Robotic application of tape

Abstract

An automated system and method is provided for applying tape onto an object surface using a tape applicator mounted on a robotic arm. The tape applicator, commanded by a controller, can automatically follow a real-time updated tape coating path on the object surface as the tape applicator moves along the object surface to optimize tape application. The tape applicator can also create tabs in real-time.

Description

[Background technology]

[0001] Various tapes, such as masking or protective tapes, can be applied to surfaces, such as the surfaces of automobile parts or replacement parts. Robotic application systems have been used to ensure proper artistic and functional application of the tapes. These tapes can be removed from the surfaces by human or robotic systems. Summary of the Invention

[0002] It is desirable to precisely apply tape onto contoured surfaces. The present disclosure provides automated systems and methods for applying removable tape onto object surfaces, such as curved, three-dimensional (3D) or contoured surfaces.

[0003] In one aspect, the present disclosure describes a method for applying tape onto an object surface. The method includes positioning a robot adjacent to the object surface. The robot includes an end effector including a tape applicator. The method further includes determining a tape coating path for applying tape to the object surface, determining a path feasibility of the tape coating path while moving the end effector along a travel trajectory, updating the tape coating path and the travel trajectory based on the determined path feasibility, and applying tape onto the updated tape coating path.

[0004] In another aspect, the present disclosure describes an automated system for applying tape onto an object surface. The system includes an end effector with a tape roll and a tabulating mechanism, a vision system including one or more imaging sensors for acquiring imaging data about the tape, the object surface, and the end effector, and a controller operatively connected to the end effector and the vision system. The controller is configured to determine a tape coating path on the object surface, determine a travel trajectory for the end effector, determine a path feasibility of the tape coating path while moving the end effector along the travel trajectory to apply tape onto the object surface via the end effector, update the tape coating path based on the determined path feasibility, and apply tape onto the updated tape coating path.

[0005] Various unexpected results and advantages are obtained in the exemplary embodiments of the present disclosure. One such advantage of the exemplary embodiments of the present disclosure is that the tape applicator can automatically follow an optimized tape coating path on the object surface while moving along the object surface to optimize tape application. In addition, the embodiments improve application accuracy, especially on non-flat surfaces where slight deviations from the desired path can lead to tape wrinkling or insufficient coverage. In addition, the optimized coating path can use a minimal amount of tape to coat an area. The tape applicator can also create tabs in real time.

[0006] The above is a summary of various aspects and advantages of exemplary embodiments of the present disclosure. The above "Summary" is not intended to describe each illustrated embodiment or every implementation of the exemplary embodiments of the present disclosure. The following figures and "Description of the Preferred Embodiments" more particularly exemplify certain preferred embodiments that employ the principles disclosed herein. [Brief description of the drawings]

[0007] The present disclosure may be more fully understood from the following detailed description of various embodiments of the disclosure when considered in conjunction with the accompanying drawings, in which: [Figure 1] FIG. 1 illustrates a side perspective view of an automated system including an end effector for applying tape onto an object surface, according to one embodiment. [Diagram 2] FIG. 2 is a side perspective view of an end effector for applying tape onto an object surface, according to one embodiment. [Figure 3A] FIG. 13 illustrates a side perspective view of a tabbing mechanism, according to one embodiment. [Figure 3B] FIG. 3B is a side perspective view of the tabbing mechanism of FIG. 3A. [Figure 3C] FIG. 3B is a side perspective view of the tabbing mechanism of FIG. 3A. [Figure 3D] FIG. 3B is a side perspective view of the tabbing mechanism of FIG. 3A. [Figure 4A] 2 illustrates a schematic diagram of a coordinate system for the end effector tool of FIG. 1, according to one embodiment. [Figure 4B] FIG. 1 is a schematic diagram of a digital 3D model of the tape coating path. [Figure 4C] FIG. 2 is a schematic diagram of a model of a portion of a tape coating path. [Figure 5A] FIG. 1 illustrates a block diagram of a tape application system, according to one embodiment. [Figure 5B] FIG. 1 illustrates a block diagram of a robot controller, according to one embodiment. [Figure 6] 1 illustrates a flow diagram of a method for applying tape onto an object surface, according to one embodiment. [Figure 7] FIG. 2 illustrates a block diagram of a tape application process, according to one embodiment.

[0008] In the drawings, like reference numbers refer to like elements. The above-identified drawings may not be drawn to scale and illustrate various embodiments of the present disclosure, however, other embodiments are also contemplated, as noted in the Detailed Description. In all cases, the disclosure describes the disclosure provided herein by way of representing exemplary embodiments, and not by way of explicit limitation. It should be understood that numerous other modifications and embodiments may be devised by those skilled in the art that are within the scope and spirit of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The present disclosure provides an automated system and method for applying tape onto an object surface. The automated system includes a robotic tape applicator for attaching tape to an object surface and an associated algorithm for ensuring that the proper trajectory and path is followed to properly cover the desired object surface. The tape application system and method described herein, such as the tape application system 100 of FIG. 1, can help overcome some technical problems encountered in traditional tape application. Typically, some problems can occur when masking a curved 3D surface using masking tape. For example, if the curvature of the tape coating path is too high, the tape may not follow the tape coating path precisely, which may result in defects such as air bubbles and / or wrinkles in the tape. If the tape is relatively rigid, multiple pieces of tape may be used to account for the geometry of the tape coating path. The tape application system and method described herein can precisely apply a deformable or rigid tape to follow the tape coating path on an undulating surface. Trying to manually apply a deformable or precision masking tape to a design feature can be a difficult task for a human operator. Proper artistic and functional application of tape can be better ensured by using the robotic application systems and methods described herein that take into account surface curvature and use appropriate force to ensure proper wet-out of the tape on the object surface. In some embodiments, the robotic application systems and methods described herein can further create tabs to facilitate removal at a later point in time.

[0010] FIG. 1 shows a side perspective view of a tape application system 100 including an end effector 20 for applying tape 4 onto an object surface 2. The tape application system 100 has a robotic arm 10 including multiple arm portions 12a, 12b connected by joints 13a, 13b. The end effector 20 is operatively connected to an attachment interface 14 at a distal end of the robotic arm 10. The attachment interface 14 may be designed based on a specific attachment standard and may be compatible with various end effector tools based on the same attachment standard. In some embodiments, the attachment interface 14 may include various mechanical and electrical means for operatively connecting the end effector 20 to the robotic arm 10. For example, the attachment interface may include any suitable fastening device for mechanically attaching the smart end effector 20 to the robotic arm 10. The attachment interface may further include any suitable electrical connection for communicating electrical signals between the end effector and the robotic arm or for providing power from the robotic arm to the end effector.

