Fixtureless Robotic Assembly With Metrology-Based Position Correction
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Solution Overview
Problem
Existing assembly processes for transport structures, such as vehicles and aircraft, face challenges in accurately positioning robotic arms to achieve precise connection of nodes with other components, especially when using additively manufactured parts, which can lead to inaccuracies and tolerance issues.
Innovation Solution
A method and system that utilize a control unit to calculate and measure the precise location of robotic arms, determining a transformation matrix to reposition them accurately, allowing for high-precision assembly operations without the need for fixtures, by using metrology guidance and computer-generated instructions to align subcomponents correctly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional assembly processes are used with fixtures, then positioning stability is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent removes traditional fixtures from the assembly system and replaces them with a robotic positioning system that uses measurement data and transformation matrices to achieve precise positioning without physical support structures
Solution Approach 2:
The patent replaces the mechanical fixture system with a computational approach using metrology measurements, coordinate transformation matrices, and robotic control algorithms to achieve positioning accuracy
2Productivity
If robotic arms are used for assembly operations, then productivity is improved, but positioning precision deteriorates due to tolerance accumulation
Solution Approach 1:
The patent implements a feedback loop where metrology systems measure the actual positions of robotic components, transformation matrices are calculated based on these measurements, and the robotic system adjusts its positioning accordingly to achieve target accuracy
Solution Approach 2:
The patent performs preliminary measurements and calculations of transformation matrices before the actual assembly operation, allowing the robotic system to pre-compensate for positioning errors and achieve accurate placement
3Adaptability or versatility
If additively manufactured nodes are used, then manufacturing flexibility is improved, but dimensional accuracy deteriorates
Solution Approach 1:
The patent performs preliminary measurements of additively manufactured nodes using metrology systems and calculates transformation matrices before assembly, allowing the system to compensate for dimensional variations inherent in additive manufacturing
Solution Approach 2:
The patent changes the reference frame parameters through transformation matrices to account for dimensional variations in additively manufactured nodes, allowing accurate positioning despite manufacturing tolerances
Data Source
AI summary
An approach to positioning one or more robotic arms in an assembly system may be described herein. For example, a system for robotic assembly may include a first robot, a second robot, and a control unit. The control unit may be configured to receive a first target location proximal to a second target location. The locations may indicate where the robots are to position the features. The control unit may be configured to calculate a first calculated location of the first feature of the first subcomponent, measure a first measured location of the first feature of the first subcomponent, determine a first transformation matrix between the first calculated location and the first measured location, reposition the first feature of the first subcomponent to the first target location using the first robot, the repositioning based on the first transformation matrix.