Compliant Actuator Force Control for Robotic Paint Repair
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Solution Overview
Problem
Automating defect-specific repairs for paint applications in the automotive industry is challenging due to the force-dependent nature of material removal and polishing processes, which traditional robotic systems struggle to precisely control.
Innovation Solution
A six-axis force/torque system with pneumatic-based control is developed, incorporating three linear pneumatic or electro-mechanical actuators that provide multiple degrees of freedom for precise force control, allowing for simultaneous abrading of multiple surfaces and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional robotic systems are used for paint repair, then automation is achieved, but force control precision deteriorates due to inherent system stiffness
Solution Approach 1:
A compliant actuator is introduced as an intermediary device between the robotic manipulator and the abrading tool. This compliant actuator with multiple degrees of freedom serves as a mediator that decouples the high-position-precision requirement from the force control requirement, allowing the robot to maintain positioning accuracy while the compliant actuator provides precise force control through its softer mechanical properties
Solution Approach 2:
The system changes the mechanical impedance parameters by introducing a compliant actuator with controlled stiffness characteristics. The compliant actuator's mechanical properties are tuned to provide the right balance between force control precision and compliance, transforming the overall system's force-displacement characteristics to achieve better force control while maintaining automation
2Manufacturing precision
If compliant actuators are added to robotic systems, then force control precision improves, but device complexity increases
Solution Approach 1:
The compliant actuator is designed with multiple degrees of freedom that can simultaneously control forces in multiple directions and accommodate various tool orientations. This multi-functional design allows a single device to handle complex force control requirements across different axes, reducing the need for multiple separate compliance mechanisms and thereby limiting the increase in overall system complexity
3Device complexity
If single axis force control is used, then device complexity is reduced, but adaptability deteriorates for complex geometries
Solution Approach 1:
The compliant actuator extends force control from single-axis to multi-axis by incorporating multiple degrees of freedom. This dimensional expansion allows the system to control forces not only in the normal direction but also in tangential directions, enabling adaptation to complex geometries and multiple surfaces while maintaining a integrated device structure
Data Source
AI summary
A robotic device that can include an end effector configured to manipulate one or more tools that drives one or more consumable abrasive products to abrade a substrate along several different surface dimensions, wherein the end effector comprises: three linear actuators each configured to move orthogonal relative to one another and at least one tool mount coupled to one of the three linear actuators and coupled to the tool.