWsdcn8uanIb"><strong>Project Advantages</strong></h3>
<p>&nbsp;</p>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-F4s2dgy59oaeN5x07YScOHK2nJf" data-list="bullet">
<div><strong>Significantly Improved Inspection Speed</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-RFpqdL2mLoE1tMxbALYcvTotnRg">Three major inspection steps are completed in just 84 seconds, delivering a 48 percent efficiency improvement over manual inspection.</div>
<div class="ace-line ace-line old-record-id-Z2vidfe6doUFvOxYzDKc55tSnsc"><img src="/uploaded/en/PartnerCase/content/1.png" alt="" width="880" height="494" /></div>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-DLc5damRMonjOxxLyWIcCm2Anfc" data-list="bullet">
<div><strong>Inspection Accuracy Beyond Human Capability</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-BJ1RdI9kiogkHDxbxmScgQ77nPf">Advanced force control and vision algorithms prevent damage to charging ports caused by improper connector handling and eliminate common human inspection oversights.</div>
<div class="ace-line ace-line old-record-id-ZwZBdoRIIo1rCSxrpQMcOCQWnjf"><img src="/uploaded/en/PartnerCase/content/2.png" alt="" width="880" height="493" /></div>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-G58TdpfnEoYKLdxKjjSc7l7Cnwf" data-list="bullet">
<div><strong>Universal </strong><strong>Compatibility</strong><strong> for Mixed-Model Production</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-YorpdI4XWozd0OxNxOLctVptnib">Two robots perform simultaneous inspection tasks across mixed production lines. Force control combined with quick-change tooling enables seamless compatibility across six vehicle models and four charging configurations.</div>
<div class="ace-line ace-line old-record-id-RWB9dcLlqoDahdxlVtqceB5FnPc"><img src="/uploaded/en/PartnerCase/content/4.png" alt="" width="880" height="494" /></div>
<ul class="list-bullet1">
<li class="ace-line ace-line old-record-id-JqxjdxEhOoFCiUx7QmicSDK6nod" data-list="bullet">
<div><strong>Data-Driven Intelligent Manufacturing</strong></div>
</li>
</ul>
<div class="ace-line ace-line old-record-id-DBOadwC3Soz3zQxQh2pcVVutnje">Robot-generated inspection data is fully traceable and integrated into NIO&rsquo;s proprietary self-inspection platform. This enables continuous process optimisation and supports the development of next-generation intelligent factories.</div>
<div class="ace-line ace-line old-record-id-DBOadwC3Soz3zQxQh2pcVVutnje"><img src="/uploaded/en/PartnerCase/content/3.png" alt="" width="880" height="493" /></div>
<div class="ace-line ace-line old-record-id-DBOadwC3Soz3zQxQh2pcVVutnje">&nbsp;</div>
<div class="ace-line ace-line old-record-id-DBOadwC3Soz3zQxQh2pcVVutnje">&nbsp;</div>
<div class="ace-line ace-line old-record-id-CDxWdItOYoEwKdxLS45cppcvnSg">&nbsp;</div>
</div>

To enhance production quality, consistency, and efficiency, NIO partnered with Flexiv to fully automate its vehicle quality assurance process. Flexiv’s adaptive robots now validate charging functionality, seat operation, and interior components with 100% precision and repeatability. By automating what was once a manual process, inspection efficiency has increased while quality standards have been elevated.

