Tolerance tracing and compensation (simulation and/or physical)

Case description

Drives (frequency converters) are an important product in Danfoss’ portfolio. While legacy drive generations are still assembled manually, the latest generation of drives is assembled in robotic production cells. Drives are assembled by stacking the parts from the backplate up to the front panel. However, the robust automation of screwing operations with robots is still challenging since small misalignments add up in the stack to the point where it is out of the tolerance limits of the robot program.

Danfoss drive (frequency converter)

Assembly stack of the drive case


Experiment with physical drive samples and CAD data to develop a concept to trace misalignments in a stack. Develop a concept to compensate misalignments, so that robot can be guided to screwing operations more robustly. (Christoffer) 

To get the team started, consider the following: 

  • Which are the relevant parameters leading to misalignments (e.g. part tolerances)? 

Keywords: Tolerance chains, mechanical design, computer vision 

Tools, methods and materials

The challenge can be addressed with many different tools, ranging from spreadsheet calculations to robot simulators. Regarding the methods for compensation, mechanical measures to reduce misalignments are possible as well as computer vision to measure and compensate the resulting misalignment. The selection of tools and methods is left to the team.

From Danfoss, the team will receive 3D CAD data of a drive stacks, assembly instructions and a physical product sample as input materials for the challenge. In addition, Danfoss will be available to discuss details of the challenge along the way.


Peter Lund Andersen


Peter Lund Andersen


Sr. Manufacturing Specialist Danfoss Drives