Robotic Machining Local Feature Reference Geometry
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Solution Overview
Problem
Robotic machining systems face inaccuracies when working with large or flexible parts that require precise positioning, as fixed coordinate systems become unreliable due to manufacturing tolerances and component flexibility, leading to compounded errors over distance.
Innovation Solution
The system employs an imaging device to locate local features on the part's surface, determining reference areas and defects, and calculates a tool path to machine the surface to a nominal geometry, eliminating the need for an absolute reference frame by using local features to establish a coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed coordinate system is used for robotic machining, then the robot can operate with a consistent reference frame, but machining accuracy deteriorates over large distances or on flexible parts due to compounded errors from manufacturing tolerances and part flexibility
Solution Approach 1:
The patent introduces an intermediary coordinate system that is dynamically established on the part surface itself, using locally detected features as reference points. This intermediary system acts as a mediator between the robot's fixed coordinate system and the actual part geometry, allowing accurate localization without relying on long-range fixed references that accumulate errors.
Solution Approach 2:
The system performs preliminary scanning and detection of local features on the part surface before machining begins. By pre-establishing the coordinate system based on detected features and pre-calculating tool paths relative to these features, the system eliminates the need for maintaining accuracy over long distances in a fixed coordinate system.
2Manufacturing precision
If local features are used to establish a coordinate system, then machining accuracy is maintained on large or flexible parts, but the system complexity increases due to the need for imaging devices and feature detection algorithms
Solution Approach 1:
The imaging device serves multiple functions: it scans the part surface, detects local features, establishes the coordinate system, and verifies machining results. This multi-functionality reduces the need for separate specialized devices, thereby limiting the increase in system complexity while maintaining high machining accuracy.
Solution Approach 2:
The part itself provides the reference features that the imaging device detects to establish the coordinate system. Rather than requiring external fixtures or complex positioning apparatus, the system uses naturally occurring or manufactured features on the part surface, allowing the part to essentially define its own reference frame.
3Ease of manufacture
If traditional fixed coordinate systems are used, then the setup is simple, but the robot cannot accurately locate itself on large or flexible parts without an absolute reference frame
Solution Approach 1:
The coordinate system transitions from a static fixed reference to a dynamic system that is adaptively established on each part based on detected local features. This dynamic approach allows the system to accommodate variations in part geometry, flexibility, and positioning while maintaining localization accuracy without requiring complex fixed infrastructure.
Data Source
AI summary
Systems and methods for retuning a surface to a nominal geometry using local reference points are disclosed. The system can include an imaging device for detecting the location of local features on an object. The system can use the location of local features, as opposed to an absolute reference frame, to determine one or more reference areas and one or more surface defects on an object. The system can then determine a nominal geometry for the surface (i.e., a surface that is substantially free of surface defects) and calculate the tool path necessary to create a nominal geometry. The system can machine the surface and, in some cases, rescan the surface to ensure the operation has machined the part to the nominal geometry.