Automated Pre-Delivery Vehicle Inspection

End-to-end AI Model Training

<div data-page-id="Xx1rdC51BoqBvzxfF4xct9JonRb" data-lark-html-role="root" data-docx-has-block-data="true">
<h3 class="heading-1 ace-line old-record-id-FVI3dHNS5oaTLexy7Y6ci0a4nXb"><strong>At a Glance</strong></h3>
<p>&nbsp;</p>
<div class="ace-line ace-line old-record-id-ISHEdrcw7oFAroxvwYQcGsChnhe">&bull;<strong> Customer</strong>: An industry-leading compressor manufacturer (subject to an NDA).</div>
<div class="ace-line ace-line old-record-id-YS8wdZbh5oGwL0x7Z7Nc8rHNnGf">&bull;<strong> Problem</strong>: During compressor manufacturing, the copper tubes connected to the compressor must be inspected before the next stage of production can proceed.</div>
<div class="ace-line ace-line old-record-id-VYa0dwN76o4HQ4xaiD6c5AKNnvc">&bull; <strong>Solution</strong>: Flexiv automated this inspection process using the Rizon 4 adaptive robot paired with a customized end-of-arm tool. This enables the robot to &lsquo;feel&rsquo; tube damage through controlled physical interaction.</div>
<div class="ace-line ace-line old-record-id-TjxBde80godcsHxnnQEcrD6Indf">&bull; <strong>Key Features</strong>: Human-like force control ensures precise and safe tube handling, while a versatile inspection fixture enables smooth insertion and tolerance to positional deviations.</div>
<div class="ace-line ace-line old-record-id-CVHjdsuNWoB4CzxsgVNcn2Vingd">&nbsp;</div>
<h3 class="heading-2 ace-line old-record-id-JgezdNlpeoh02GxvLCmck3WTnfb"><strong>Solution Components</strong></h3>
<div class="image-uploaded gallery old-record-id-EWUmdBZgUobExSxhQlycdYcPnhy" data-type="image" data-ace-gallery-json="{&quot;items&quot;:[{&quot;uuid&quot;:&quot;614ed919-5c7d-4035-978d-4b753c19ca6d&quot;,&quot;height&quot;:1538,&quot;width&quot;:3000,&quot;currHeight&quot;:1538,&quot;currWidth&quot;:3000,&quot;natrualHeight&quot;:1538,&quot;natrualWidth&quot;:3000,&quot;pluginName&quot;:&quot;imageUpload&quot;,&quot;scale&quot;:1,&quot;src&quot;:&quot;https%3A%2F%2Finternal-api-drive-stream.feishu.cn%2Fspace%2Fapi%2Fbox%2Fstream%2Fdownload%2Fpreview%2FJIs7bZyqxome6RxlCyAcNmVfnpd%2F%3Fpreview_type%3D16&quot;,&quot;file_token&quot;:&quot;JIs7bZyqxome6RxlCyAcNmVfnpd&quot;,&quot;image_type&quot;:&quot;image/jpeg&quot;,&quot;size&quot;:673544,&quot;comments&quot;:[]}]}"><img src="/uploaded/en/PartnerCase/content/1280X1280.JPEG" width="880" height="451" data-single-block="true" data-snapshot="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" data-suite="eyJmaWxlVG9rZW4iOiJKSXM3Ylp5cXhvbWU2UnhsQ3lBY05tVmZucGQiLCJvYmpUeXBlIjoiZG9jeCIsIm9ialRva2VuIjoiRVdVbWRCWmdVb2JFeFN4aFFseWNkWWNQbmh5Iiwib3JpZ2luU3JjIjoiaHR0cHM6Ly9pbnRlcm5hbC1hcGktZHJpdmUtc3RyZWFtLmZlaXNodS5jbi9zcGFjZS9hcGkvYm94L3N0cmVhbS9kb3dubG9hZC9wcmV2aWV3L0pJczdiWnlxeG9tZTZSeGxDeUFjTm1WZm5wZC8/cHJldmlld190eXBlPTE2In0=" data-src="https://internal-api-drive-stream.feishu.cn/space/api/box/stream/download/all/JIs7bZyqxome6RxlCyAcNmVfnpd/?mount_node_token=EWUmdBZgUobExSxhQlycdYcPnhy&amp;mount_point=docx_image" data-width="3000" data-height="1538" data-lark-image-uri="drivetoken://JIs7bZyqxome6RxlCyAcNmVfnpd" data-lark-image-width="3000" data-lark-image-height="1538" /></div>
<h3 class="heading-2 ace-line old-record-id-J89Eds75RoncBNxeW4XcI8jnnjd"><strong>Advantages</strong></h3>
<p>&nbsp;</p>
<div class="ace-line ace-line old-record-id-UXNndylyBousPgxRhL8cPVwVndh">&bull; Inspections can be quickly modified to support line changeovers.</div>
<div class="ace-line ace-line old-record-id-WsjedtHsLosFraxj39wcpq2onld">&bull; Each inspection cycle takes less than 3 seconds.</div>
<div class="ace-line ace-line old-record-id-KJj2dKuJLo3WiXxy5e3cTIF4nec">&bull; An accuracy of 0.025 mm guarantees inspection validity.</div>
<div class="ace-line ace-line old-record-id-S8xUdrHsuowjH6xk2sbclfckn5g">&bull; Provides actionable quality assurance data.</div>
<div class="ace-line ace-line old-record-id-LNnLdWobZoWR1XxmKNjcSncrnKB">&nbsp;</div>
<h3 class="heading-2 ace-line old-record-id-DgmGd1HIpoIc71xDbxpcDTkYn6f"><strong>Customer Profile</strong></h3>
<p>&nbsp;</p>
<div class="ace-line ace-line old-record-id-QBJodzLUfoFE0CxiZWrc2vgXnte">An industry-leading compressor manufacturer sought to automate the inspection of the copper tubes that enter and exit its compressors. The existing inspection process was entirely manual and subject to inconsistency and human error. Because the solution needed to be integrated into an existing production line, the inspection station also had to accommodate unavoidable workpiece positional variance.</div>
<div class="ace-line ace-line old-record-id-CIJvdVOFWoPaL3xVF3Qc3CHdnTg">The internal bore for tube insertion is typically designed to achieve a fit precision of approximately 0.025 mm. However, incoming copper compressor tubes often exhibit significant angular deviation of up to &plusmn;5 degrees, while cumulative positional errors are introduced during the upstream bending and welding processes. These combined factors made automation impractical for conventional industrial robots, even when equipped with ultra-high-precision 3D vision systems.</div>
<div class="ace-line ace-line old-record-id-BKOvd25cLoLSskxSTzncmMoxnUg">&nbsp;</div>
<h3 class="heading-2 ace-line old-record-id-Nvuhd2k1somy7Nxx5mtcxZGrn2g"><strong>Project Advantages</strong></h3>
<p>&nbsp;</p>
<div class="ace-line ace-line old-record-id-DX2tdFK3Qo5LsGx3EbfcFouHnQh"><strong>Innovative Inspection Fixture</strong></div>
<div class="ace-line ace-line old-record-id-QzpOdDcsYol90AxnaHccQpzKnQg">Flexiv&rsquo;s solution integrates an adaptive robot with a tapered guide sleeve and a high-precision straightening mandrel. While protecting the mandrel during insertion, the robot&rsquo;s industrial-grade force control guides the sleeve into parallel alignment with the compressor tube, enabling smooth, controlled, and repeatable insertion even in the face of workpiece misalignment.</div>
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<div class="ace-line ace-line old-record-id-XDXgdPzR9o6n5wxpVTmccV9Unif"><strong>High Error Tolerance</strong></div>
<div class="ace-line ace-line old-record-id-MayOdsEs3oBc0UxagbLcQeshn6j">Leveraging human-like force control, the Rizon 4 adaptive robot automatically overcomes workpiece positional offsets, spatial angular deviation, and bending damage in the compressor input and output pipes. The system achieves a mating precision of up to 0.025 mm, ensuring complete and accurate pipe inspection while preventing mandrel damage or breakage.</div>
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<div class="ace-line ace-line old-record-id-GWlddGS82oNsmyxRcuCclVdDnIb"><strong>Force Feedback for Intelligent Management</strong></div>
<div class="ace-line ace-line old-record-id-LSJFdanBKov0Y6xupnic9Er6nyh">With an end-of-arm force feedback sensitivity of 0.1 N, the solution delivers ultra precise inspection results. Force feedback curves can be displayed in real-time to support operator assessment, process optimization, and intelligent production line management.</div>
<div class="ace-line ace-line old-record-id-UhBCd60vAoaBQnxzsfDcjGvGnDg">&nbsp;</div>
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<div class="ace-line ace-line old-record-id-AC1VdsvnrozA8Yx5oXqczH7Bnqh"><strong>High Efficiency and Versatility </strong></div>
<div class="ace-line ace-line old-record-id-X11zdJWwQo5U2axh61Wciiamnah">During production, each inspection is completed in under three seconds, with a total workstation cycle time of less than 5.5 seconds. By eliminating the need for vision systems and specialized auxiliary equipment, the setup delivers a highly reliable cost-effective automation solution with a 99.9% success rate.</div>
<div class="ace-line ace-line old-record-id-WUgidyYhqolQ8ex4TDbc5grVnWe">Built around the unique capabilities of an adaptive robot, the system supports multiple pipe diameters and excels in small-batch, high-mix manufacturing.</div>
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<div class="ace-line ace-line old-record-id-B5f7dOanuoThAUxJHlCctfY7n1f">&nbsp;</div>
<div class="ace-line ace-line old-record-id-B5f7dOanuoThAUxJHlCctfY7n1f">&nbsp;</div>
<div class="ace-line ace-line old-record-id-B5f7dOanuoThAUxJHlCctfY7n1f">&nbsp;</div>
</div>

An industry-leading compressor manufacturer sought to automate the inspection of the copper tubes that enter and exit its compressors. The existing inspection process was entirely manual and subject to inconsistency and human error. Because the solution needed to be integrated into an existing production line, the inspection station also had to accommodate unavoidable workpiece positional variance.