[0011] A robot controller 16 may be used to execute a robot arm command program to control the motion of the robot arm 10 such that the movement trajectory of the end effector 20 can be precisely controlled. In some embodiments, the robot arm command program may control the motion of the robot arm 10 through a set of motion parameters including, for example, positions, orientations, and velocities of the arm segments and joints.

[0012] In the embodiment shown in FIG. 1, the tape application system 100 applies an adhesive tape 4 that is attached to an object surface 2. The object surface 2 can be, for example, an automobile part surface (e.g., a side window surface as shown in FIG. 1). The object surface may have a planar surface or a non-planar manifold with various surface curvatures. The robot controller 16 can control the motion of the robot arm such that the end effector 20 approaches and moves around the object surface 2 to apply the tape 4 on the tape coating path of the object surface 2. In some embodiments, the robot controller 16 can include an optional power interface to a power source of the robot controller 16 to provide power to the end effector 20 in the form of electricity, pneumatics, etc.

[0013] The end effector 20 includes a robotic tape applicator, such as robotic tape applicator 40 shown in FIG. 2. Tape applicator 40 is attached to an end plate 45 that is attached to the robotic arm 10. Tape roll 3 is attached to a motorized feed roller 44, which is attached to a servo motor for automatically unwinding the tape 4. The tape 4 from the tape roll 3 is fed to a pressing and tabming mechanism 50. Pressing and tabming mechanism 50 includes a vacuum plate 52 for holding the tape 4 in place. A guide roller 51 and a first pressing roller 53 are provided to guide the tape 4 from the tape roll 3 to the vacuum plate 52.

[0014] As shown in FIG. 3A, the vacuum plate 52 is configured to hold the tape leading edge 42 on the non-adhesive surface 43 of the tape 4, with the adhesive surface 41 of the tape facing the object surface 2. The vacuum plate 52 has two parts 522 and 524 connected to each other via a rotary joint 523. The part 524 of the vacuum plate 52 is fixed, but the part 522 can be rotated relative to the part 524 along the arrow direction 7 by a rotary motor (not shown). When the rotary motor is activated, the part 522 of the vacuum plate 50 is folded over the part 524, so as to fold the tape leading edge 42 and join the adjacent adhesive surfaces 41 together, forming a tab 5 on the tape leading edge 42, as shown in FIG. 3B. As shown in FIG. 3C, while the vacuum plate 52 holds the tape leading edge 42 in place, the pressure roller 53 presses down on the tape 4, attaching the adhesive surface 41 to the object surface 2. The vacuum plate 50 can then be opened and removed from the tape 4.

[0015] 3D, pressure rollers 53, 55 are provided for pressing the tape 4 against the object surface 2. The pressure rollers 53, 55 are each attached to an air cylinder and can be operated to tuck down and wet out the tape 4 on the object surface 2. A blade 54 is attached to the air cylinder for cutting the tape 4 after a desired length of tape 4 has been applied onto the tape coating path of the object surface 2. Prior to cutting the tape 4, a vacuum plate 52 can be positioned to hold the new tape head 42 being formed and to create a new tab as described above after cutting.

[0016] In the embodiment shown in Figures 3A-3D, the pressing and tabbing mechanism 50 includes two pressing rollers 53 and 55 and one guide roller 51. It should be understood that other numbers and types of rollers can be used to apply the tape to the tape coating path on the object surface. In some embodiments, the orientation and position of each roller, such as pressing rollers 53 and 55, can be adjusted in real time so that the tape can be controlled to precisely follow the tape coating path on the object surface. In addition, an appropriate pressing force can be applied via the pressing roller to ensure proper wet-out of the tape on the object surface 2. Various force sensors can be used to monitor the pressure that the applicator is applying to the tape (e.g., a force value divided by the tape width). Force feedback can be used to adjust the pressure in real time. In the illustrated embodiment, the vacuum plate 52 is positioned between the pressing rollers 53 and 55. The blade 54 is positioned downstream of and adjacent to the vacuum plate 52.

[0017] A tab formed at the beginning of the tape can facilitate removal of the tape from the object surface at a later time. When removing the attached tape 4 from the object surface 2, the gripping mechanism of the end effector 20 can grip the tape tab, for example, with a pair of gripper jaws. In various embodiments, the gripping mechanism can further include a wedge, a scraper, an air blower, or a combination thereof to facilitate gripping of the tape tab by the gripping mechanism. For example, the tape tab can be lifted by an air blower for gripping.

[0018] The tape 4 may be any flexible adhesive tape. The tape 4 includes an adhesive surface that is adhesively bonded to the object surface 2. The adhesive surface of the tape 4 may include any suitable adhesive, such as a releasable adhesive, including, for example, rubber, silicone, acrylic adhesives, and the like. The adhesive surface may include, for example, a non-stretch release adhesive, such as a pressure sensitive adhesive (PSA) or an epoxy adhesive. The adhesive surface may be disposed on a flexible backing layer that has sufficient flexibility to allow the adhesive surface to be separated from the object surface 2. The adhesive tape 4 may also provide conformability and elastic properties as required by the desired application.

[0019] In some embodiments, the end effector 20 can include an unwinding mechanism for unwinding the tape 4 from the tape roll 3 as the tape application progresses. The unwinding mechanism can unwind the tape at a rate such that the length of tape applied to the object surface is substantially the same as the length of the tape coverage path on the object surface.

[0020] In operation, the tape application system 100 starts by initializing communication between a robot arm and its end effector (e.g., tape applicator). The robot arm (e.g., robot arm 10) and end effector (e.g., end effector 20) communicate with each other to update their respective state information. Such respective state information may include, for example, power on self-tests (POST), starting orientation and coordinate system, tape coating path on the object surface, etc. The end effector may receive the robot arm state information from the robot control interface of the robot arm. The robot arm state information may include, for example, a set of motion parameters including positions, orientations, or velocities of arm segments and joints.

