Glass Ribbon Robot Force Feedback for Sheet Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional robot operational control in glass manufacturing processes is inadequate for handling the variability in glass ribbon-robot interfaces, leading to potential damage and defects in thinner glass sheets due to excessive forces and torques, especially at elevated glass ribbon flow rates.
Innovation Solution
A method and system that utilize a robot arm with a sensor to monitor and adjust the force and torque applied to the glass ribbon in real-time, allowing for precise control of the end effector's position and velocity to prevent excessive force application, employing a multiple-axis force sensor and a control system to adjust the robot's operation based on sensed parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional robot operational control is used based on expected glass ribbon location and flow rate, then the robot can perform predetermined tasks automatically, but excessive forces and torques are applied to the glass ribbon causing damage and defects
Solution Approach 1:
The patent implements a feedback control system using force sensors mounted on the robot arm to continuously monitor forces and torques applied to the glass ribbon. The control system processes sensor data in real-time and dynamically adjusts robot operational parameters (position, velocity, acceleration) to maintain forces within safe thresholds, resolving the contradiction between automated operation and force control
Solution Approach 2:
The patent transitions from static preprogrammed robot operations to dynamic adaptive control. The robot operational cycle is continuously modified based on real-time force sensor measurements, allowing the system to respond to actual glass ribbon conditions rather than following fixed predetermined paths, thereby preventing excessive force application while maintaining automation
2Ease of manufacture
If the robot applies sufficient force to separate the glass sheet from the glass ribbon, then the separation process is effective, but motion induced into the glass ribbon propagates upward causing stresses that become frozen in the solidifying glass
Solution Approach 1:
Force sensors provide real-time feedback on the forces applied during separation. The control system uses this feedback to precisely modulate the bending motion applied by the robot, ensuring sufficient force for clean separation while preventing excessive motion that would propagate stresses upward into the solidifying glass ribbon
Solution Approach 2:
The patent dynamically changes robot operational parameters (position, velocity, acceleration profiles) based on real-time force measurements during the separation process. This allows optimization of the separation force application to achieve clean breaks without inducing harmful stresses in the glass ribbon
3Productivity
If the robot operates at elevated glass ribbon flow rates to meet market demands for thinner glass sheets, then productivity increases, but the inherent variabilities in the glass ribbon-robot interface lead to deleterious interfaces
Solution Approach 1:
The feedback control system continuously monitors forces and torques during high-speed operations, allowing the robot to adapt to variabilities in the glass ribbon-robot interface in real-time. This maintains reliable operation even at elevated flow rates where traditional preprogrammed control would fail due to environmental variabilities
Solution Approach 2:
The system transitions from static preprogrammed control to dynamic adaptive control that responds to actual interface conditions. This enables reliable operation at higher productivity rates by continuously adjusting robot parameters based on real-time force sensor feedback, accommodating the increased variability associated with faster glass ribbon movement
Data Source
AI summary
A method for forming a glass sheet includes forming a glass ribbon. A robot arm is operated to move an end effector through a preprogrammed cycle. The cycle includes engaging a segment of the glass ribbon with the end effector, separating the engaged segment from the glass ribbon to generate a glass sheet, and moving the glass sheet away from the glass ribbon. The preprogrammed cycle designates predetermined positions of the end effector at predetermined points in time. While the robot arm is operating through the preprogrammed cycle, a parameter indicative of a force being exerted on the glass ribbon by the end effector is sensed. A position of the end effector is altered to differ from the predetermined position at the corresponding point in time when the sensed parameter deviates from a target value. An excessive force applied to the glass ribbon can be reduced in real-time.