Automated Compressor Tube Inspection

<h3><strong>At a Glance</strong></h3>
<p>&nbsp;</p>
<p><strong>&bull; Customer</strong>: An industry leading compressor manufacturer (subject to an NDA).</p>
<p><strong>&bull; Problem</strong>: During compressor production, the copper tubes used for discharge, charging, and suction must be plugged to prevent oil leakage.</p>
<p><strong>&bull; Solution</strong>: Flexiv developed a fully automated tube plugging solution powered by the Rizon 4 adaptive robot. Using advanced force sensing, it replicates the precision and care of manual plug insertion.</p>
<p><strong>&bull; Key Features</strong>: Automatic compensation for workpiece variation, human-like force-controlled insertion, integrated failure detection, and real-time data monitoring.</p>
<p>&nbsp;</p>
<h3><strong>Advantages</strong></h3>
<p>&nbsp;</p>
<p>&bull; Supports multiple compressor models and five plug types.</p>
<p>&bull; Compensates for up to &plusmn;5 degrees of tube deviation.</p>
<p>&bull; Enables quick line changeovers in under three minutes.</p>
<p>&bull; Reduces cycle times while improving quality and throughput.</p>
<p>&nbsp;</p>
<h3><strong>Customer Profile</strong></h3>
<p>&nbsp;</p>
<p>The client&rsquo;s production line handles several compressor models, each requiring different rubber plug types. During production, each plug must be slightly deformed to fit securely into the copper tubes, a task traditionally performed by skilled operators. Because the tube positions varied, automating the process with traditional robotic solutions was found to be impossible.</p>
<p>&nbsp;</p>
<h3><strong>Flexiv&rsquo;s Solution</strong></h3>
<p>&nbsp;</p>
<p>Equipped with real-time force sensing and hybrid force/motion control, Flexiv&rsquo;s adaptive robots can accurately replicate the manual plug insertion process.</p>
<p>Through an intuitive drag-and-drop teaching interface, operators can perform line changeovers in under three minutes without programming experience.</p>
<p>The result is a smarter, faster, and more flexible approach to compressor production that ensures consistency, precision, and repeatability across every unit.</p>
<p><img src="/uploaded/en/PartnerCase/content/20251120-110924.jpg" alt="" width="880" /></p>
<h3><strong>Solution Advantages</strong></h3>
<p>&nbsp;</p>
<p><strong>High Tolerance for Angular Deviation</strong></p>
<p>Flexiv&rsquo;s automated plugging solution compensates for up to &plusmn;5 degrees of tube deviation, ensuring rapid and precise plug insertion without impacting cycle time.</p>
<p><img src="/uploaded/en/PartnerCase/content/20251120-110932.jpg" alt="" width="880" /></p>
<p><strong>Autonomous Force Monitoring</strong></p>
<p>With industry-leading force sensitivity, the Rizon 4 can detect when a plug is at risk of puncture or deformation, even when fitted with multi-kilogram end-of-arm tools.</p>
<p><img src="/uploaded/en/PartnerCase/content/20251120-110939.jpg" alt="" width="880" /></p>
<p><strong>Human-Like Force-Controlled Insertion</strong></p>
<p>When insertion resistance is detected, the robot automatically activates a hybrid force/position control, replicating the nuanced motion of manual insertion for consistent and reliable results.</p>
<p><img src="/uploaded/en/PartnerCase/content/20251120-110943.jpg" alt="" width="880" /></p>
<p><strong>Quick Training &amp;&nbsp;Effortless Setup</strong></p>
<p>With no prior robotics experience required, operators can be fully trained to use the solution in less than thirty minutes. This reduces downtime, maximizes productivity, and enables staff to move into supervisory positions.</p>
<p><img src="/uploaded/en/PartnerCase/content/20251120-110947.jpg" alt="" width="880" /></p>
<p><strong>Exceptional Flexibility</strong></p>
<p>Flexiv&rsquo;s solution supports multiple compressor models and five plug types. With drag-to-teach programming, a quick-change end-of-arm flange, and a touchscreen PLC with an adjustable insertion force from 15 to 100N, the system can be easily adapted to new compressor models or line adjustments.</p>
<p><img src="/uploaded/en/PartnerCase/content/20251120-110950.jpg" alt="" width="880" /></p>
<p><strong>Retrofit-Friendly</strong></p>
<p>Designed with integration in mind, Flexiv&rsquo;s compact solution can be installed into existing production lines without layout modifications, making it ideal for both new and legacy facilities.</p>
<p><strong><em>&nbsp;<img src="/uploaded/en/PartnerCase/content/20251120-110955.jpg" alt="" width="880" /></em></strong></p>
<p><strong><em>Why Choose Flexiv?</em></strong></p>
<p><strong><em>&nbsp;</em></strong></p>
<p><strong><em>Our robots fuse advanced force control and artificial intelligence to achieve unparalleled industrial efficiency. Simple to use, ultra-reliable, and requiring no barriers, our automation solutions don&rsquo;t just replicate manual labor, they exceed it.</em></strong></p>
<p>&nbsp;</p>

Flexiv developed a fully automated tube plugging solution powered by the Rizon 4 adaptive robot. Using advanced force sensing, it replicates the precision and care of manual plug insertion.

