Collaborative Robotic Fastening System with Force Sensing
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Solution Overview
Problem
Current robotic systems for fastening in production, whether manual or fully automated, face challenges such as cross-threading errors, operator fatigue, and limited applicability due to their complexity, cost, and application-specific configurations, which hinder efficiency and flexibility in fastening various devices and components.
Innovation Solution
A robotic system comprising a support structure, movable platform, center serial chain, outer serial chains, motors, sensors, and a control module that provides six degrees-of-freedom motion, allowing for collaborative operation with human operators to assist in fastening tasks, reducing operator fatigue and increasing flexibility across different applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fully automated robotic system is used for fastening operations, then productivity and fastening accuracy are improved, but device complexity and cost increase significantly
Solution Approach 1:
The robotic system is designed with a universal platform that can perform multiple fastening operations across different applications and devices. The system includes interchangeable fastening tools and adjustable end effectors that can accommodate various fastener types (screws, bolts, nuts) and configurations, allowing one system to replace multiple application-specific systems.
Solution Approach 2:
The system employs dynamic control capabilities with sensors that detect real-time conditions during fastening operations. The control system adjusts parameters such as torque, speed, and positioning dynamically based on feedback from force sensors, torque sensors, and vision systems, enabling adaptive operation that maintains high accuracy without requiring overly complex mechanical structures.
2Manufacturing precision
If a fully automated robotic system is configured for a particular application, then fastening accuracy is improved, but adaptability to other devices and components deteriorates
Solution Approach 1:
The robotic system incorporates a library of interchangeable end effectors and fastening tools that can be quickly swapped depending on the application. The system includes universal mounting interfaces and programmable control that allow the same base system to perform precise fastening operations on different devices, components, and fastener types without requiring complete system reconfiguration.
Solution Approach 2:
The system maintains high fastening accuracy across different applications by dynamically adjusting operational parameters such as torque specifications, screw feed rates, positioning coordinates, and clamping forces based on the specific fastening task. The control system stores parameter sets for different fastener types and automatically selects appropriate parameters, enabling precision across diverse applications without sacrificing versatility.
3Adaptability or versatility
If manual fastening operations are performed, then adaptability and system cost are improved, but operator fatigue and error rate increase
Solution Approach 1:
The robotic system incorporates multiple sensors including force sensors, torque sensors, and vision systems that provide real-time feedback during fastening operations. This feedback enables the system to detect and correct potential errors such as cross-threading, improper torque application, or misalignment, significantly reducing the error rate compared to manual operations while maintaining the flexibility to handle various fastening scenarios.
4Adaptability or versatility
If an operator performs continuous manual fastening operations, then adaptability is maintained, but operator fatigue increases due to the strength required to hold the tightening gun
Solution Approach 1:
The robotic system performs fastening operations autonomously without requiring human physical strength to hold or operate the tightening tool. The automated end effector holds and actuates fastening tools, eliminating the physical burden on operators. This allows the system to operate continuously for extended durations without fatigue, while the programmable control maintains the adaptability to handle different fastening requirements.
Data Source
AI summary
A robotic system includes a support structure, a platform, a center serial chain, outer serial chains, motors, a sensor, and a control module. The center serial chain connects a center of the platform to the support structure and includes first joints connected to a linear sliding shaft. The outer serial chains are disposed radially outward of the center serial chain. Each of the outer serial chains includes second joints connecting a bar to the platform and the supporting structure. The motors are connected to the outer serial chains. The sensor is connected to the platform and detects at least one of force or torque applied by a human operator on the platform and generates a signal indicative thereof. The control module controls the motors based on the signal to assist the human operator in at least one of moving or rotating the platform.