Drilling Robot Accuracy Checking With Jig-Guided Reference Marks
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Solution Overview
Problem
Existing methods for checking the accuracy of drilling robots are inefficient, requiring manual measurement of marks on components, which disrupts manufacturing and is cumbersome, especially for large aircraft components.
Innovation Solution
A method involving a tool jig to create calibrated marks on components, which are then compared to marks made by the robot, allowing for automated assessment of accuracy and reducing the need for manual intervention, enabling efficient calibration and subsequent drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual measurement methods are used to check robot accuracy, then measurement can be performed, but the process is inefficient and requires operator access to the component
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated vision system that uses imaging devices to capture and analyze component images. The vision system automatically detects mark positions and calculates accuracy, eliminating the need for operator access and manual measurement tools.
Solution Approach 2:
The system enables self-service accuracy checking where the robot and vision system work together autonomously. The robot creates marks, the vision system captures images, and the system automatically processes the data to determine accuracy, all without requiring operator intervention during the checking process.
2Reliability
If the robot accuracy is checked on each component, then accuracy can be confirmed, but manufacturing efficiency is reduced due to frequent interruptions
Solution Approach 1:
The patent implements preliminary accuracy checking by creating reference marks on the component before the robot begins drilling operations. The vision system captures images and verifies accuracy at predetermined check points during the drilling process, allowing early detection of accuracy issues without requiring complete rework.
Solution Approach 2:
The system provides continuous feedback during the drilling process by periodically checking mark positions against the drilling program. When accuracy deviations are detected, the system provides feedback to stop the robot and alert operators, preventing further incorrect drilling while maintaining overall manufacturing efficiency.
3Extent of automation
If automated vision system is implemented, then accuracy checking can be automated, but device complexity increases
Solution Approach 1:
The vision system is designed to perform multiple functions: capturing component images, detecting mark positions, calculating accuracy deviations, and providing feedback control. This multi-functionality consolidates what would otherwise require separate systems into a single integrated unit, reducing overall system complexity.
Solution Approach 2:
The patent introduces an image processing algorithm as an intermediary between the vision system and the accuracy determination. This software intermediary automatically extracts mark positions from captured images and compares them with programmed positions, simplifying the integration between hardware and control systems while enabling automated accuracy assessment.
Data Source
AI summary
A method of checking the accuracy of a robot is disclosed providing a component; fitting a tool jig to the component; using the tool jig to guide a stamp tool against the component to create a first mark on the component representative of a calibrated drilling location; removing the tool jig; providing a robot, the robot including an end effector holding a marking tool; operating the robot according to a program to manoeuvre the marking tool against the component to create a second mark representative of a robot drilling location; and comparing the position of the first mark to the position of the second mark to measure a distance between the first mark and the second mark.