Automated Tube Plugging Solution for Compressors

<h3>At a Glance</h3>
<p><br /><strong>Customer</strong>: A leading seafood processing company (subject to an NDA).</p>
<p>&nbsp;</p>
<p><strong>Problem</strong>: The labor-intensive process of shaping fish fillets, which results in inconsistent product quality and difficulty in attracting and retaining workers.</p>
<p>&nbsp;</p>
<p><strong>Solution</strong>: Flexiv's fully automated fish fillet shaping solution consists of a Rizon 4 adaptive robot, AI-powered computer vision, customized end-of-arm tooling, and a data monitoring system.</p>
<p>&nbsp;</p>
<p><strong>Key Features</strong>: AI-powered computer vision, force-controlled shaping, conveyor speed matching, self-cleaning, and real-time data monitoring.</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<h3>Overview</h3>
<p>&nbsp;</p>
<p>During the creation of breaded fish fillets, ensuring a uniform size and shape is essential so that customers are provided with a product that fully meets their expectations.&nbsp;</p>
<p><br />On traditional production lines, this is achieved through manual labor, with workers shaping the fillets while taking care not to press too tightly to avoid damaging the delicate fish.&nbsp;</p>
<p><br />Due to the labor-intensive and monotonous nature of the manual shaping process, attracting and retaining workers for this task is challenging.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/10/16/1.jpg" alt="shaping fish fillets" width="1920" height="1080" /></p>
<h3>&nbsp;</h3>
<h3>Case Study Customer</h3>
<p>&nbsp;</p>
<p><strong>A Leading Seafood Processing Company (Subject to an NDA)</strong></p>
<p><br />A leading seafood processing company required a solution to automate the labor-intensive and repetitive process of shaping fish fillets.&nbsp;</p>
<p><br />Aiming to ensure consistent portion size and shape, the client sought to remove their dependency on manual labor, improve production efficiency and throughput rate, and overcome the challenge of attracting and retaining employees for this task.</p>
<p>&nbsp;</p>
<p>&nbsp;</p>
<h3>Flexiv's Solution</h3>
<p><br />Flexiv, a leading <span style="color: #285780;"><a style="color: #285780;" href="https://www.flexiv.com/" data-lark-is-custom="true">robot arm company</a></span>, offers fully automated fish fillet shaping solution consisting of a Rizon 4 adaptive robot, AI-powered computer vision, customized end-of-arm tooling, and a data monitoring system.</p>
<p><br />This combination enables the position of each fillet to be detected on a moving conveyor belt and then shaped with a precise pressure, ensuring a uniform size and form factor.&nbsp;</p>
<p><br />The delivered solution fully automates the shaping process, providing improved throughput and consistency compared to manual labor.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/10/16/2.jpg" alt="" /></p>
<h3>&nbsp;</h3>
<h3>Technical Features</h3>
<p><br /><strong>AI-Powered Computer Vision</strong>: Enables accurate detection and engagement with fish fillets on the conveyor belt.</p>
<p><strong><img src="/uploaded/en/PartnerCase/content/2024/10/16/视觉.gif" alt="" /></strong></p>
<p><strong>Force-Controlled Shaping</strong>: The Rizon 4 adaptive robot utilizes its integrated force sensor to precisely apply the necessary pressure to shape the fillet without damaging the delicate fish.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/10/16/力控.gif" alt="" /></p>
<p><strong>Data Monitoring System</strong>: Provides floor managers with the ability to track the shaping process in real time while enabling data collection, visualization, and analysis to optimize production efficiency.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/10/16/鱼_batch.gif" alt="" /></p>
<h3>&nbsp;</h3>
<h3>Advantages</h3>
<p><br /><strong>Swift Deployment</strong>: Designed as a plug-and-play solution, Flexiv's fillet shaping application can be easily integrated into an existing production environment within half a day.</p>
<p>&nbsp;</p>
<p><strong>Easy to Use</strong>: For maximum convenience, operators can monitor and control the solution without specialized training or prior robotic experience.</p>
<p>&nbsp;</p>
<p><strong>Improved Quality and Consistency</strong>: Never tiring and not subject to human error, Flexiv's solution quickly identifies all fillets on the conveyor and then shapes them by applying a precise and uniform pressure.</p>
<p>&nbsp;</p>
<p><strong>Compact Footprint</strong>: Inherently safe and requiring no barriers or fencing, Flexiv's Rizon adaptive robot can be integrated into practically any space within a production environment.</p>
<p>&nbsp;</p>
<p><strong>Scalable and Futureproof</strong>: Easily modified and suitable for countless applications, the Rizon 4 adaptive robot can be used for a range of jobs that previously necessitated human labor. From slicing and portioning to picking and packing,</p>
<div data-page-id="Yw8dduqWKoqsrbxhqFNc86DRnWg" data-lark-html-role="root" data-docx-has-block-data="false">
<div class=" old-record-id-Fh4FdnNI2oSAlVxIogBcRtO7nOh"><span style="color: #285780;"><a style="color: #285780;" href="https://www.flexiv.com/products/rizon">the 7-axis Rizon 4 robot</a></span> ensures precision and efficiency, regardless of the task.</div>
</div>

Elevate automated fish fillet shaping solution with Flexiv robotics in food processing automation, which is engineered for unmatched precision, consistency, and automation excellence.

Robotics in Food Processing Automation Solution - Flexiv

Automated Fish Fillet Shaping Solution

<h3>At a glance</h3>
<p>&nbsp;</p>
<p>&bull; <strong>Customer</strong>: EsVata, a leading California-based shutter supplier.</p>
<p>&bull; <strong>Problem</strong>: The time-consuming, labor-intensive process of manually sanding wooden shutters to ensure a uniform and consistent surface finish.</p>
<p>&bull; <strong>Solution</strong>: Flexiv automated the complete shutter sanding process with a Rizon 4 robot, a fully customized user interface, and an <span style="color: #285780;"><a style="color: #285780;" href="https://onrobot.com/en/products/onrobot-sander">OnRobot Sander with Automatic Grit Changer</a></span>.</p>
<p>&bull;<strong> Key features</strong>: A simple-to-operate user interface, fully automated sanding, automated sanding pad replacement, and increased output quality and throughput rate.</p>
<p>&nbsp;</p>
<h3>Advantages</h3>
<p>&nbsp;</p>
<p>&bull; Fully compatible with multiple shutter sizes and types.</p>
<p>&bull; Delivers a high-quality and consistent surface finish.</p>
<p>&bull; 80% faster than manual sanding.</p>
<p>&bull; Easy integration into the existing production environment.</p>
<p>&nbsp;</p>
<h3>Case Study Customer</h3>
<p>&nbsp;</p>
<p><strong>EsVata Shutters</strong></p>
<p>EsVata, a successful California-based provider of customized shutters, aimed to reduce its turnaround time without compromising its renowned production quality standards. Identifying the sanding stage as the most time-consuming and labor-intensive part of their production process, they sought Flexiv's expertise to automate this task. They required the new solution to be user-friendly, highly automated, and capable of achieving or surpassing the work quality produced by their experienced technicians. Paul Hsieh, EsVata's founder, stated, &ldquo;Our commitment to quality led us to select the Rizon 4 from a sea of competitors. Its exceptional precision, powered by advanced force sensors in each joint, made it the ideal solution for our sanding needs.&rdquo;<strong><br /></strong></p>
<p><img src="/uploaded/en/PartnerCase/content/2024/05/22/zzi3r4nwpfr.png" alt="" /><img src="/uploaded/en/PartnerCase/content/2024/05/22/zkeuymkyx1k.png" alt="" width="1920" height="1080" /></p>
<h3>Overview</h3>
<p>&nbsp;</p>
<p>Ensuring that the shutter is sanded to a uniform level before priming and painting is crucial for EsVata as it ensures their customers receive high-quality, long-lasting shutters. Any imperfections in the shutter surface could result in improperly applied surface coatings, potentially affecting both the shutter's visual appearance and its longevity. Recognizing this, EsVata partnered with Flexiv to enhance their labor-intensive manual sanding process, aiming for improved consistency and reduced work time per shutter.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/05/22/i0moe9lwa3d.JPG" alt="" width="4032" height="3024" /></p>
<h3>Flexiv's Solution</h3>
<p>&nbsp;</p>
<p>Flexiv's fully automated sanding solution comprises a Rizon 4 adaptive robot, an OnRobot Sander with Automatic Grit Changer, and a customized Flexiv user interface. This combination maximizes output quality and consistency by utilizing the Rizon 4's hybrid motion and force control along with its seven degrees of freedom. This enables an optimized sanding path for each shutter to be created, which significantly reduces sanding times while enhancing surface finish consistency.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/05/22/9kyf6kt5wzw.JPG" alt="" /></p>
<p><img src="/uploaded/en/PartnerCase/content/2024/05/22/7hdkcnk6z0m.JPG" alt="" /></p>
<h3>Technical Features</h3>
<p>&nbsp;</p>
<p><strong>Custom UI</strong></p>
<p>EsVata's staff, unfamiliar with robotic programming, required an easy-to-use interface. Given the frequent production of bespoke-sized shutters, it was essential to enable operators to input different dimensions for accurate sanding trajectory calculations. Flexiv responded by creating a straightforward, clear, and intuitive touchscreen interface accessible to all EsVata employees.</p>
<p>&nbsp;</p>
<p><strong>Responsive Force Control</strong></p>
<p>Wood naturally varies in grain structure, hardness, and surface contours. To achieve a uniform surface finish during sanding, applying consistent force is crucial. Rizon enables this with its 1 kHz force response rate, ensuring that the force exerted is the exact amount required for an optimal sanding outcome.&nbsp;</p>
<p>&nbsp;</p>
<p><strong>Whole Body Control Algorithm</strong></p>
<p>To reduce the sanding time per shutter, Rizon's seven degrees of freedom and whole-body algorithm work together to enable the creation of highly efficient movement trajectories. These not only reduce sanding times but also aid in optimizing Rizon&rsquo;s force control capacity.&nbsp;</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/05/22/lhrha2znbx.JPG" alt="" /></p>
<p><img src="/uploaded/en/PartnerCase/content/2024/05/22/m2lihbwiev7.JPG" alt="" /></p>
<h3>Solution Advantages</h3>
<p>&nbsp;</p>
<p><strong>Easy to Deploy</strong></p>
<p>Flexiv's modular solution, built with extruded aluminum framing, can be easily transported and installed. Setup and troubleshooting are managed via the Flexiv Elements graphical programming application, with day-to-day operations handled through the simple to use custom touchscreen UI.</p>
<p>&nbsp;</p>
<p><strong>Inherently Safe</strong></p>
<p>Fully CE and ETL certified, the Rizon 4 is designed to work safely alongside humans. Its ability to dynamically respond or cease all activity upon encountering a person or object eliminates the need for a traditional safety cage, enabling a workspace to be utilized to its fullest extent.</p>
<p>&nbsp;</p>
<p><strong>Time Savings</strong></p>
<p>By reducing the average sanding time of a shutter by 80%, EsVata has significantly increased their throughput rate without sacrificing quality or consistency. Eliminating this bottleneck in their production capacity allows for quicker turnaround times and the ability to serve more clients.</p>
<p>&nbsp;</p>

