Autonomous Robot Arm Control Beyond Fixed-Rail Manufacturing
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Solution Overview
Problem
Current manufacturing processes using rail-mounted robot arms are inflexible and costly due to the need for significant infrastructure planning and limited adaptability when altering manufacturing lines, as they require new machines to fit within existing rail systems.
Innovation Solution
A system comprising a self-driving vehicle and a robot arm that autonomously navigates to different process locations using a stored map and sensors, allowing for flexible movement and tool changes without the need for fixed rail infrastructure, with safety sensors to detect and avoid obstacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a robot arm is mounted on a fixed rail, then the robot arm can be moved to and from process steps, but the manufacturing process becomes inflexible and costly with limited adaptability
Solution Approach 1:
The patent replaces the static fixed-rail system with a dynamic autonomous mobile robot (AMR) that can independently navigate to different process locations. The AMR uses onboard sensors, processors, and navigation algorithms to dynamically adjust its path and position, enabling flexible reconfiguration of manufacturing processes without physical infrastructure changes.
Solution Approach 2:
The patent substitutes the mechanical fixed-rail guidance system with an intelligent navigation system based on sensors (laser scanners, cameras, ultrasonic sensors), processors, and software algorithms. This replaces rigid mechanical constraints with flexible electronic control, allowing the robot arm to move freely throughout the workspace while maintaining precise positioning.
2Ease of operation
If a fixed rail infrastructure is installed, then robot arm movement is enabled, but significant infrastructure planning and cost are required
Solution Approach 1:
The patent extracts the guidance function from the fixed environmental infrastructure and relocates it to the mobile robot itself. The AMR carries its own navigation system, sensors, and processing capabilities, eliminating the need for external rails, guideways, or fixed infrastructure. This portability dramatically reduces installation complexity and cost.
Solution Approach 2:
The autonomous mobile robot is self-sufficient with onboard navigation capabilities including laser scanners, cameras, ultrasonic sensors, and processing units that enable it to independently determine its position, plan paths, and navigate to targets without external infrastructure support. This self-contained approach eliminates dependency on complex installed systems.
3Productivity
If new machines are added to a manufacturing line with fixed rail, then production capacity increases, but the new machines must fit within existing rail constraints
Solution Approach 1:
The autonomous mobile robot provides dynamic reconfigurability, allowing manufacturing processes to be easily modified by simply updating software parameters, waypoints, or task sequences. Physical reconfiguration is unnecessary when adding or relocating machines, as the AMR can adapt its navigation and operations through software changes alone, enabling rapid scaling and flexibility.
Data Source
AI summary
Systems and methods for process tending with a robot arm are presented. The system comprises a robot arm and robot arm control system mounted on a self-driving vehicle, and a server in communication with the vehicle and/or robot arm control system. The vehicle has a vehicle control system for storing a map and receiving a waypoint based on a process location provided by the server. The robot arm control system stores at programs that is executable by the robot arm. The vehicle control system autonomously navigates the vehicle to the waypoint based on the map, and the robot arm control system selects a target program from the stored programs based on the process location and/or a process identifier.