Robot Arm Fabric Burrs Detection Force Sensor
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Solution Overview
Problem
Current methods for detecting burrs on vehicle components, especially aerodynamic surfaces, are inefficient and unable to accurately identify small burrs that can disrupt airflow, leading to suboptimal vehicle performance.
Innovation Solution
A burr detection system utilizing a robot arm with a test fabric holder and force sensor to detect changes in force required to move a test fabric over a surface, where the presence of a burr is indicated by a threshold increase in force, and a secondary sensor confirms the burr's presence through scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional detection methods are used, then the detection process is simple, but the detection precision is insufficient for small burrs
Solution Approach 1:
A test fabric is introduced as an intermediary element between the detection system and the component surface. The fabric's fibers interact with burrs through friction and mechanical contact, converting small surface defects into measurable force variations that the force sensor can detect, thereby enhancing detection precision without requiring complex optical or electronic systems
Solution Approach 2:
The patent replaces traditional optical or electronic detection systems with a mechanical detection approach using a force sensor and test fabric. This mechanical system directly measures the frictional forces generated when fabric fibers contact burrs, providing simple yet effective detection of small surface defects
2Productivity
If manual inspection is used, then the equipment cost is low, but the productivity is low and small burrs cannot be accurately identified
Solution Approach 1:
The test fabric serves a dual function: it both detects burrs through force measurements and provides visual confirmation through fiber displacement or snagging. This self-documenting capability eliminates the need for separate verification systems, maintaining simplicity while enabling automated high-speed inspection
Solution Approach 2:
The system changes the detection parameter from visual inspection to mechanical force measurement. By measuring frictional forces and their variations as the fabric moves across the surface, the system can rapidly detect small burrs that are invisible to the human eye, significantly improving detection speed and accuracy
3Measurement precision
If visual inspection is used, then the equipment is simple, but the detection precision for small burrs is insufficient
Solution Approach 1:
The test fabric acts as a mediator that amplifies the effect of small burrs. When fabric fibers encounter even minute surface protrusions, the friction and mechanical interaction generate detectable force signals, making invisible defects visible to the detection system without requiring complex imaging equipment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate and efficient detection of burrs on large vehicle components, improving aerodynamic performance by identifying even small burrs that may not be visible to the human eye, thus enhancing operational efficiency.
Implementation Method 1
detect changes in force required to move a test fabric over a surface
Data Source
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AI summary
Various techniques are provided for a burr detection system. In a certain example, a burr detection system can include a test piece holder configured to hold a test piece, a robot arm, a test fabric holder disposed on a first end of the robot arm and configured to hold a test fabric, a force sensor coupled to the robot arm and configured to output force data associated with a force required to move the test fabric when the test fabric is contacting the surface of the test piece, and a controller configured to receive the force data and determine based on the force data a possible presence of a burr within an area of the test piece force data. In certain other examples, related methods for detecting burrs are also provided.