Optimize automated sanding processes with Flexiv intelligent robotics—featuring high-precision end effectors and compliant force technology for flawless material removal.

Flexiv | Robotic Automated Sanding Solution

Automated Shutter Sanding

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

Adaptive Robotic Keyboard Testing

<h3>At a Glance</h3>
<p>&bull; Customer: A leading automotive seat supplier (Subject to an NDA).<br />&bull; Problem: The time-consuming and labor-intensive task of removing creases from leather seats.<br />&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.<br />&bull; Key Features: Real-time data collection, advanced force control capabilities, and customized tooling to attach ironing equipment.<br />&bull; Advantages: Precise real-time force sensing, safe human-robot collaboration, consistent results, and adaptability to various seat models.</p>
<p>&nbsp;</p>
<h3>Overview</h3>
<p>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.</p>
<h3><img src="/uploaded/en/PartnerCase/content/2024/04/15/v1ovy482t5.jpg" alt="" width="1080" height="807" /><br />Customer Profile</h3>
<p>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.</p>
<h3><br />Flexiv's Solution</h3>
<p>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.</p>
<p>&nbsp;</p>
<h3>Key Advantages</h3>
<p><strong>1. Contour Tracking</strong></p>
<p><img src="/uploaded/en/PartnerCase/content/2024/04/15/mvgu6cq8mxm.gif" alt="" /><br />&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.<br />&bull; Able to sense and adapt to the resistance of the foam, the <a title="7-axis robot arm" href="https://www.flexiv.com/products/rizon"><span style="color: #285780;">7-axis robot arm</span></a> maintains the exact pressure required for optimal crease removal with a precision level that meets or exceeds human capability.</p>
<p>&nbsp;</p>
<p><strong>2. Rapid Deployment and Debugging</strong></p>
<p><img src="/uploaded/en/PartnerCase/content/2024/04/15/97v426r18s.gif" alt="" width="640" height="360" /><br />&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.<br />&bull; Rizon's &lsquo;free-float&rsquo; functionality enables engineers to record new ironing trajectories for faster, simpler debugging and deployment.<br />&bull; Whole-body force control ensures that Rizon is inherently safe, allowing operation without cages or barriers in close proximity to human workers.</p>
<p>&nbsp;</p>
<p><strong>3. Mixed-Line Production</strong></p>
<p><img src="/uploaded/en/PartnerCase/content/2024/04/15/k29ja92ut9k.gif" alt="" /><br />&bull; Once programmed, the Rizon 4 can operate on multiple seating models in succession, enabling a true mixed-line production process.<br />&bull; With an end-effector force control accuracy of 0.03N, Flexiv's ironing solution can achieve a greater precision than is humanly possible.<br />&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.</p>
<p>&nbsp;</p>
<p><strong>4. Real-time Quality Assurance&nbsp;</strong></p>
<p><img src="/uploaded/en/PartnerCase/content/2024/04/15/anoh2jhxs4.png" alt="" width="800" height="473" /><br />&bull; Force control data from every stage of the ironing process is automatically recorded, allowing the full traceability of every seat coving ironed. Every move a <a title="force-controlled robot" href="https://www.flexiv.com/products"><span style="color: #285780;">force-controlled robot</span></a> makes can be automatically recorded, along with the resistance it encounters at its end-of-arm tool. Managed by the Elements programming system, real-time error flagging and production data logging enable full traceability of every seat that&rsquo;s been ironed, ensuring consistent quality across the entire production line.</p>
<p>&nbsp;</p>

Discover Flexiv's Rizon 4 leather seat robot ironing solution for a top automotive supplier—delivering precision force control, real-time data, and consistent quality.