[0021] The operating state of the end effector when applying tape onto an object surface can be detected by various sensors. For example, the embodiment shown in FIG. 1 includes a vision system 32 for providing machine vision or 3D vision sensing. The vision system 32 can capture image data of the end effector, analyze the image data to determine the operating state of the end effector, and can determine whether to abort the initialization of the robot arm by sending a notification or command to the robot controller to stop or adjust the motion of the robot arm. For example, in some embodiments, a notification to stop the initialization can be sent when an emergency event is detected.

[0022] The vision system 32 may also provide machine vision or three-dimensional (3D) vision sensing to receive user instructions regarding a tape coating path on the object surface 2. Once the vision system 32 receives instructions from the user and determines an initial tape coating path, the instructions may be sent to a robot controller to coordinate the motion of the robot arm to position the end effector at an initial position in preparation for application of tape onto the initial tape path.

[0023] The vision system 32 may further help to evaluate or verify the tape covering on the object surface 2 and provide feedback to the user. The vision system 32 may acquire imaging data for the tape 4 on the object surface 2 to provide surface mapping information. For example, a 2D perspective projection or contour of the tape 4 on the object surface 2 may be generated and processed to determine whether the tape covering matches a predefined tape covering path on the object surface 2. In some embodiments, the tape covering on the object surface 2 may be determined by scanning the surface of the tape and corresponding coordinates (x, y, z) relative to a predefined tape covering path in the coordinate system of the end effector. The determined tape covering may be communicated to the robot controller as an input for adjusting the motion parameters of the robot arm and the operating parameters of the end effector.

[0024] The end effector 20 may be attached to a mounting interface of the robot arm 10. The end effector 20 is controlled to adjust its position, orientation, movement trajectory, etc., by the motion of the robot arm 10 as it navigates around the object surface 2. Once an initial tape coating path on the object surface 2 has been determined, instructions including an initial set of application parameters may be sent to the end effector to move the end effector along the initial tape coating path to apply tape onto the object surface.

[0025] FIG. 4 shows a schematic diagram of various tape applicator angles / orientations in the coordinate system of an end effector that applies tape on an object surface. The end effector moves at a certain speed along a direction 21 to apply tape to follow a tape coating path 9. The orientation of the end effector, tape applicator, and any rollers of the tape applicator, such as the pressure rollers 53 and 55 and the guide roller 51 in FIG. 3D, can be adjusted by changing at least one of the pitch angle θ, the yaw angle ψ, and the roll angle φ to match the end effector's movement trajectory with the tape coating path 9, which may be a curved three-dimensional (3D) surface or an undulating surface. The speed can range, for example, from about 0.001 m / s to about 1.0 m / s. The pitch angle θ, the yaw angle ψ, and the roll angle φ can each range, for example, from about -30 degrees to about 30 degrees.

[0026] FIG. 5A illustrates a block diagram of a tape application system 500, according to one embodiment. The tape application system 500 includes an end effector 510 operatively connected to a powered robot arm 520. The end effector 510 includes one or more sensors 512 (e.g., sensor 1, ... sensor N) for detecting operational status information when applying tape onto an object surface. The sensors 512 may include, for example, a force sensor that measures real-time force applied to press the tape 4 against the object surface 2. In some embodiments, a force sensor may be attached between a compatible robot flange and the tape applicator to measure the force of the tape application. Force feedback may be used to monitor the pressure the applicator is applying to the tape to ensure proper wet-out for a desired adhesion quality. The force data may also be analyzed to determine the deformation state of a portion of the tape applied onto the object surface. A suitable force sensor may include, for example, a multi-axis load cell that utilizes silicon strain gauges to measure all six components of force and torque in a three-dimensional (3D) coordinate system. The force sensor may include a transducer, interface electronics, and a cable.

[0027] The sensor 512 may also include one or more imaging or vision sensors that may be included by or supplement the vision system 32 of FIG. 1. In some embodiments, one or more of the vision sensors may be integrated with the vision system 32. In some embodiments, one or more of the vision sensors may be integrated with the end effector 20 and operatively connected to the vision system 32. The vision system 32 may receive various imaging data from the imaging sensor and process the data to obtain relevant information, such as, for example, 3D image model information of the object surface, tape and object surface condition information, etc. For example, the vision sensor or imaging sensor may scan the object surface to provide a 3D image model of the object surface. The image data may also be combined with a computer-implemented imaging model (e.g., CAD) of the object surface and possibly some global registration process to ensure the position of the object surface relative to the robotic tape applicator. The image sensor may also detect the relative position / orientation of the end effector with respect to the object surface, and the vision system 32 may measure real-time changes in displacement between the object surface and the end effector based on the image data. A vision or imaging sensor located on the end effector 20 can detect the tape coverage on the object surface and communicate the imaging data to the vision system 32. The vision system 32 can determine the condition of the tape coverage on the object surface based on the image data.

[0028] The sensors 512 may also include various sensors to detect environmental information, such as, for example, ambient temperature, ambient humidity, or other conditions of the end effector, the tape, and / or the object surface. In the operating environment, one or more wireless-enabled sensing stations may be provided that include one or more sensors and a controller configured to output data indicative of the sensed environmental conditions. The detected environmental condition data may be used to adjust the force applied to the tape to stretch it and press it against the object surface. Under different temperatures and humidity, the material properties of the tape adhesive and backing may change, which changes the applied force. By incorporating the environmental information, it is possible to obtain a more accurate estimate of the desired force to ensure proper tape application, for example, without overstretching the tape to introduce defects.

[0029] Sensing signals (e.g., analog sensor signals) from the sensors 512 are received and processed by the processor unit 514. The processor unit 514 may include an analog-to-digital converter (ADC) component that samples the analog sensor signals and converts the analog sensor signals to digital signals. The processor unit 514 may further include digital signal processing components that process and extract the digital signals to generate real-time tool status information, notifications, or instructions, and communicate the generated information to the robot controller. In some embodiments, the processor unit 514 may be integrated into the robot controller 16 and may not be located at the end effector.

[0030] In some embodiments, the real-time tool state information generated by the processor unit 514 may include, for example, the current position / orientation information of the end effector relative to the tape cladding path on the object surface 2. The real-time tool state information may further include the tape stretching or pressing force. The real-time tool state information may further include, for example, the tape cladding state, real-time changes in the displacement between the object surface and the end effector, etc.

