Autonomous Robotic Sanding With Adaptive Force and Toolpath Control
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Solution Overview
Problem
Current automated finishing systems lack the ability to autonomously and accurately process parts with varying surface contours and materials, leading to inefficiencies and inconsistencies in surface finishing.
Innovation Solution
A robotic system equipped with an optical sensor and a sanding head that autonomously scans a part, generates a toolpath based on surface contours, and adjusts the sanding force in real-time to maintain a target force, ensuring precise and efficient processing of parts with diverse geometries and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated finishing systems use fixed toolpaths and constant force application, then the system structure remains simple, but the manufacturing precision and adaptability deteriorate when processing parts with varying surface contours and materials
Solution Approach 1:
The system dynamically adjusts the robotic manipulator's motion parameters and sanding head force in real-time based on sensor feedback. The controller continuously modifies toolpath execution and application force according to detected surface contours and material properties, transforming a static system into an adaptive one that maintains precision across varying part geometries
Solution Approach 2:
The system incorporates sensors that detect surface contours, material properties, and sanding head force, feeding this information back to the controller. The controller uses this feedback to adjust toolpaths and force parameters in real-time, creating a closed-loop control system that automatically compensates for variations in part geometry and material characteristics
2Manufacturing precision
If the system processes each part with high-resolution scanning and real-time adjustments, then manufacturing precision improves, but processing time and productivity worsen
Solution Approach 1:
The system applies real-time force adjustments and adaptive control only where needed based on detected surface variations and material properties. Rather than uniformly processing all areas with maximum detail, the system concentrates computational and mechanical resources on regions requiring precision adjustment, allowing faster processing of uniform areas while maintaining accuracy where complexity is needed
Solution Approach 2:
The system dynamically changes processing parameters such as sanding head force, toolpath speed, and scan resolution based on real-time detection of surface contours and material properties. By adjusting parameters adaptively rather than maintaining constant high-resolution processing throughout, the system achieves high precision where required while maintaining overall productivity
3Manufacturing precision
If the system uses high sanding force to ensure consistent material removal, then manufacturing precision improves, but the risk of damaging the part or tool increases
Solution Approach 1:
The system uses sensors to detect material removal rates, surface contours, and applied force in real-time, feeding this information back to the controller. The controller adjusts sanding force dynamically to maintain consistent material removal while preventing excessive force that could damage the part or tool, creating a self-regulating process
Solution Approach 2:
The system dynamically changes the sanding force parameter based on real-time detection of material properties, surface contours, and removal rates. By adjusting force levels adaptively rather than applying constant high force, the system achieves consistent material removal while reducing the risk of part damage or tool wear
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
The system achieves high-resolution surface processing with high repeatability and efficiency by combining low-resolution scanning with real-time force adjustments, enabling the processing of various part types and surface processes with improved accuracy and throughput.
Implementation Method 1
an optical sensor configured to: autonomously translate an optical sensor across a part arranged within the work zone; and capture a set of optical images
Implementation Method 2
move a sanding head along a toolpath; monitor a force value of the sanding head on the part
Data Source
AI summary
One variation of a method for autonomously scanning and processing a part includes: accessing a part model representing a part positioned in a work zone adjacent a robotic system; retrieving a sanding head translation speed; retrieving a toolpath for execution on the part defining positions, orientations, and target forces applied by the sanding head to the part. The method includes traversing the sanding head along the toolpath, at the sanding head translation speed; reading a sequence of applied forces from a force sensor coupled to the sanding head at positions along the toolpath; and deviating from the toolpath to maintain the set of applied forces within a threshold difference of a sequence of target forces along the toolpath. In one variation of the method, the robotic system executes a toolpath at a duration less than target duration by selectively varying target force and sanding head translation speed across the part.