Compliant Multi-Axis Manipulator for 3D Tape Application
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Solution Overview
Problem
Existing tape application systems are limited to 2-dimensional applications on flat surfaces and struggle with applying tapes to workpieces with complex, 3D contours and shapes, lacking the precision and flexibility needed for spatial processing.
Innovation Solution
A multi-axis manipulator with compliant axes that can yield to forces, allowing for precise, spatial application of media like tapes to workpieces with complex shapes, enabling 3D processing and deformation of the media during application, and can be used manually or with a robot, ensuring constant application force and path accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a heavy media supply is integrated into the robotic application tool, then the application system can handle complex 3D contours, but the robot's positioning precision and speed are reduced due to the increased weight
Solution Approach 1:
The system is divided into two independent parts: a stationary media supply and a mobile application tool mounted on the robot. This segmentation allows the heavy media supply to remain fixed while only the lightweight application tool is moved by the robot, resolving the contradiction between handling capability and positioning precision
Solution Approach 2:
A flexible connection (such as a hose or cable) serves as an intermediary between the stationary media supply and the mobile application tool, enabling the transfer of media while allowing independent movement of the application tool without being constrained by the weight of the media supply
2Ease of operation
If the application tool is made lightweight for manual operation, then ease of operation improves, but the tool cannot provide sufficient pressing force for complex shapes
Solution Approach 1:
A flexible hose or cable acts as an intermediary to transmit driving force from the stationary media supply to the lightweight application tool, enabling the tool to maintain low weight for manual operation while still receiving sufficient pressing force through the flexible connection
Solution Approach 2:
The heavy mechanical pressing system is replaced with a lightweight application tool that receives force through a flexible connection, substituting direct mechanical coupling with a more flexible force transmission mechanism that preserves both lightness and force capability
3Measurement precision
If a rigid application tool is used for precise positioning, then positioning accuracy improves, but the tool cannot adapt to varying workpiece contours and tolerances
Solution Approach 1:
The application tool is designed with flexible degrees of freedom that allow it to dynamically adapt its position and orientation to match varying workpiece contours, while the robot provides precise positioning control, combining rigidity for positioning with flexibility for adaptation
4Adaptability or versatility
If the application tool includes all functions for media supply and application, then functionality is complete, but the device complexity and weight increase
Solution Approach 1:
The complete application system is segmented into two parts: media supply functions are located in the stationary unit while application functions are in the mobile tool, reducing the complexity and weight of the robot-mounted tool while maintaining full functionality across the entire system
Solution Approach 2:
The heavy media supply function is extracted from the mobile application tool and placed in a stationary unit, leaving only the essential application functions in the lightweight tool, thereby reducing tool complexity while preserving complete system functionality
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
Enables high-precision, three-dimensional tape application on workpieces with complex shapes, accommodating tolerances and errors, and allows for manual or automated operation, improving teachability and reducing the weight and complexity of the application tool.
Implementation Method 1
The flexible axis(s) has a compliance control with which the axis(s) and thus also the manipulator can yield to an acting force. In compliance control, pure force control or a combination of position and force control is used.
Implementation Method 2
Here, a spring-loaded pressure roller for the sealing tape is arranged in the tool, which only yields and does not have its own drive.
Data Source
AI summary
The invention relates to a device and method for the web-like machining of workpieces (3), in particular for applying a medium (2) to a workpiece (3), comprising a machining tool (15) and a media supply unit (16). The machining tool (15) is guided relative to the workpiece (3) by a multi-axis manipulator (13) having one or more driven flexible axes (n) (I-VII).