[0031] In some embodiments, real-time notifications generated by the processor unit 514 may include, for example, position notifications (e.g., a notification to a robot controller that the end effector is at the edge of the tape), path adjustment notifications (e.g., a notification to a robot controller that the tape retrieval path has been partially or completely adjusted), etc.

[0032] In some embodiments, instructions generated by the processor unit 514 may include, for example, tool operation instructions on how to control the movement of the end effector, movement instructions instructing the robot controller to adjust the position of the end effector, the movement trajectory of the end effector, the peel speed, the orientation of the end effector, etc. Tool operation instructions may include, for example, on / off instructions to the robot controller to turn the end effector on / off, motor control instructions to the robot controller to control the operation of the motors of the end effector, etc.

[0033] The real-time status information, notifications, or commands from the end effector 510 can be sent to the robot controller 16 via the tool control interface 516 and the robot control interface 526. The robot controller 16 can then use the real-time status information to simultaneously update the motion parameters of the robot arm so that the movement trajectory of the end effector 510 can be precisely controlled. The robot controller 16 can also control the tape application system 100 accordingly by taking action with notifications or according to commands from the end effector 510. In some embodiments, the robot controller 16 may receive real-time status information, notifications, or commands from the end effector, interpret the received information, check whether the notifications or commands are compatible with pre-set rules, and implement the commands accordingly. For example, the robot controller 16 may provide the end effector with a movement vector to adjust its position relative to the object surface. The robot controller 16 can command the robot arm to apply an appropriate force for the tape applicator to press the tape against the object surface. The robot controller 16 can provide an emergency stop command to the end effector to stop it when an emergency condition is determined by the robot controller, and can also command various parts to perform other actions.

[0034] 5B is a block diagram of the robot controller 16, according to one embodiment. The robot controller 16 operatively connects to various parts of the system and regulates the operation of the system through various controls, processors, storage devices, etc. In the illustrated embodiment of FIG. 5B, the robot controller 16 includes an input unit 162 for receiving various sensing data from the vision system 32, the sensor 512, and / or the end effector 310. For example, the input unit 162 may receive imaging data from an imaging sensor regarding a tape coating path on an object surface. The robot controller 16 further includes an instruction unit 164 that processes the data received by the input unit 162 and provides instructions to various parts of the system based on the received data.

[0035] In some embodiments, the instruction unit 164 can process the received imaging data or other sensing data related to the tape coating path and analyze the sensing data to determine if there are any collision points or impossible curvatures on the tape coating path. A collision point may be an area on the object surface where the desired tape repair is located where the robot and end effector cannot achieve tape application. For example, around some headlamp assemblies, the path may be at a position where the robot arm or end effector cannot place tape on the indicated surface without colliding with another object adjacent to the object surface. A collision point can be detected by running an inverse kinematic algorithm along the Cartesian waypoints indicated by the desired path and checking the joint positions and robot model at each waypoint to see if any part of the robot model is colliding with any part of the environment / substrate model. An impossible curvature may be a part that has a radius of curvature that is too low to be achieved by a single piece of tape (using either a rigid or deformable tape quality). In order to successfully apply tape along this curvature, it may be necessary to split this part into two or more parts. It may be necessary to warn the user that this location cannot be processed using a single line of tape. Detecting this comes down to pre-processing (by CAD, or image processing / 3D part scanning) along the desired glue path and then using certain algorithms to determine if the tape curvature is too high for a tape with a certain deformability.

[0036] In some embodiments, the vision system 32 may acquire and process imaging data and send the processed imaging data to the input unit 162. The robot controller 16 further includes a storage unit 166 that stores information including, for example, a predefined 3D model of the object surface, a predefined tape coating path on the substrate / object surface, predefined rules or policies, dynamically updated status information, etc. The predefined rules or policies may be predetermined for various events that may occur during tape application. For example, a user operating the system may set a rule that detection of a tape break is an emergency event.

[0037] 6 shows a flow diagram of a method 600 for applying tape onto an object surface, according to one embodiment. Method 600 can be implemented by various tape application systems described herein, including, for example, robotic tape applicator 40 of FIG. 2. At 610, a robot is provided with an end effector attached to a robot arm, such as robot arm 10 of FIG. 1. An end effector, such as end effector 20 of FIG. 1, is operatively connected to a distal end of robot arm 10. The end effector includes a tape applicator, such as tape applicator 40 of FIG. 2, configured to apply tape to the object surface. Method 600 then proceeds to 620.

[0038] At 620, the tape application system determines an initial tape coating path on the object surface. The tape coating path can be a digital two-dimensional (2D) or digital three-dimensional (3D) perspective projection, or a surface contour, of a portion of the object surface to be covered by the tape. Such a 2D or 3D perspective projection of the tape or the contour of the object surface portion can be determined in advance and updated in real time by the vision system 32. For example, in some embodiments, the vision system may include a camera that scans the object surface to develop a 2D or 3D perspective projection or contour of the object surface relative to the coordinate system of the robot arm.

[0039] A 3D model of the object surface to which the tape is to be applied can be provided to the system so that the robot knows where to move in space to apply the tape in the right place and with the right application sequence. This model can be obtained through various means, including, for example, by 3D scanning of the object surface (e.g., manually or with a robot), by using a predefined digital 3D model, or other suitable methods. In some embodiments, the geometry of the object surface can be represented by a digital two-dimensional (2D) or digital three-dimensional (3D) model. The digital model can be in the form of an electronic file for computer-aided design (CAD), computer-aided manufacturing (CAM), computer-aided engineering (CAE), or other suitable applications. The digital model can be predetermined and stored, for example, in the storage unit 166 of FIG. 5B, and retrieved by the robot controller 16. Global part alignment can be implemented by motion capture or machine vision techniques, or other suitable methods. This process allows the robot to know the geometry of the part as well as its location in space.

[0040] The robot then needs to know where to apply the tape. In some embodiments, the system can receive from a user a specification for a tape coating path in a digital three-dimensional (3D) model of the object surface. The tape coating path in the digital 3D model can be represented by a digital dotted curve that includes a start point, an end point, and a series of waypoints connecting the start point and the end point. One exemplary model of a tape coating path is shown in FIG. 4B, including a start point a, an end point b, and a series of waypoints ...(i-1), i, (i+1) connecting the start point a and the end point b. The user can specify the location of the tape on the object surface (i.e., the tape coating path) by various means. For example, in some embodiments, the user can specify the tape coating path in the 3D space of the object surface using a virtual reality (VR) device (e.g., a VR headset), by tracing the path by a computer using CAD / CAM software, by using machine vision or motion tracking to trace the position of the user's hands as they trace, or by using some other method.

