Folding Robot Force Sensing via a Central Measuring Connection
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Solution Overview
Problem
Existing folding robots require multiple sensors for each folding roller, leading to increased wiring and calibration efforts, especially when rollers are replaced, and are difficult to retrofit without powerful and expensive real-time processing units.
Innovation Solution
A folding robot design where the connecting element between the connection and head elements serves as a measuring body with integrated sensor elements, allowing force measurement independent of roller configuration, and a processing unit adjusts the folding force to match a target profile, reducing the need for individual sensors per roller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is assigned to each folding roller, then the folding force of each roller can be detected, but the wiring and calibration effort increases significantly, especially when rollers are replaced
Solution Approach 1:
Multiple sensor elements that would traditionally be assigned to individual folding rollers are merged into a single measuring body (connecting element). This single measuring body with integrated sensor elements detects the combined folding force from multiple rollers, eliminating the need for separate sensors per roller and significantly reducing wiring and calibration complexity.
Solution Approach 2:
The measuring body (connecting element) is designed to serve multiple functions: it structurally connects the robot arm to the head element while simultaneously serving as the measuring platform for all folding rollers. This universal component detects forces from any combination of rollers without requiring roller-specific sensors, enabling easy roller replacement without reconfiguration.
2Manufacturing precision
If real-time force adjustment is implemented, then the folding force can be precisely controlled, but a powerful and expensive processing unit is necessary
Solution Approach 1:
Instead of implementing complex real-time force control during the folding process, the system performs preliminary action by pre-calculating and storing optimal folding paths that inherently achieve the desired force profile. The robot executes these pre-planned paths, and force adjustments are made by selecting different pre-calculated paths rather than through real-time processing, avoiding the need for expensive powerful processing units.
3Reliability
If folding robots are equipped with force measurement systems, then quality assurance is improved, but existing folding robots without such systems are difficult to retrofit
Solution Approach 1:
The connecting element serves as an intermediary component that bridges existing robot arms and head elements while incorporating the measuring body with sensor elements. This intermediary design allows retrofitting of existing folding robots by simply replacing the connecting element, without requiring modifications to the robot arm or head element, thus enabling easy integration of force measurement capabilities into legacy systems.
4Adaptability or versatility
If the connecting element is designed as a measuring body with sensor elements, then force measurement is independent of roller configuration, but the connecting element structure becomes more complex
Solution Approach 1:
The measuring body (connecting element) is designed with adjustable parameters such as the number, position, and type of sensor elements that can be configured based on the specific roller arrangement. This parameter-based design allows the same connecting element structure to adapt to different roller configurations (e.g., different numbers of rollers, different positions) without requiring fundamentally different structural designs, thus achieving versatility while controlling complexity.
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 affordable, robust folding robots with precise force control, reducing wear and increasing service life by detecting and adjusting folding forces without real-time control, facilitating easy retrofitting and improved quality assurance.
Implementation Method 1
at least one sensor element, in particular by means of applied strain gauges, for detecting the folding force exerted on a folding flange during a folding process
Data Source
Figure 1~3
Figure 2
Figure 4a~4c
AI summary
The present invention relates to a folding robot that is designed to carry out a folding operation, with a folding head (1) comprising an attachment element (16), a connection element (11), a head element (13) and folding rollers (151, 152, 153), wherein the connection element (11) is arranged between the attachment element (16) and the head element (13), and the folding rollers (151, 152, 153) are arranged on the head element (13). A part of the connection element (11) is designed as a measuring body (111), wherein the measuring body (111) is designed with sensor elements (17) for detecting folding force (5) exerted during a folding operation by one of the folding rollers (151, 152, 153) on a fold flange. The invention also relates to a method for modernising a folding robot, in which an old connection element is exchanged for a new connection element (11) having a measuring body (111) and sensor elements (17). Finally, the invention relates to a method for operating a folding robot with a folding head (1), wherein a folding force exerted on a fold flange is determined by detecting the elastic deformation of the connection element (11).