Cobotic Assembly Imaging for Human-Induced Change Detection
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Solution Overview
Problem
In cobotic manufacturing processes where humans and robots collaborate, manual condition-of-assembly checks are time-consuming and prone to human error, leading to quality non-conformance due to evolving work environments and structures.
Innovation Solution
A robotic manufacturing system equipped with a presence sensor and imaging device that detects human presence, acquires images of the workpiece, and compares them to reference data to ensure conformity, updating the control plan and digital twin to reflect human-induced changes.
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 prone to human error
Solution Approach 1:
The patent replaces manual visual inspection with an automated imaging system that captures images of the workpiece and compares them against reference data. The control unit automatically detects deviations and updates the digital twin, eliminating the need for human operators to manually walk around and compare assembly status against engineering drawings.
Solution Approach 2:
The system creates and maintains a digital twin (virtual copy) of the workpiece that is continuously updated based on imaging data. This digital replica allows for automatic comparison between the actual workpiece state and the expected state, enabling rapid quality verification without manual intervention.
2Adaptability or versatility
If human operators work together with robots in a cobotic process, then manufacturing flexibility and adaptability improve, but quality non-conformance increases due to evolving work environments
Solution Approach 1:
The system continuously monitors the workpiece using imaging devices and provides feedback to the control unit. When deviations are detected, the control unit updates the digital twin and can adjust the robot's control plan in real-time, ensuring that the robotic operations adapt to the actual workpiece state while maintaining quality standards.
Solution Approach 2:
The digital twin and control plan are not static but dynamically updated based on real-time imaging data. This allows the system to adapt to changes in the workpiece state caused by human operators or environmental factors, maintaining reliability in a flexible cobotic environment.
3Manufacturing precision
If the robot operates autonomously according to a fixed control plan, then manufacturing precision is maintained, but the system cannot adapt to human-induced changes in the workpiece
Solution Approach 1:
The system performs self-verification by automatically comparing imaging data against the digital twin and control plan. When deviations are detected, the system self-corrects by updating the digital twin and adjusting the control plan, enabling autonomous adaptation without human intervention while maintaining precision.
4Measurement precision
If continuous imaging is performed to monitor workpiece changes, then quality detection capability improves, but system complexity and processing load increase
Solution Approach 1:
Instead of continuous imaging, the system performs periodic imaging at key stages of the manufacturing process or when triggered by specific events (such as human presence detection). This reduces the imaging and processing load while maintaining adequate quality monitoring capability.
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
Ensures quality conformance by pausing operations when human intervention occurs, updating the control plan to account for changes, thereby reducing errors and improving manufacturing efficiency.
Implementation Method 1
A presence sensor is configured to detect presence of a human within the working area
Implementation Method 2
An imaging device is configured to acquire an image of at least a portion of the workpiece
Data Source
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AI summary
A robotic manufacturing system (100) and method include a robot (102) including a control unit (108) in communication with an operative member (110). The control unit (108) is configured to operate the operative member (110) in relation to a workpiece (104) within a working area (106) according to a control plan (114). A presence sensor (118) is configured to detect presence of a human within the working area (106). An imaging device (120) is configured to acquire an image (122) of at least a portion of the workpiece (104) in response to the presence sensor (118) detecting the presence of the human within the working area (106).