[0041] With the specified initial tape coating path, the system can plan an initial movement trajectory for the end effector to move relative to the object surface. In the present disclosure, the system can plan the movement trajectory including, for example, smoothing the trajectory curve, determining constraints / feasibility on the tape coating path, updating / informing the feasibility of the tape coating path, adjusting the tape coating path based on the feedback, etc.

[0042] In some embodiments, the system can smooth the trajectory curve, such as the curve shown in FIG. 4B. For example, depending on how the tape-covered path is input, there may be some noise at the input waypoints or in areas with large spikes in acceleration or jerk or angular acceleration or jerk. The system can smooth the trajectory to remove noise, to reduce acceleration / jerk, or for other goals based on the user's needs. Various algorithms can be used to remove noise from the signal, smooth the trajectory to minimize acceleration / jerk, and other smoothing needs.

[0043] In some embodiments, the system can determine whether a specified tape coating path is feasible. This may include using constraints (e.g., collision points, impossible curvatures on the specified tape coating path) to determine path feasibility. The system can ensure that the tape coating path waypoints (and the waypoints updated by the sensor) provide a path that can be traced within some range of the tape's deformability. If a waypoint exceeds that range, the constraints can be relaxed. For example, a waypoint can be adjusted by moving along a tangent perpendicular to the intersection line of the previous and next waypoints (to maintain distance).

[0044] A tape coating path can be considered feasible if it allows the robot to complete the trajectory with the desired application parameters. In the context of tape application, this means that the robot can apply tape at the desired waypoints in the desired orientation without causing collisions or undesirable point-to-point problems. In other words, if the path is properly defined point-to-point, there are no collisions between the robot and the object, between the robot and itself, or between the robot and other objects around the robot. This also means that the robot maintains its relative orientation point-to-point, and there are no joint reversals (moving from negative joint angles to positive joint angles to meet kinematic requirements) or singularity problems.

[0045] With regard to path constraints, the tape coating path may need to be modified or corrected (either in position or orientation) to meet kinematic, application, or material requirements. Kinematic requirements include possible issues of collision, joint reversal, singularity, joint limits, or other robot / kinematic chain constraints. Standard robot planning algorithms can be used to account for kinematic constraints by considering the robot and part geometry. Application requirements include, for example, coverage of a particular geometric part, maximum deviation from a nominal path, or proper tape wet-out or compression. Material requirements include, for example, tape deformability (e.g., how much the tape can or will stretch / compress around a longitudinal axis to achieve a curve while still maintaining paint line tolerances, etc.).

[0046] The deformability of the tape can be determined by any suitable algorithm. Figure 4C shows a schematic diagram of an algorithm that determines whether a portion of the tape coating path may introduce excessive deformation into the tape applied thereon. The following equation can be used to determine whether the path needs to be modified to reduce possible tape deformation.

number

[0047] The re-pathing may include manual or automatic processes. In a manual process, a particular waypoint (e.g., point i in FIG. 4C) that caused excessive deformation may be flagged by the system to the user. The user may manually modify the tape path via a user interface until the deformation is within a specified limit. The system may also automatically modify the tape path, for example, by moving point i to preserve the distance (maintaining equal distances from i-1 to i and from i to i+1). Point i may be adjusted, for example, by moving it along a secant vector that points from the intersection of equal-radius circles (of the distance between the above-mentioned points) around point i+1 and point i-1. Possible distances to move the point include moving along the secant to the bisector vector that points from point i-1 to i+1, moving to the opposite secant intersection, or moving a portion of this distance. One default behavior is to move to the midpoint / bisector position. Smaller or larger distances are considered if the distance traveled does not cover critical geometries, if collisions occur, or for other reasonable reasons. This process of adjusting the tape path may be repeated over the entire path (except for the first and last points) wherever the deformability is exceeded.

[0048] If the system determines that at least one of the kinematic, material, and application constraints is violated (e.g., the desired geometry is no longer covered or the path deviates significantly from the nominal path, etc.), the system may inform the user that the desired path is not feasible and may request further instructions. In some cases, the system may enable the tape coating path to be divided into usable and unusable portions, where the usable portion may be feasible but the unusable portion may need to be manually coated, or the path may need to be manually reconfigured via a tape coating definition process technique.

[0049] Based on the determined path feasibility, the system may provide feedback to the user including, for example, suggesting an alternative or better path, updating and presenting the path, informing the user to manually change the path, etc. Based on the determined initial tape coating path, the tape application system further determines an initial movement trajectory for the end effector relative to the object surface. In some embodiments, the robot may be initialized by providing an initial movement trajectory that corresponds to the tape coating path. The initial movement trajectory provides a path in the robot coordinate system for moving the end effector. At 620, an initial movement trajectory of the end effector may be determined based on the initial tape coating path on the object surface. Once the initial tape coating path and the corresponding movement trajectory for the end effector are determined, method 600 proceeds to 630.

[0050] At 630, the robot controller 16 can command the robot arm to move the end effector along a travel trajectory to apply tape onto the object surface. The system can start by initializing the robot to position the end effector and prepare to apply tape onto the object surface. The robot controller 16 can communicate with various parts of the system, such as the robot arm, the end effector, the vision system, and various sensors, to update their respective position / location information, status information, and other relevant information. The method 600 then proceeds to 640.

[0051] At 640, while the end effector moves along the travel trajectory to apply tape on the object surface, the system determines the path feasibility of the tape coating path in real time, similar to that described above at 620. In some embodiments, the vision system 32 can scan the path and detect any constraints in applying the tape in real time, such as, for example, collision points, impossible curves along the tape coating path, etc. If the system determines that the path feasibility violates some predefined constraints, in some embodiments, the system can provide a notification to the user and / or receive a user's instruction regarding updating the tape coating path. In some embodiments, the system can automatically adjust or correct the tape coating path or the applicator position to satisfy the constraints. For example, the tape coating waypoints may be updated by the following process: The system's sensors may look beyond the current waypoints of the tape path, the system determines that the sensed substrate features do not match the preprocessing model, and the waypoints may be updated (e.g., XYZ position and RPY orientation are all subject to update). These parameters can then be substituted into a particular deformability formula to determine the arc lengths of the inner and outer edges of the tape between the two waypoints. If the arc lengths are within the deformability tolerances, the path may continue with the updated orientation. If not, the system may stop processing and wait for further instructions, or cut the tape line into a new tape line at that waypoint. Method 600 then proceeds to 650.

