Robot Connector Insertion with Offset Alignment and Force Feedback
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Solution Overview
Problem
Existing connector insertion methods lack a planned approach, leading to potential difficulties in smooth insertion, increased time, and risk of damage to connectors during the process.
Innovation Solution
A method involving a robot system that includes gripping, axis shifting, first insertion with axis alignment, and second insertion along the central axis to ensure precise and smooth insertion and pull-out of connectors, utilizing a six-axis vertically articulated robot with a force sensor and imaging device for accurate positioning and force detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robot directly inserts a connector along its central axis without preliminary alignment, then the insertion process is simple, but the insertion may fail, take longer, or cause damage to the connectors
Solution Approach 1:
The insertion process is divided into three distinct phases: (1) approaching with offset between central axes, (2) aligning the central axes, and (3) final insertion along the aligned axis. This segmentation allows each phase to be optimized independently, improving overall reliability without excessive complexity.
Solution Approach 2:
The robot performs preliminary actions before the main insertion: first approaching the connector with an offset position, then aligning the axes, and only then executing the final insertion. These preliminary actions prepare the system for successful insertion, preventing failures and damage.
2Productivity
If a robot performs preliminary alignment before connector insertion, then the insertion becomes smoother and faster, but the overall process time increases due to additional steps
Solution Approach 1:
The robot moves quickly through the alignment phase by maintaining a constant offset distance and using efficient motion paths. The transition from offset positioning to axis alignment is optimized to minimize the time spent in the intermediate state, rushing through the necessary adjustments without unnecessary delays.
Solution Approach 2:
The robot dynamically adjusts its motion parameters during the insertion process, transitioning from offset movement to aligned insertion. The system optimizes speed and position in real-time, allowing faster completion of the alignment phase while maintaining precision.
3Object-affected harmful factors
If a robot inserts connectors without force detection, then the system is simpler, but the risk of applying excessive force and damaging connectors increases
Solution Approach 1:
The robot uses a force sensor to detect resistance during the insertion process. When the sensor detects that the connectors are properly engaged or when excessive resistance is encountered, the system automatically adjusts or stops the insertion force. This feedback mechanism prevents damage while maintaining system simplicity through automated control.
Solution Approach 2:
The force sensor enables the system to self-regulate the insertion process. The robot monitors its own insertion force in real-time and automatically adjusts to prevent damage, making the system self-protecting without requiring external intervention or complex additional components.
Data Source
AI summary
A connector insertion method for inserting a first connector into a second connector by using a robot includes a gripping step of gripping the first connector by the robot, a first insertion step of inserting the distal end section of the first connector into the second connector in a state where the central axis of the first connector is shifted with respect to the central axis of the second connector, an axis alignment step of aligning the central axis of the first connector with the central axis of the second connector by displacing the first connector, and a second insertion step of advancing the first connector in a direction along the central axis of the first connector and inserting the first connector into the second connector.