Automotive Door Robot Insertion Detection Without Optical Sensors
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Solution Overview
Problem
Existing door opening and closing robots in automotive painting lines face reliability issues due to increased sensor complexity and risk of sensor deterioration from paint mist, leading to inefficient door operation.
Innovation Solution
A door opening and closing robot with a robotic arm and control device that uses a door operating tool with an insertion portion and restricting portion, employing servomotors and position sensors to detect proper insertion into the window groove without relying on noncontact-type sensors, thereby reducing sensor count and avoiding paint mist interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If noncontact-type sensors (optical sensors) are used to detect door position, then detection capability is provided, but sensor performance deteriorates due to paint mist adhesion in explosion-proof zones
Solution Approach 1:
The patent removes noncontact-type optical sensors from the system entirely. Instead, it uses only contact-type sensors (proximity sensors, force sensors) that are not affected by paint mist, thereby eliminating the reliability problem while maintaining door position detection capability through alternative sensing methods.
Solution Approach 2:
The patent employs contact-type sensors that can be easily replaced or maintained if needed, rather than using expensive optical sensors that deteriorate due to paint mist. The focus shifts to robust, maintainable components suitable for explosion-proof zone conditions.
2Measurement precision
If three force sensors are mounted on the robotic arm to detect deflection and position the grip finger, then positioning accuracy is improved, but the number of sensors and components increases
Solution Approach 1:
The patent makes the door operating tool multi-functional by integrating both insertion portion (for window groove engagement) and grip finger (for door edge holding) functions into a single tool. This eliminates the need for separate force sensors on the robotic arm, as the tool itself performs multiple positioning and gripping functions.
Solution Approach 2:
The patent combines the functions of insertion portion and grip finger into a single door operating tool, and uses a single proximity sensor to detect both insertion and gripping states. This merging reduces the number of sensors from three force sensors to one proximity sensor while maintaining positioning accuracy.
3Adaptability or versatility
If a door opening and closing robot is installed next to the painting robot to perform door operations, then door opening and closing functionality is provided, but the system complexity and sensor requirements increase
Solution Approach 1:
The painting robot is given dual functionality by equipping it with both painting apparatus and door operating tool. The same robotic arm that performs painting operations also performs door opening and closing operations, eliminating the need for a separate door operating robot and reducing overall system complexity.
Solution Approach 2:
The patent merges the painting robot and door operating robot into a single integrated system. The painting robot's robotic arm can switch between holding the painting apparatus and holding the door operating tool, consolidating two functions into one device and reducing the total number of sensors and components required.
Data Source
AI summary
A door opening and closing robot includes: a door operating tool including an insertion and restricting portion; a robotic arm that moves the door operating tool; and a control device that: operates the robotic arm, wherein the door operating tool moves to a first reference position, then moves toward a first presence confirmation position; obtains a position of the door operating tool as a first evaluation position; and determines a deviation between the first presence confirmation position and the first evaluation position, when the deviation is less than or equal to a predetermined first threshold, detects failed presence of the insertion portion in a window groove. The first reference position is the operating tool which is inserted in the window groove and the restricting portion is in contact with an edge of the window groove or positioned above the edge of the window groove.