[0052] At 650, the system automatically updates the tape coating path based on the determined path feasibility or based on a user command. The end effector travel trajectory can be adjusted accordingly. The method 600 then proceeds to 660.

[0053] In some cases, the system can automatically update the path and inform the user of the update. In some cases, the system can inform the user that a constraint is violated and allow the user to update the path by manual intervention. The tape covering path can be updated / modified to satisfy kinematic, application, and material constraints. Kinematic constraints can often be satisfied by filtering / smoothing and / or slight movement of problematic waypoints. These constraints can also be resolved by user modification of problematic waypoints (e.g., manually adjusting the position or orientation of the waypoint to satisfy the condition) if not satisfied. Manual corrections may not be done in real time, as they are too labor intensive for real time feedback; this may be a pre-processing routine only. Application constraints can be satisfied by ensuring that the desired geometry and path are properly matched in the model and then in the actual part. Material constraints on the deformability of the tape may affect which trajectories are possible. If a curved segment exceeds the deformability of the tape and a path change may violate kinematic or application constraints, multiple paths must be used, in which case the system can automatically split into multiple paths or inform the user that the path is not feasible as designed.

[0054] At 660, the system commands the tape applicator to apply tape on the updated tape coating path. In some embodiments, when the system detects that the tape applicator is at the start of a new portion on the tape coating path, the tape may be loaded into a tab mechanism to create a tab on the edge of the tape. In some embodiments, when the system detects that the tape applicator is at the end of a new portion on the tape coating path, the tape applicator may cut the tape with a blade. Method 600 then proceeds to 670.

[0055] At 670, while the tape applicator applies the tape on the object surface, the system determines real-time tool status information based on various sensor data or feedback. The real-time tool status information may include, for example, the current position / orientation information of the end effector relative to the tape coating path on the object surface. The real-time tool status information may further include tape stretching or pressing information. The real-time tool status information may further include, for example, the coating status of the tape on the object surface, real-time changes in the displacement between the object surface and the end effector, etc. For example, when the vision system 32 detects that the object surface to which the tape is applied moves during application, the system can adjust the movement trajectory of the end effector accordingly so that the end effector can follow the tape coating path on the object surface. The vision system 32 can further monitor the application process and provide relevant orientation / position / status information of the tape applicator relative to the object surface, so that the robot controller 16 can modify the motion parameters of the robot arm and / or adjust the orientation / position of the tape applicator relative to the object surface. The vision system 32 can further provide feedback related to the tape covering by displaying the image date to the user, who can then adjust the operation of the robotic system accordingly.

[0056] In some embodiments, while the tape applicator applies tape onto the object surface, the robot controller 16 commands various sensors (e.g., vision system 32, sensor 512, etc.) to provide feedback regarding positional errors that may be introduced into the model due to variations between the nominal / modeled part and the actual part. Errors may be introduced in the scanning process, manufacturing process, or part / robot positioning. Due to this variable positioning, proper applied pressure or tape position needs to be ensured.

[0057] One type of feedback is force feedback, with the force sensor used to measure the force of the tape application. Force feedback can be used to monitor the pressure the applicator is applying to the tape to ensure proper wet-out for the desired adhesion quality. Upper and lower pressure limits can be set based on an acceptable tolerance around the nominal desired pressure.

[0058] Based on the monitored pressure, the system can adjust the end effector distance along the surface normal by some correction distance for the next point in the trajectory if the pressure range is exceeded at either extreme. The correction distance can be calculated by multiplying the difference between the current pressure value and either the upper or lower limit (depending on whether the pressure exceeds the upper or lower limit, respectively) by some gain value. Thus, the equation follows the standard proportional gain formula. d=(P current -P limit ) * G...(2) where d is the correction distance and P current is the measured pressure, P limit are the upper or lower pressure limits, and the gain G is some value set by the user. The default gain value is determined by using the maximum expected distance deviation (e.g., the maximum expected difference between the actual part and the 3D model) and multiplying it by the average of the upper and lower pressure limits. The user may want to increase the default gain value to be more aggressive or more passive, or decrease the gain, as desired. In some cases where vibration is a concern, a proportional-derivative (PD) loop can be employed by using the current time derivative of the pressure multiplied by another gain H (e.g., the default value is about 1 / 10 of the first gain G).

number

[0059] Similar to force feedback, position feedback has an equation that determines how much the next point (in the waypoint's frame of reference) should be changed in the x or y direction. d=(x current -x limit ) * G...(4) where d is the correction distance and X current is the measured position, and X limit are upper or lower position limits, where the gain G is some value set by the user. The default gain value is typically about 1. The user may want to increase the default gain value or decrease the gain G to be more aggressive or more passive, as desired. In some cases where vibration is a concern, a PD loop can be similarly employed by using the current Cartesian velocity multiplied by another gain (the default value is about 1 / 10 of the first gain).

number

[0060] Vision feedback can also incorporate tape deformability concerns as well, and a deformability check can be performed after updating the remaining path points with the algorithm shown. Also, in case of any violations, the aforementioned deformability corrections can be performed over the remaining path points. If, after the vision feedback corrections of the path, the path is no longer feasible, the process can be aborted and a new tape segment can be started with the remaining path (based on user preferences), or the user can be informed that the desired path is not possible to perform.

[0061] In some embodiments, while the tape applicator applies tape on the object surface, the robot controller 16 commands various sensors (e.g., vision system 32, sensor 512, etc.) to monitor and determine the condition of the tape applicator and the tape applied to the object surface. The robot controller 16 can provide different commands to each part depending on the monitored condition. For example, in one case, the robot controller 16 can receive sensor data from the sensors and process the data to verify that the actual coverage of the tape substantially matches the predetermined tape coverage path on the object surface. In another case, the robot controller 16 can detect whether an event has occurred that results in an adjustment of the system. For example, the robot controller 16 can process the sensor data to detect a movement of the object surface during the application of the tape that results in a bad path for the end effector. The robot controller 16 can command the robot arm to adjust the position of the end effector to accommodate such displacement. If the automatic adjustment is not successful, the robot controller 16 can send a notification regarding the condition. In various embodiments, the robot controller 16 can receive sensing data from various environmental sensors to determine various environmental conditions including, for example, ambient temperature and ambient humidity.

