Cobot Assembly Imaging for Human-Induced Workpiece Changes
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Solution Overview
Problem
In cobotic manufacturing settings, human-robot collaboration leads to quality non-conformance due to manual changes made by human operators, which are not recognized by robots, resulting in time-consuming and error-prone condition-of-assembly checks.
Innovation Solution
A robotic manufacturing system with a control unit, presence sensor, and imaging device that detects human presence, compares workpiece images with reference data, and updates the control plan and digital twin to reflect changes made by humans, ensuring accurate operation and quality conformance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual condition-of-assembly checks are performed by human operators, then quality conformance can be verified, but the process becomes time-consuming and subject to human error
Solution Approach 1:
The patent replaces manual visual inspection with an automated imaging system that captures images of the workpiece and uses image processing to automatically detect assembly conditions. This substitution eliminates human operators from the inspection process, thereby reducing inspection time while maintaining or improving reliability through consistent automated measurement and detection capabilities
Solution Approach 2:
The system creates digital copies (images) of the workpiece and its assembly state, then analyzes these copies to determine conformance. By working with image data rather than physical inspection, the system achieves rapid automated verification of assembly conditions without the time constraints of manual processes
2Productivity
If human operators work independently from robots in traditional automated assembly, then manufacturing efficiency is maintained, but the system cannot detect human-induced changes to the workpiece
Solution Approach 1:
The patent implements a feedback mechanism where the imaging system continuously monitors the workpiece and detects changes made by human operators. This feedback loop provides real-time information about workpiece state changes to the control system, enabling the robot to adapt its operations accordingly and preventing quality non-conformance while maintaining collaborative productivity
Solution Approach 2:
The imaging system serves as an intermediary between human operators and the robotic system. It captures and transmits information about human-induced changes to the workpiece, bridging the information gap that exists when humans and robots work independently, thereby enabling coordinated collaboration without sacrificing manufacturing efficiency
3Adaptability or versatility
If a cobot and human operator work together in a collaborative manner, then flexibility and adaptability improve, but quality non-conformance occurs when the cobot cannot recognize human alterations to the workpiece
Solution Approach 1:
The imaging system provides continuous feedback to the cobot about the actual state of the workpiece, including any changes made by human operators. This feedback enables the cobot to recognize and adapt to human-induced modifications, maintaining quality conformance while preserving the collaborative flexibility that allows humans and cobots to work together on complex assembly tasks
Solution Approach 2:
The system dynamically adjusts the cobot's operation based on real-time image analysis of the workpiece state. When human operators modify the workpiece, the system detects these changes and updates the control plan accordingly, allowing the cobot to adapt its behavior dynamically rather than following a fixed program, thereby maintaining both collaborative flexibility and quality reliability
Data Source
AI summary
A robotic manufacturing system and method include a robot including a control unit in communication with an operative member. The control unit is configured to operate the operative member in relation to a workpiece within a working area according to a control plan. A presence sensor is configured to detect presence of a human within the working area. An imaging device is configured to acquire an image of at least a portion of the workpiece in response to the presence sensor detecting the presence of the human within the working area.