Automated Ironing Solution for Electric Vehicles - Flexiv

Automated Ironing Solution for Electric Vehicles

<div class="container">
<div class="text-base text-regular leading-relaxed Content_content__dLo3I w-8/12 mx-auto">
<h3><strong>At a glance</strong></h3>
<p>&nbsp;</p>
<p><strong>Customer</strong>: A leading automotive supplier (Subject to an NDA).</p>
<p><strong>Problem</strong>: The calibration and automated testing of turn signal levers.</p>
<p><strong>Solution</strong>: 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.</p>
<p><strong>Key Features</strong>: Real-time data collection, data mapping, trajectory planning, and customizable host control systems.</p>
<p><strong>Advantages</strong>: Precise real-time force-sensing accuracy, enhanced safety features, scalability, and improved line-changeover speed.</p>
<p>&nbsp;</p>
<h3><strong>Overview</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/lqnb3vvhx0g.JPEG" alt="" /></p>
<h3><strong>Customer Profile&nbsp;</strong></h3>
<p>&nbsp;</p>
<p>The customer is a leading automotive supplier, providing a wide range of OEM products to the automotive industry.&nbsp;</p>
<p>&nbsp;</p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/hzgbz4c7gm8.gif" alt="" /></p>
<h3><strong>Flexiv's Solution</strong></h3>
<p>&nbsp;</p>
<p>Employing the adaptive Rizon 4s robot and <span style="color: #285780;"><a style="color: #285780;" title="the Flexiv Robotic Development Kit (RDK)" href="https://www.flexiv.com/software/rdk">the Flexiv Robotic Development Kit (RDK)</a></span>, 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.</p>
<p><br />During testing, the <span style="color: #285780;"><a style="color: #285780;" title="7-axis robot" href="https://www.flexiv.com/products/rizon">7-axis robot</a></span> 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.</p>
<p>&nbsp;</p>
<h3><img src="/uploaded/en/PartnerCase/content/2024/02/01/qv8dplz6wb.gif" alt="" /><br /><strong>Technical Features</strong></h3>
<p>&nbsp;</p>
<p><strong>Real-time Data Collection</strong></p>
<p>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.<br />&nbsp;</p>
<p><strong>Robot Motion Planning</strong></p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/uilf71m518q.gif" alt="" width="640" height="401" /></p>
<h3><strong>Solution Advantages</strong></h3>
<p>&nbsp;</p>
<p><strong>Real-time Precision&nbsp;</strong><br />The Rizon 4s robot features a force-sensing accuracy of 0.03N and a response frequency of 1kHz, resulting in a communication delay of just 1ms.</p>
<p><br /><strong>Easy-to-Deploy</strong><br />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.</p>
<p><br /><strong>Safe and Reliable</strong><br />Flexiv&rsquo;s adaptive robots are CE and ETL-certified, ensuring the safety of human-robot collaboration while enabling flexible deployment.&nbsp;</p>
</div>
</div>

See how Flexiv's Rizon 4s adaptive robot arm automated turn signal lever testing & calibration——enabling real-time force sensing, smart trajectory planning & rapid line changeovers.

Automated Calibration of Car Turn Signal Levers - Flexiv

Automotive Signal Switch Calibration

<h3><strong>Overview</strong></h3>
<p>&nbsp;</p>
<p>In June 2023, at the Science Centre Singapore, the large-scale STEM performance "The Electrified Show" was organized. The adaptive robot 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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/qfjxif3g8tr.jpg" alt="" width="1280" height="854" /></p>
<h3><strong>Case Introduction</strong></h3>
<p>&nbsp;</p>
<p><strong>Client: Science Centre Singapore</strong></p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/w4mp3ys5sy.jpg" alt="" width="1280" height="853" /></p>
<p>According to the script, Rizon 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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/tiafioxxxqr.png" alt="" /></p>
<h3><strong>Technical Features</strong></h3>
<p>&nbsp;</p>
<p>1. With seven degrees of freedom, Rizon 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.</p>
<p>&nbsp;</p>
<p>2. By using the graphical programming system Flexiv Elements, staff from the Science Centre Singapore can intuitively and concisely program and control the <a title="7-axis robot" href="https://www.flexiv.com/products/rizon"><span style="color: #285780;">7-axis robot</span></a>, leveraging the many functions and features of Rizon.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/07/24/kfcjw8qxjvg.png" alt="" width="880" height="495" /></p>

Rizon 4 Performing in STEM Event The Electrified Show

<h3><strong>At a glance</strong></h3>
<p>&nbsp;</p>
<p><strong>Customer</strong></p>
<p>A leading new energy car company.</p>
<p><strong>Problem</strong></p>
<p>Ensuring the quality of car bodywork and worker safety while performing weld grinding tasks.</p>
<p><strong>Solution</strong></p>
<p>Flexiv introduced an adaptive grinding solution using the Rizon 10 <a title="adaptive robot " href="https://www.flexiv.com/products/rizon"><span style="color: #285780;">adaptive robot</span></a> and standard electric grinding tools.</p>
<p><strong>Key Features</strong></p>
<p>Adaptive polishing, user-friendly operations, and adherence to international human-robot interaction safety standards.</p>
<p><strong>Advantages</strong></p>
<p>Cost-effectiveness, improved polishing quality, user-friendly experience, safe and flexible deployment.</p>
<p>&nbsp;</p>
<h3><strong>Overview</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<h3><br /><strong>Case Study Customer</strong></h3>
<p>&nbsp;</p>
<p><strong>A Leading New Energy Car Company (Subject to an NDA)</strong><br />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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/wyyc77xs33.gif" alt="" width="440" height="248" /></p>
<h3><strong>Flexiv's Solution</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>The Rizon 10's force control also enabled the introduction of force-controlled height probing. This groundbreaking approach allows the <a title="7-dof robot arm" href="https://www.flexiv.com/products/rizon"><span style="color: #285780;">7-dof robot arm</span></a> 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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/05/31/hziy1fxfw1e.png" alt="" width="1047" height="676" /></p>
<h3><strong>Technical Features</strong></h3>
<p><br /><strong>Adaptive Polishing</strong><br />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.</p>
<p>&nbsp;</p>
<p><strong>User-Friendly Primitives</strong><br />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;</p>
<p>&nbsp;</p>
<p><strong>Safe and Reliable</strong><br />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.</p>
<h3><br /><strong>Solution Advantages</strong></h3>
<p>&nbsp;</p>
<p><strong>Straightforward and Cost-Effective</strong><br />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.</p>
<p>&nbsp;</p>
<p><strong>Improved Polishing Quality</strong><br />Adaptive positioning technology eliminates the problems caused by over or under-grinding, resulting in a superior surface finish compared to manual techniques.</p>
<p>&nbsp;</p>
<p><strong>User-Friendly Experience</strong><br />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.</p>
<p>&nbsp;</p>
<p><strong>Flexible Deployment and Safe Collaboration</strong><br />Flexiv's grinding solution can be safely and flexibly deployed in fully automated or hybrid automated/manual production lines without requiring extensive line modifications.</p>

Discover how Flexiv's robotic grinding solution revolutionized weld grinding for a top EV automaker—delivering smart automation, adaptive polishing, and ISO-safe operation.