[0062] Figure 7 shows a block diagram of a tape application method 700, according to one embodiment. Method 700 may be implemented by various tape application systems described herein, including, for example, robotic tape applicator 40 of Figure 2. It should be understood that any steps or sub-steps of method 700 may be combined in any suitable manner with steps or sub-steps of method 600 of Figure 6 to arrive at a variety of suitable methods or processes for applying tape onto an object surface.

[0063] At 710, the tape application system obtains a digital 3D model of the object surface to which the tape will be applied. At 712, the system determines an initial tape coating path on the object surface. At 714, the system determines a movement trajectory for the robotic tape applicator. At 716, the system determines whether the planned movement trajectory or tape coating path satisfies the kinematic constraints. If the system determines that there is a violation of the kinematic constraints, the method 700 proceeds to 718. If the system determines that there is no violation of the kinematic constraints, the method 700 proceeds to 724. At 718, the system determines whether the tape coating path should be corrected or adjusted to satisfy the kinematic constraints. If the system determines that a correction or adjustment of the tape coating path is not feasible, the method 700 proceeds to 720. At 720, the system determines whether to abort the tape application or to split the tape coating path into usable and unusable portions. If the system determines to abort the tape application, the method 700 proceeds to 722. If the system determines that a correction or adjustment to the tape coating path is feasible, method 700 proceeds to 724. At 722, the system decides to interrupt the tape application or to start a new tape application and notify the user. If the system determines to split the tape coating path into usable and unusable portions, method 700 proceeds to 714.

[0064] If the system determines that there is no violation of the kinematic constraints or if the system determines that a correction or adjustment of the tape coating path is feasible, method 700 proceeds to 724. At 724, the system determines whether the planned movement trajectory or tape coating path satisfies the tape deformability constraints. If the system determines that there is a violation of the tape deformability constraints, method 700 proceeds to 726. At 726, the system determines whether the tape coating path should be corrected or adjusted to satisfy the tape deformability constraints. If the system determines that a correction or adjustment of the tape coating path is not feasible, method 700 proceeds to 728. If the system determines that a correction or adjustment of the tape coating path is feasible, method 700 proceeds to 730. At 728, the system decides whether to abort the tape application or to split the tape coating path into usable and unusable portions. If the system determines to abort the tape application, method 700 proceeds to 722. If the system determines to split the tape coating path into usable and unusable portions, method 700 proceeds to 714 .

[0065] If the system determines that there is no violation of the tape deformability constraints or if the system determines that a correction or adjustment of the tape coating path is feasible, method 700 proceeds to 730. At 730, the system determines whether the planned movement trajectory or tape coating path satisfies the tape application constraints. If the system determines that there is a violation of the tape application constraints, method 700 proceeds to 732. If the system determines that there is no violation of the tape application constraints, method 700 proceeds to 736. At 732, the system decides to abort the tape application or to split the tape coating path into usable and unusable portions. If the system determines to abort the tape application, method 700 proceeds to 722. If the system determines to split the tape coating path into usable and unusable portions, method 700 proceeds to 714.

[0066] If the system determines that there is no violation of the tape application constraints, method 700 proceeds to 736. At 736, the system operates to apply tape onto the object surface. While applying the tape, at 740, the system checks in real time the pressure used to apply the tape under a particular force feedback algorithm. While applying the tape, at 742, the system checks in real time the tape position under a particular vision feedback algorithm. If the system determines that both the pressure and the position are appropriate and not the end of the movement trajectory, method 700 proceeds to 736 and continues applying the tape, for example, by moving the applicator to the next waypoint of the path. If the system determines that at least one of the pressure and the position is inappropriate and not the end of the movement trajectory, method 700 proceeds to 744. At 744, the system decides to adjust or update the applicator movement trajectory or the tape coating path, and method 700 proceeds to 714. If the system determines that it is not the end of the travel trajectory, the method 700 proceeds to 746 where the tape is cut, the status is communicated to the user, and the system moves on to the next tape application.

[0067] Unless otherwise indicated, all numbers expressing quantities or ingredients, property measurements, and the like used in the specification and embodiments are to be understood in all instances as being modified by the term "about". Thus, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and accompanying list of embodiments may vary depending upon the desired properties one of ordinary skill in the art would obtain utilizing the teachings of the present disclosure. At the very least, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques, which is not intended to limit the application of the doctrine of equivalents to the scope of the embodiments described in the claims.

[0068] Various modifications and variations can be made to the exemplary embodiments of the present disclosure without departing from the spirit and scope of the present disclosure. Therefore, it should be understood that the embodiments of the present disclosure are not limited to the exemplary embodiments described below, but are to be controlled by the limitations set forth in the claims and their equivalents.

[0069] List of Exemplary Embodiments Exemplary embodiments are listed below. It should be understood that any one of the embodiments 1 to 13 and the embodiments 14 to 18 can be combined.

[0070] Embodiment 1 is a method of applying tape onto a surface of an object, comprising the steps of: positioning a robot adjacent to an object surface, the robot comprising an end effector, the end effector comprising a tape applicator; determining a tape coating path for applying tape to a surface of the object; While moving the end effector along the travel path, determining path feasibility of the tape cladding path; updating the tape cladding path and the movement trajectory based on the determined path feasibility; applying tape onto the updated tape coating path; The method includes:

[0071] Example 2 is the method of example 1, wherein determining a tape coating path on the object surface further comprises receiving, from a user, specifications for the tape coating path on a three-dimensional (3D) model of the object surface.

[0072] Example 3 is the method of example 1 or 2, further comprising acquiring imaging data of the tape, the object surface, and the end effector via a vision system.

[0073] Example 4 is the method of example 3, further comprising verifying tape coverage on the tape coverage path based on the imaging data.

[0074] Example 5 is the method of any one of Examples 1 to 4, wherein determining path feasibility includes determining at least one of a collision point and a curvature portion on the tape covering path.

