Robot Dispense Head Alignment Using Force Feedback
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Solution Overview
Problem
Existing dispensing systems require significant manual personnel effort and pose safety risks due to hazardous chemicals, and automated systems face jamming issues due to manufacturing tolerances causing misalignment between the dispense head and container openings.
Innovation Solution
A dispensing system with force sensors on a robot arm that detects misalignment forces and performs compensation movements to align the dispense head optimally with the container opening and dip tube, minimizing forces for a reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual attachment and release of dispense head is used, then ease of operation is maintained, but personnel outlay increases and safety risks arise
Solution Approach 1:
The system uses force sensors to detect misalignment automatically and triggers compensation movements without human intervention, making the system self-correcting and eliminating the need for manual adjustment during the connection process
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robot arm controlled by force sensor feedback, substituting human labor with an automated electromechanical system that can operate continuously without fatigue or safety risks
2Ease of operation
If vertical approach direction is used for dispense head, then ease of operation is maintained, but manufacturing tolerances cause jamming
Solution Approach 1:
The robot arm dynamically adjusts its approach angle based on real-time force sensor feedback, transitioning from a fixed vertical approach to a variable approach that compensates for manufacturing tolerances and prevents jamming
Solution Approach 2:
Force sensors provide real-time feedback during the approach and connection process, allowing the control system to detect misalignment forces and automatically adjust the robot arm's movement to compensate for manufacturing tolerances
3Productivity
If automated connection is implemented, then productivity increases, but misalignment due to manufacturing tolerances causes jamming
Solution Approach 1:
Force sensors provide real-time feedback during the approach and connection process, allowing the control system to detect misalignment forces and automatically adjust the robot arm's movement to compensate for manufacturing tolerances
Solution Approach 2:
The system changes the approach parameters (angle, position, speed) dynamically based on force sensor readings, adapting the connection process to accommodate variations in container opening geometry caused by manufacturing tolerances
Data Source
AI summary
A method for operating a dispensing system (1) with at least one container (2) having a container opening (6), and a dispense head (4) mounted on a robot arm (11) of a robot (10). The dispense head (4) is automatically connected to the container opening (6) of the container by means of the robot (10), such that liquid (3) can be removed from the container (2) or liquid (3) can be supplied to the container (2). When the dispense head (4) is inserted into the container opening (6), forces acting on the dispense head (4) are detected by means of an arrangement of force sensors (14). The robot arm (11) carries out compensation movements dependent upon the detected forces, whereby the dispense head (4) is aligned to the container opening (6).