Coordinated Robot Assembly Without Dedicated Locating Fixtures
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Solution Overview
Problem
Current manufacturing systems require multiple part locating fixtures for various part sizes and shapes, which are inflexible and inefficient, as they need to be modified or rebuilt for different components, leading to a need for a more adaptable and efficient assembly method.
Innovation Solution
A fixtureless component assembly system where robots communicate to determine the relative position of components, using a camera to locate datum features, calculate offsets, and create a coordinate frame for precise positioning and assembly without the need for dedicated fixtures, allowing for flexible assembly of different components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If part locating fixtures with fixed pins and clamps are used, then parts can be accurately located and held in place, but the system requires multiple fixtures for different part sizes and shapes, increasing device complexity
Solution Approach 1:
The patent implements a universal fixtureless assembly system where robots with vision systems can locate and assemble any part size or shape by detecting datum features and calculating coordinate transformations. The system replaces multiple dedicated fixtures with a single multi-functional robotic system that adapts to different components through software-based coordinate frame registration rather than physical reconfiguration.
Solution Approach 2:
The patent replaces the mechanical fixture system (pins and clamps) with a vision-based measurement and control system. Cameras capture images of datum features, controllers calculate coordinate transformations, and robots position components accordingly. This substitution eliminates the need for physical locating fixtures while maintaining positioning accuracy through computational methods.
2Adaptability or versatility
If multiple part locating fixtures are used for various parts, then different part sizes and shapes can be accommodated, but the system requires modification or rebuilding of fixtures, reducing ease of operation
Solution Approach 1:
The patent implements a dynamic, adaptive system where the coordinate frame registration process automatically adjusts to different part geometries. The vision system detects datum features in real-time, and the controller dynamically calculates the appropriate coordinate transformations. This eliminates the static, pre-configured nature of traditional fixtures and enables on-the-fly adaptation to any part configuration without physical modification.
Solution Approach 2:
The patent changes the system from fixed physical parameters (fixture dimensions and configurations) to variable computational parameters (coordinate frame transformations). By storing multiple coordinate frame definitions in memory and selecting/applying the appropriate transformation based on the specific part being assembled, the system achieves versatility without requiring physical reconfiguration or rebuilding of hardware fixtures.
3Adaptability or versatility
If fixtureless assembly with robot-to-robot communication is used, then the system becomes more adaptable to different components, but the measurement and positioning complexity increases
Solution Approach 1:
The patent merges the measurement, calculation, and control functions into an integrated system. The camera mounted on one robot serves as the measurement device for both robots, and the coordinate frame registration process combines data from both controllers to achieve synchronized positioning. This consolidation reduces overall system complexity compared to having separate measurement and control systems for each robot.
Solution Approach 2:
The patent introduces coordinate frame registration as an intermediary process that mediates between the two robots. Rather than requiring direct complex communication protocols between robots, the system uses the registered coordinate frames as an intermediary reference system. Each robot positions itself relative to the registered coordinate frame, simplifying the control architecture while maintaining precise relative positioning.
Data Source
AI summary
A method of assembling a secondary component to a primary component comprises grasping a primary component with a first end-of-arm tool, wherein the first end-of-arm tool is attached to a first robot arm and grasping a secondary component with a second end-of-arm tool, wherein the second end-of-arm tool is attached to a second robot arm. Moving the primary component to an interfacing position, wherein interfacing surfaces on the primary component are presented at a proper position and orientation for the secondary component to be attached thereto. Moving the second end-of-arm tool to bring the secondary component into engagement with the interface surfaces of the primary component, and forming a joint between the primary component and the secondary component with a joining tool attached to a joining robot arm.