[0075] Example 6 is the method of any one of Examples 1 to 5, wherein determining path feasibility further comprises detecting deformation of the tape.

[0076] Example 7 is the method of any one of Examples 1 to 6, wherein determining path feasibility further comprises detecting movement of the object surface during application of the tape.

[0077] Example 8 is the method of any one of Examples 1 to 7, wherein determining the path feasibility further includes determining environmental conditions, including an ambient temperature and an ambient humidity.

[0078] A ninth embodiment is the method according to any one of the first to eighth embodiments, further comprising sending a notification to a user based on the determined route feasibility.

[0079] An embodiment 10 is the method according to any one of embodiments 1 to 9, further comprising: receiving feedback from a user; and updating the tape coating path based on the feedback.

[0080] Example 11 is the method of any one of Examples 1 to 10, wherein applying the tape onto the object surface further comprises loading the tape into a tab mechanism and creating tabs on edges of the tape.

[0081] Example 12 is the method of example 11, in which creating the tab includes folding an edge of the tab.

[0082] Example 13 is the method of example 11 or 12, further comprising cutting the tape to create a new edge of the tape before creating the tab.

[0083]

[0023] Embodiment 14 is an automated system for applying tape onto a surface of an object, comprising: an end effector including a tape roll and a tabulating mechanism; a vision system including one or more imaging sensors for acquiring imaging data about the tape, the object surface, and the end effector; a controller operatively connected to the end effector and the vision system; The controller determining a tape coating path on a surface of the object; While moving the end effector along the movement trajectory to apply tape onto the object surface via the end effector, determining route feasibility of the tape-covered route; updating the tape cladding path based on the determined path feasibility; Applying tape onto the updated tape coating path; It is an automated system configured to:

[0084] Embodiment 15 is the automated system of embodiment 14, wherein the tabulating mechanism further comprises a vacuum plate to hold the edge of the tape in place.

[0085] Embodiment 16 is the automated system of embodiment 15, wherein the vacuum plate comprises a first portion and a second portion foldable relative to the first portion.

[0086] Embodiment 17 is an automated system according to any one of embodiments 14 to 16, further comprising a robot arm, the end effector being attached to the robot arm.

[0087] Embodiment 18 is an automated system described in any one of embodiments 14 to 17, wherein the controller is further configured to determine a condition of the tape on the object surface based on imaging data from the vision system.

[0088] The operation of the present disclosure will be further described with reference to the following detailed examples. These examples are provided to further illustrate various specific preferred embodiments and techniques. However, it should be understood that many variations and modifications can be made while remaining within the scope of the present disclosure.

[0089] Throughout this specification, reference to "one embodiment," "a particular embodiment," "one or more embodiments," or "an embodiment" means that the particular feature, structure, material, or characteristic described in connection with that embodiment is included in at least one of the particular exemplary embodiments of the disclosure, regardless of whether the term "embodiment" includes the term "exemplary." Thus, the appearances of phrases such as "in one or more embodiments," "in a particular embodiment," "in one embodiment," or "in an embodiment" in various places throughout this specification do not necessarily refer to the same particular exemplary embodiments of the disclosure. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

[0090] Although certain exemplary embodiments have been described in detail herein, it will be understood that those skilled in the art, upon understanding the above description, can easily conceive of modifications, variations, and equivalents of these embodiments. It is therefore to be understood that the present disclosure is not to be unduly limited to the exemplary embodiments described thus far. In particular, as used herein, the recitation of numerical ranges by endpoints is intended to include all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5). In addition, all numbers used herein are intended to be modified by the term "about." Furthermore, various exemplary embodiments have been described. These and other embodiments are within the scope of the following claims.

Claims

1. 1. A method of applying tape onto a surface of an object, comprising: positioning a robot adjacent to the object surface, the robot comprising an end effector, the end effector comprising a tape applicator; determining a tape coating path for applying the tape to the object surface; While the end effector is moving along a movement path, determining path feasibility of the tape-covered path; updating the tape covering path and the movement trajectory based on the determined path feasibility; applying the tape onto the updated tape path; A method comprising:

2. The method of claim 1 , wherein determining the tape coating path on the object surface further comprises receiving, from a user, specifications for the tape coating path on a three-dimensional (3D) model of the object surface.

3. The method of claim 1 , further comprising acquiring imaging data of the tape, the object surface, and the end effector via a vision system.

4. The method of claim 3 , further comprising verifying the coating of the tape on the tape coating path based on the imaging data.

5. The method of claim 1 , wherein determining path feasibility includes determining at least one of collision points and curvatures on the tape coating path.

6. The method of claim 1 , wherein determining the path feasibility further comprises detecting deformation of the tape.

7. The method of claim 1 , wherein determining path feasibility further comprises detecting movement of the object surface during the application of the tape.

8. The method of claim 1 , wherein determining the path feasibility further comprises determining environmental conditions including ambient temperature and ambient humidity.

9. The method of claim 1 , further comprising sending a notification to a user based on the determined route feasibility.

10. The method of claim 1 , further comprising receiving feedback from the user and updating the tape coating path based on the feedback.

11. 10. The method of claim 1, wherein applying the tape onto the object surface further comprises loading the tape into a tab mechanism and creating a tab on an edge of the tape, wherein creating the tab comprises folding the edge of the tab over, and further comprising cutting the tape to create a new edge of the tape before creating the tab.

12. 1. An automated system for applying tape onto a surface of an object, comprising: an end effector including a tape roll and a tabulating mechanism; a vision system including one or more imaging sensors for acquiring imaging data about the tape, the object surface, and the end effector; a controller operatively connected to the end effector and the vision system; The controller: determining a tape coating path on the object surface; While moving the end effector along a movement path to apply the tape onto the object surface via the end effector, determining path feasibility of the tape-covered path; updating the tape covering path based on the determined path feasibility; applying the tape onto the updated tape coating path; An automated system that is configured to:

13. 13. The automated system of claim 12, wherein the tabulating mechanism further comprises a vacuum plate for holding the edges of the tape in place.

14. 14. The automated system of claim 13, wherein the vacuum plate comprises a first portion and a second portion foldable relative to the first portion.

15. 13. The automated system of claim 12, further comprising a robotic arm, the end effector attached to the robotic arm, and the controller further configured to determine a condition of the tape on the object surface based on the imaging data from the vision system.

Images