Automated Weld Grinding for Automotive Manufacturing - Flexiv

Automated Weld Grinding for Automotive Manufacturing

<h3><strong>At a glance</strong></h3>
<p>&nbsp;</p>
<p><strong>Customer</strong></p>
<p>A leading automobile manufacturer (Subject to an NDA).</p>
<p><strong>Problem</strong></p>
<p>High costs, human error, and inconsistencies associated with manually removing welding debris.</p>
<p><strong>Solution</strong></p>
<p>Flexiv introduced an automated grinding solution using the Rizon 10 robot with off-the-shelf electric grinding tools.</p>
<p><strong>Key Features</strong></p>
<p>Simplified operations, human-inspired adaptability, safe and efficient human-robot interaction.</p>
<p><strong>Advantages</strong></p>
<p>Consistent, high-quality results, cost-effectiveness, and ease of deployment.</p>
<p>&nbsp;</p>
<h3><strong>Overview&nbsp;</strong></h3>
<p>&nbsp;</p>
<p>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;</p>
<p>&nbsp;</p>
<p>Complex shapes, large sizes, tolerance variations, and throughput demands of the workpieces make automated grinding and polishing a significant challenge.&nbsp;</p>
<p>&nbsp;</p>
<p>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;</p>
<h3>&nbsp;<br /><strong>Case Study Customer</strong></h3>
<p>&nbsp;</p>
<p><strong>(Subject to an NDA)</strong></p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/o7h1kucub.gif" alt="" width="440" height="248" /></p>
<h3><strong>Flexiv's Solution&nbsp;</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>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;<br />&nbsp;<img src="/uploaded/en/PartnerCase/content/2024/02/01/gp4ag4pw1pv.gif" alt="" width="440" height="248" /></p>
<h3><strong>Technical Features</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>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;</p>
<p>&nbsp;</p>
<p>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;</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/gapstc28mg.gif" alt="" width="640" height="360" /></p>

Discover how Flexiv's material removal robot automated welding debris cleanup. Our robotic material removal system delivers consistent quality, cost savings & safe material removal automation.

Flexiv | Robotic Material Removal Automation

Automated Welding Debris Removal in Automobile Manufacturing

<h3><strong>Overview</strong></h3>
<p><br />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.<br />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.</p>
<h3><br /><strong>Case Introduction</strong></h3>
<p><br /><strong>Case Study Customer</strong></p>
<p>Stavros Didakis, Greek Media Artist, and Professor at New York University</p>
<p><br />"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;</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/02/y8k33vcm8j.gif" alt="" /></p>
<p>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.</p>
<p>&nbsp;</p>
<h3><strong>Technical Features</strong></h3>
<p><br />1. "Xenoforms" fully utilizes the design features and technical capabilities of the <span style="color: #285780;"><a style="color: #285780;" title="adaptive robot" href="https://www.flexiv.com/products">adaptive robot</a></span> 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.</p>
<p>&nbsp;</p>
<p>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;</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/02/p184smb09v.gif" alt="" /></p>
<div class="container">
<div class="text-base text-regular leading-relaxed Content_content__dLo3I w-8/12 mx-auto">
<p>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.</p>
<p>He stated, "I'd been looking for a <a title="robot arm company" href="https://www.flexiv.com/"><span style="color: #285780;">robot arm company</span></a> to work with for a while, and collaborating with Flexiv was a great experience. True professionals, their engineers helped optimize various algorithms, allowing me to fully control the robot and make sure its movements were as natural as possible."</p>
</div>
</div>

Avant Garde Art Installation Xenoforms

<h3><strong>At a glance</strong></h3>
<p>&nbsp;</p>
<p><strong>Customer</strong></p>
<p>A renowned new energy car company (Subject to an NDA).</p>
<p><strong>Problem</strong></p>
<p>Reliance on manual labor for potentially harmful primer application tasks in automotive manufacturing.</p>
<p><strong>Solution</strong></p>
<p>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.</p>
<p><strong>Key Features</strong></p>
<p>High-response force control, force-controlled application.</p>
<p><strong>Advantages</strong></p>
<p>Tolerance to workpiece positional errors, consistent results, easy deployment, and scalability.</p>
<p>&nbsp;</p>
<h3><strong>Overview&nbsp;</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>Primers are often made from volatile solvents, which are potentially harmful to human health. Despite this, most automotive priming processes are currently performed manually.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/x9k8syejs5o.png" alt="" width="1970" height="1182" /></p>
<h3><strong>Case Study Customer</strong></h3>
<p>&nbsp;</p>
<p><strong>A Renowned New Energy Car Company (Subject to an NDA)</strong></p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/4rjv2u7t9qt.png" alt="" /></p>
<h3><strong>Flexiv&rsquo;s Solution</strong></h3>
<p>&nbsp;</p>
<p>Flexiv's automotive adhesive primer application employs a Rizon 4 <a title="adaptive robot" href="https://www.flexiv.com/products"><span style="color: #285780;">adaptive robot</span></a>, a customized brush, a standard adhesive supply system, and a gluing software package.</p>
<p>&nbsp;</p>
<p>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.</p>
<h3><img src="/uploaded/en/PartnerCase/content/2024/02/01/acc8p9z9h4h.gif" alt="" width="640" height="360" /><br />&nbsp;<br /><strong>Technical Features</strong></h3>
<p>&nbsp;</p>
<p><strong>Responsive Force Control</strong><br />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.</p>
<p><br /><strong>Force-Controlled Application</strong><br />Real-time feedback and force control from the contact between the end-of-arm tool of the <span style="color: #285780;"><a style="color: #285780;" title="seven-axis robot" href="https://www.flexiv.com/products/rizon">seven-axis robot</a></span> and the workpiece enables the surface to be tracked exactly. This allows complex curvatures to be followed and reduces coating breakage and trajectory issues.<br /><img src="/uploaded/en/PartnerCase/content/2024/02/01/2zvxt1ljg9q.gif" alt="" /></p>
<h3><strong>Solution Advantages</strong></h3>
<p>&nbsp;</p>
<p><strong>High Trajectory Error Tolerance</strong><br />Rizon&rsquo;s hybrid motion force control counters position disturbances from workpiece misalignment or imperfections, ensuring comprehensive surface coverage and no coating breaks.</p>
<p>&nbsp;</p>
<p><strong>Consistent Results</strong><br />The application has demonstrated a coverage and accuracy rate exceeding 99% in rigorous real-world testing.</p>
<p>&nbsp;</p>
<p><strong>Easy Deployment</strong><br />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.</p>
<p>&nbsp;</p>
<p><strong>Scalability</strong><br />Fully customizable and infinitely adaptable, Flexiv's adhesive application solution can be seamlessly integrated into any production environment.</p>
<p>&nbsp;</p>
<p>The Rizon 4 <span style="color: #285780;"><a style="color: #285780;" title="force-controlled robot" href="https://www.flexiv.com/products">force-controlled robot</a></span> is designed to meet the demanding needs of automated manufacturing processes&mdash;<a title="contact our team" href="https://www.flexiv.com/contact"><span style="color: #285780;">contact our team</span></a> to explore how it can optimize your production line.</p>

See how Flexiv's automated adhesive primer solution replaced manual primer application. Featuring force-controlled precision and tolerance to positional errors, our automated glue dispensing systems deliver consistent quality while protecting workers.

