Linear Robot Rail Compensation Without Per-Unit Measurement
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Solution Overview
Problem
Linear robots with welded steel structures face low positioning accuracy due to complex and costly manufacturing processes, and the need for expensive measurements to compensate for inaccuracies.
Innovation Solution
A method using extruded profiles as support rails with a mathematical model to calculate and compensate for geometric changes, allowing for high accuracy and reproducibility without the need for measurements, by modifying the travel path of the carriage and actuator positioning based on parameter changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If welded steel structures are used as support rails, then the linear robot can be manufactured, but the positioning accuracy is very low
Solution Approach 1:
The patent changes the material parameter from welded steel structure to extruded aluminum profile, which fundamentally alters the geometric stability and thermal expansion characteristics of the support rails. This parameter change enables high positioning accuracy while maintaining ease of manufacture through standardized extrusion processes
Solution Approach 2:
The patent employs aluminum profiles with integrated guiding structures and stiffening elements, creating a composite structural design that combines guiding functionality with structural support. This allows achieving high positioning accuracy through the inherent geometric precision of extruded profiles without complex welding and post-processing operations
2Manufacturing precision
If post-processing is applied to improve accuracy of welded steel structures, then positioning accuracy improves, but production becomes very complex and expensive
Solution Approach 1:
The patent applies preliminary action by pre-forming the support rails through precision extrusion processes that inherently produce the required geometric accuracy. The profiles are manufactured with precise cross-sectional geometries and guiding structures before assembly, eliminating the need for post-welding heat treatment and post-machining operations
Solution Approach 2:
The patent changes the manufacturing process parameter from welding-based assembly to extrusion-based fabrication. This fundamental parameter change allows achieving high positioning accuracy directly during the primary manufacturing process without requiring complex secondary post-processing operations
3Manufacturing precision
If measurements are performed on each supporting structure to compensate for inaccuracies, then positioning accuracy improves, but the cost increases significantly
Solution Approach 1:
The patent applies copying by using standardized, repeatedly manufacturable extruded profiles that serve as precise geometric templates. Each support rail is a copy of the same precisely defined profile geometry, ensuring consistent positioning accuracy across multiple components without requiring individual measurement and compensation for each unit
Solution Approach 2:
The patent changes the approach from individual measurement and compensation to inherent geometric consistency through extrusion. By changing the manufacturing method to precision extrusion, the need for expensive per-unit measurement and computational compensation is eliminated, as the extrusion process inherently produces uniform, high-precision geometry
4Ease of manufacture
If welded steel structures with individual geometry are used, then manufacturing is possible, but measurements are always necessary to compensate for positional inaccuracies
Solution Approach 1:
The patent changes the geometric consistency parameter by transitioning from welded assembly (which produces individual variations) to extrusion (which produces identical repeated geometry). This parameter change eliminates individual geometric variations, making measurements for compensation unnecessary while maintaining ease of manufacture through standardized extrusion processes
Solution Approach 2:
The patent applies universality by designing standardized extruded profiles that can be universally used across multiple support rail applications. These universal profiles incorporate integrated guiding structures and mounting features, providing consistent geometric properties that eliminate the need for individual measurement and compensation while maintaining manufacturing flexibility
Data Source
AI summary
The invention relates to a method for compensating for positioning inaccuracies of a linear robot, which has a supporting and guiding structure having at least one a support rail with at least one linear guide and a carriage which can be moved on this rail by means of a motor, using a mathematical model of the supporting and guiding structure, which calculates geometric changes to the supporting and guiding structure on the basis of one or more parameters.