Force-Guided Robotic Machining for Precise Workpiece Contours
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Solution Overview
Problem
Current industrial robots are limited in their ability to perform machining operations such as deburring due to poor accuracy, difficulty in localizing workpieces, and high process complexity, leading to low adoption and high costs in industries like aerospace and automotive, where manual deburring is prevalent and error-prone.
Innovation Solution
A system and method using an industrial robot controlled by a data processing subsystem, equipped with an imaging subsystem and a force sensor, adjusts the machining tool's path and speed based on real-time force readings and estimated tool wear to accurately machine workpiece contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If industrial robots are used for machining operations, then productivity and scalability are improved, but manufacturing precision and reliability deteriorate due to poor accuracy and difficulty in localizing workpieces
Solution Approach 1:
The system continuously measures contact forces between the machining tool and workpiece surface, using this feedback to dynamically adjust the tool path and maintain precise machining. The force sensor data is fed back to the control system which modifies the robot's motion in real-time to compensate for positioning errors and maintain manufacturing precision while preserving high productivity
Solution Approach 2:
The system changes the operational parameters of the robot by dynamically adjusting tool path coordinates and machining speeds based on real-time force measurements. This allows the robot to adapt its motion parameters to maintain precision during machining operations, resolving the contradiction between high-speed automated machining and manufacturing precision
2Extent of automation
If traditional robot deburring systems are implemented, then automation extent is improved, but device complexity increases due to high process complexity and difficulty in workpiece localization
Solution Approach 1:
The system enables the robot to automatically adapt to workpiece variations and localization challenges through self-adjustment based on force sensor feedback. The robot performs its own path correction and adaptation without requiring complex external positioning systems or manual intervention, thereby reducing overall device complexity while maintaining high automation extent
Solution Approach 2:
The system replaces complex mechanical positioning and localization systems with a sensor-based feedback control approach. Instead of using elaborate mechanical fixtures and precision positioning mechanisms, the system uses force sensing and software-based path adjustment to achieve accurate deburring, significantly reducing device complexity
3Manufacturing precision
If manual deburring is used, then manufacturing precision is maintained, but loss of time increases and productivity decreases
Solution Approach 1:
The system enables continuous automated machining operations without the interruptions and cycle times associated with manual deburring. The robot can continuously traverse the workpiece contour while force feedback ensures precision is maintained throughout the entire process, eliminating the time loss inherent in manual operations while preserving manufacturing precision
4Manufacturing precision
If force control is implemented for real-time path adjustment, then manufacturing precision is improved, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The force sensor serves multiple functions: it measures contact force for path adjustment, detects workpiece surface features, monitors tool wear, and provides feedback for speed modulation. This multi-functionality reduces the need for separate specialized components, thereby limiting the increase in device complexity while achieving improved manufacturing precision through force control
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
This approach enables faster cycle times, reduced costs, improved machining quality, and reduced tool wear by allowing for adaptive control and real-time registration and tool wear tracking, enhancing the efficiency and safety of robotic deburring processes.
Implementation Method 1
a force sensor provides force readings, the force readings being readings of the force exerted by the tool on the surface
Data Source
AI summary
Systems and methods relating to automated machining. A machining tool is controlled by an industrial robot that guides the tool around the contour of a workpiece. As the tool traverses the estimated contour of the workpiece, the tool machines the surface while a force sensor provides force readings, the force readings being readings of the force exerted by the tool on the surface. The path followed by the tool around the contour of the workpiece is adjusted based on the force readings. The speed at which the tool traverses the workpiece may be modulated and the path may be adjusted based on estimated tool wear.