Automated Preloading System for Robotic Actuator Backlash Control
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Solution Overview
Problem
Industrial robot arms with high-precision servo actuators face challenges due to wear and tear, requiring frequent replacement of expensive components and manual preload adjustments that are not repeatable, leading to inefficiencies and excessive mechanical component wear.
Innovation Solution
An automated preloading system for actuators that adjusts preload levels based on measured values and target values, using sensors and controllers to maintain optimal backlash and preload levels, reducing the need for high-precision components and ensuring consistent, repeatable adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive high-precision servo actuators with tightly-tuned fits and tolerances are used to achieve preload, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The system automatically adjusts preload levels through automated actuators that self-regulate based on measured values and target values, eliminating the need for manual adjustments and high-precision manual tuning of components
Solution Approach 2:
The system dynamically changes the preload parameter through automated adjustment mechanisms, allowing the same actuator to operate at different preload levels without requiring multiple high-precision components with fixed tolerances
2Adaptability or versatility
If manual preload adjustments are performed, then adaptability is improved, but productivity deteriorates due to frequent replacements and non-repeatable adjustments
Solution Approach 1:
The system uses sensors to measure actual preload values and compares them against target values, automatically adjusting the preload to maintain optimal levels. This closed-loop feedback ensures repeatable, consistent adjustments without manual intervention
Solution Approach 2:
The patent replaces manual mechanical adjustment operations with an automated control system that uses sensors, controllers, and automated actuators to perform preload adjustments, eliminating human error and improving repeatability
3Manufacturing precision
If high-precision components with tightly-tuned fits and tolerances are used, then manufacturing precision is improved, but loss of substance increases due to excessive wear and tear
Solution Approach 1:
The system dynamically adjusts preload levels based on real-time measurements and wear conditions, allowing the actuator to adapt to changing mechanical conditions and extend component life by optimizing preload throughout the operational cycle
Solution Approach 2:
The automated monitoring and adjustment system continuously maintains optimal preload levels, preventing excessive wear by self-regulating the mechanical loads on components without requiring external intervention
Data Source
AI summary
In one embodiment, a method includes accessing a target value for a gear system, where the target value includes a target backlash or a target preload, and where the gear system includes a driving gear, a driven gear, a preloading actuator coupled to the driving gear, and a preloading actuator controller, determining a measured value for the gear system, where the measured value includes a measured backlash or a measured preload, determining that an error value between the measured value and the target value exceeds a threshold error, and sending, by the preloading actuator controller, instructions to the preloading actuator to adjust the driving gear in response to determining the error value between the measured value and the target value exceeds the threshold error.