3D-Guided Polyarticulated Tool Paths for Collision-Free Operation
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Solution Overview
Problem
Existing methods for performing operations like cutting, welding, and measuring in changing or poorly defined environments, such as radioactive dismantling sites, are inefficient due to safety concerns, inaccuracy, and high costs associated with manual operation or remote-controlled polyarticulated systems.
Innovation Solution
A method and facility utilizing a polyarticulated system equipped with 3D sensors to capture and merge images of the object and environment with CAD models, allowing for the definition of tool trajectories and simulation of movements to ensure feasibility and safety, thereby enabling automatic and precise operations in uncertain environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation with protective equipment is used, then operator safety is improved, but operation performance and efficiency deteriorate
Solution Approach 1:
The polyarticulated system performs operations autonomously based on pre-planned trajectories and real-time sensor feedback, eliminating the need for operator intervention in hazardous environments. The system serves itself by automatically adjusting positions and executing tasks without human physical presence.
Solution Approach 2:
Manual mechanical operation by operators is replaced with automated polyarticulated system control. The system uses computer-based trajectory planning and sensor feedback loops to substitute human mechanical actions with automated actuation, improving both safety and precision.
2Reliability
If remote control with indirect vision is used, then operator safety is improved, but control accuracy and operation speed deteriorate
Solution Approach 1:
The system implements real-time feedback through multiple sensors (cameras, force sensors, encoders) that continuously monitor tool position, contact forces, and environmental conditions. This feedback is processed by control algorithms that automatically adjust trajectories and actuation commands to maintain high precision without operator intervention.
Solution Approach 2:
The system creates a digital replica of the work environment using 3D mapping and CAD models, allowing virtual simulation and verification of trajectories before actual execution. This digital twin approach enables precise control by pre-validating paths against the virtual model of the physical environment.
3Adaptability or versatility
If polyarticulated system with remote control is used, then accessibility to confined environments is improved, but operation time and tool wear increase
Solution Approach 1:
The system performs preliminary 3D mapping of the environment and pre-plans operation trajectories using CAD models before actual execution. Trajectories are simulated and validated in advance to ensure feasibility and optimality, eliminating trial-and-error adjustments during real operations and reducing overall operation time.
Solution Approach 2:
The system dynamically adapts pre-planned trajectories in real-time based on sensor feedback about actual environmental conditions, object positions, and tool states. This dynamic adjustment allows the system to maintain optimal operation speed while navigating confined spaces, reducing tool wear through smooth, collision-free motion.
4Manufacturing precision
If automatic operation is implemented, then precision and speed are improved, but environmental definition requirements increase
Solution Approach 1:
The environment definition process is segmented into distinct phases: initial 3D mapping, CAD model integration, trajectory planning, and real-time validation. Each phase processes specific aspects of environmental data independently, reducing overall complexity while enabling high-precision automatic operation through systematic breakdown of the definition task.
Data Source
AI summary
Automatically performing an operation on an object-with a tool-carried by a polyarticulated system-that can be moved in a working environment, the object-and the working environment being open-ended or insufficiently defined to carry out the operation. A method comprises: capturing a scatter plot image of the object-and the working environment-with a 3D sensor, merging this image with the CAD model of the system and the environment into a working image, and defining anti-collision parameters;— defining a path of the tool-on the portion of the working image representing the object and executing a simulation of the corresponding movement of the system-and the tool in the working image so as to ensure that the operation is feasible;— and if the operation is feasible executing the actual movement of the system carrying the tool-according to the path defined for performing the operation on the object.