Automated Adhesive Primer Application in Automotive Assembly - Flexiv

Automated Adhesive Primer Application in Automotive Assembly

<h3><strong>At a glance</strong></h3>
<p>&nbsp;</p>
<p><strong>Customer</strong></p>
<p>Hycan, a Mobility Power Supply (MPS) product designer.</p>
<p><strong>Problem</strong></p>
<p>Inefficiencies and high costs associated with electric vehicle charging in parking lots.</p>
<p><strong>Solution</strong></p>
<p>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.</p>
<p><strong>Key Features</strong></p>
<p>Seven degrees of freedom, precision-based control, artificial intelligence, machine vision, dual safety certifications, and the adaptability to charge any electric car model.</p>
<p><strong>Advantages</strong></p>
<p>Enhanced safety, optimized operation, universality, and flexibility in handling different car models.<br /><br /></p>
<h3><strong>Overview&nbsp;</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<h3><br /><strong>Case Study Customer</strong></h3>
<p>&nbsp;</p>
<p><strong>Hycan</strong></p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/01hfbbcqpos3.jpg" alt="" /></p>
<h3><strong>Flexiv&rsquo;s Solution</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/r6d4uz7gxc.gif" alt="" /><br /><strong>&nbsp;</strong></p>
<h3><strong>Technical Features</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p><br />1. The solution&rsquo;s high-speed, precision-based control ensures accurate and reliable task completion.</p>
<p>2. Dual CE and ETL safety certifications provide peace of mind that the <a title="7-degree-of-freedom robotic arm" href="https://www.flexiv.com/products/rizon"><span style="color: #285780;">7-degree-of-freedom robotic arm</span></a> meets or exceeds international safety and quality standards.&nbsp;</p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/789y0ducnb4.gif" alt="" /></p>
<h3><strong>Solution Advantages</strong></h3>
<p>&nbsp;</p>
<p><strong>Safety and Reliability</strong><br />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.<br /><strong>&nbsp;</strong></p>
<p><strong>Compliant Operation</strong><br />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.<br />&nbsp;</p>
<p><strong>Universality and Flexibility</strong><br />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 <a title="7-dof" href="https://www.flexiv.com/products/rizon"><span style="color: #285780;">7-dof</span></a> robot can complete the charging task regardless of body styling, port location, or charging port height.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/7jhv3a7edtk.gif" alt="" /></p>
<p>&nbsp;</p>
<p>The Rizon <a title="force-controlled robot" href="https://www.flexiv.com/products"><span style="color: #285780;">force-controlled robot</span></a> is engineered to transform EV charging automation&mdash;<span style="color: #285780;"><a style="color: #285780;" title="request a quote" href="https://www.flexiv.com/contact">request a quote</a></span> or <span style="color: #285780;"><a style="color: #285780;" title="learn more about RIZOM" href="https://www.flexiv.com/products/rizon">learn more</a></span> about how its adaptive capabilities can optimize your charging infrastructure.</p>

Discover Flexiv's autonomous charging robot — an AI-powered EV charging robot that automates mobile charging system in public areas like parking lots. Our car charging robot features machine vision & force control for universal EV compatibility.

Flexiv | Autonomous Car EV Charging Robot

Automated Charging Solution for Electric Vehicles

<h3><strong>At a glance</strong></h3>
<p>&nbsp;</p>
<p><strong>Customer</strong>&nbsp;</p>
<p>An undisclosed leading audio device manufacturer.</p>
<p><strong>Problem</strong></p>
<p>The complex, time-consuming, and manual process of voice coil assembly in audio devices.</p>
<p><strong>Solution</strong></p>
<p>Flexiv provided a unique interference-fit assembly solution leveraging advanced computer vision and industry-leading force control technology.</p>
<p><strong>Key Features</strong></p>
<p>Adaptive grasping, force-controlled searching, and component insertion.</p>
<p><strong>Advantages</strong></p>
<p>Enhanced assembly quality, improved operational efficiency, flexibility, and the universality of the assembly process.</p>
<h3><br /><strong>Overview&nbsp;</strong></h3>
<p>&nbsp;</p>
<p>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.<br />&nbsp;</p>
<h3><strong>Case Study Customer</strong></h3>
<p>&nbsp;</p>
<p><strong>(Subject to an NDA)&nbsp;</strong></p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/6p703bkdgen.png" alt="" /></p>
<h3><strong>Flexiv's Solution</strong></h3>
<p>&nbsp;</p>
<p>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.</p>
<p>&nbsp;</p>
<p>Our solution achieved pinpoint accuracy in coil positioning and rotation using standardized components and AI-powered vision.</p>
<p>&nbsp;</p>
<p>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.<br />&nbsp;<img src="/uploaded/en/PartnerCase/content/2024/02/01/djg8d8tdif8.jpg" alt="" /></p>
<h3><strong>Technical Features</strong></h3>
<p>&nbsp;</p>
<p><strong>Adaptive Grasping</strong></p>
<p>Flexiv's proprietary force-control technology adapts to positional errors, ensuring accurate and non-deformable grasping.</p>
<p><strong>Force-Controlled Searching</strong></p>
<p>Precise placement into installation grooves is enabled using a fine force-controlled -searching algorithm.&nbsp;&nbsp;</p>
<p><strong>Force-Controlled Insertion</strong></p>
<p>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.</p>
<p><img src="/uploaded/en/PartnerCase/content/2024/02/01/m45wylujkqo.png" alt="" width="1826" height="1028" /></p>
<h3><strong>Solution Advantages</strong></h3>
<p>&nbsp;</p>
<p><strong>Enhanced Quality</strong></p>
<p>Flexiv's voice coil assembly process has a yield rate greater than 99% and an angle deviation rate below 25%.</p>
<p><strong>Automated Efficiency</strong></p>
<p>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;</p>
<p><strong>Flexibility and Universality</strong></p>
<p>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.</p>

Explore how Flexiv's automated robotic assembly system revolutionizes voice coil production. Our precison assembly robot combines force control & computer vision for precision interference-fit assembly.

Case Study