Aircraft Component Processing Robot with Optical Position Offset

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Solution Overview

Problem

Current robotic systems for aircraft assembly lack precision and efficiency in processing aircraft components due to variability in feature positions caused by manufacturing tolerances, leading to potential human error and ergonomic issues.

Innovation Solution

A robotic method and system that uses a light emitting device and camera to determine the actual position of features on an aircraft component, compare them to a model, calculate position offsets, and adjust the robotic arm's path for accurate processing, incorporating a gripper tool and processing tools to modify the component based on these offsets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If traditional robotic systems are used for aircraft component processing, then automation is achieved, but precision and accuracy deteriorate due to manufacturing tolerance variability

Engineering Contradiction:

ImproveautomationVSAvoidprocessing precision

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The system performs preliminary scanning and measurement of the aircraft component before processing begins. The light source and camera capture images of features to determine their actual positions, allowing the system to pre-calculate path offsets and adjust the robotic trajectory in advance, ensuring precise processing despite manufacturing tolerances

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements a feedback loop where the actual positions of features are measured and compared against the model, path offsets are calculated based on these comparisons, and the robotic processing path is dynamically adjusted. This closed-loop control ensures that processing precision is maintained by continuously adapting to actual feature positions

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If manual processing methods are used to accommodate feature position variability, then flexibility is maintained, but productivity and efficiency deteriorate

Engineering Contradiction:

ImproveflexibilityVSAvoidprocessing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The robotic system performs self-adjustment by automatically measuring feature positions, calculating path offsets, and modifying its own processing trajectory without human intervention. The system uses its own sensing capabilities to detect deviations and corrects them through automated path compensation, maintaining both flexibility and high productivity

Inventive Principle:

Principle #25Self-service

3Device complexity

If traditional robotic systems without feature detection are used, then device complexity is reduced, but reliability and accuracy deteriorate due to potential human error

Engineering Contradiction:

Improvesystem complexityVSAvoidprocessing reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system replaces manual measurement and alignment operations with an automated optical measurement system. The light source and camera capture images of features, and the controller automatically processes these images to determine feature positions and calculate path offsets, eliminating human error and improving reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system introduces an intermediary measurement and calculation layer between the robotic system and the component. The light source, camera, and controller work together to mediate the interaction by providing accurate feature position data and calculating appropriate path adjustments, ensuring reliable and accurate processing

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances accuracy, productivity, reduces human error, and mitigates ergonomic risks by enabling precise alignment and processing of aircraft components, improving overall assembly efficiency and safety.

Implementation Method 1

illuminating a feature of the aircraft component with a light emitting device which is mechanically coupled to a robot; receiving light reflected from the feature on the aircraft component to capture at least one image using a camera

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS10086514B2Robotic system and method for processing aircraft component

Publication Date: 2018.10.02 TEXTRON INNOVATIONS INC

AI summary

Embodiments of the present disclosure include a robotic method for processing an aircraft component that includes determining feature positions by illuminating with light, imaging the reflected light with a camera, and processing images from the camera. The method further includes determining a position offset of the features by comparing to a model of the aircraft component, determining a path offset for movement by a robot arm, and modifying the aircraft component using a processing tool coupled to the robot arm. A robotic system for processing an aircraft component includes a light emitting device and a camera configured for respectively illuminating and imaging features of an aircraft component, a gripper tool for gripping and moving the aircraft component to a workstation, a processing tool for modifying the aircraft component, and a controller to control the light emitting device, camera, gripper tool, workstation, and processing tool to modify the aircraft component.