Manipulator Operating Point Compensation With Real-Time Feedback
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Solution Overview
Problem
Existing methods for compensating for deviations in the operating point of a manipulator during machining fail to accurately account for dynamic changes, such as temperature variations and process forces, leading to discrepancies between target and actual positions.
Innovation Solution
The method involves measuring the actual position of the working point during machining and dynamically adjusting compensation parameters in real-time, using feedback to account for unknown disturbance variables and changing relationships, with the aid of optical sensors and environmental measurements like temperature and pressure, and integrating these adjustments into the NC control's interpolation cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature compensation is performed using fixed coefficients determined during initial calibration, then compensation for temperature variations can be provided, but compensation accuracy deteriorates when boundary conditions change during machining
Solution Approach 1:
The patent transitions from static fixed compensation coefficients to dynamic compensation parameters that are continuously updated during machining. The control device adjusts compensation parameters in real-time based on current temperature measurements and actual position deviations, allowing the system to adapt to changing boundary conditions such as temperature distribution changes and process force variations that occur during actual machining operations.
Solution Approach 2:
The patent implements a feedback mechanism where the actual position of the operating point is measured during machining, compared with the target position, and the deviation is used to update compensation parameters. This closed-loop feedback allows the system to learn from actual performance and continuously improve compensation accuracy, addressing the limitation of fixed coefficients that cannot adapt to changing conditions.
2Measurement precision
If multiple distributed temperature sensors are used to measure temperature distribution, then temperature measurement coverage is improved, but the system cannot adequately differentiate complex temperature distributions or account for process forces
Solution Approach 1:
The patent uses feedback from actual position measurements to compensate for limitations in temperature measurement. By measuring the real position deviation and using it to update compensation parameters, the system can account for effects that temperature sensors alone cannot detect, such as complex temperature distribution patterns and process force influences.
Solution Approach 2:
The patent changes from relying solely on temperature parameters to using a broader set of compensation parameters that include position deviations and their corrections. This allows the system to account for multiple sources of error including temperature effects, boundary condition changes, and process forces by adjusting the compensation parameter set based on actual measured deviations.
3Measurement precision
If compensation parameters are dynamically adjusted during machining, then positioning accuracy is improved, but control system complexity increases
Solution Approach 1:
The patent implements a feedback-based parameter adjustment mechanism where the control device continuously updates compensation parameters based on measured position deviations. This systematic feedback approach improves positioning accuracy while maintaining manageable control complexity through automated adaptation rather than manual intervention.
Solution Approach 2:
The control device performs self-adjustment of compensation parameters using its own measurement and calculation capabilities. The system automatically updates its compensation parameters based on measured deviations without requiring external calibration or manual intervention, enabling dynamic adaptation while keeping the control architecture relatively simple.
4Productivity
If rapid position changes occur during machining, then productivity is improved, but temperature compensation becomes insufficient due to rapid boundary condition changes
Solution Approach 1:
The patent implements dynamic compensation parameter adjustment that can keep pace with rapid position changes. By continuously updating compensation parameters during machining based on real-time position measurements, the system can adapt to rapid boundary condition changes that occur during high-speed machining operations, maintaining accuracy even when productivity requirements demand rapid movement.
Solution Approach 2:
The patent ensures continuous compensation adjustment throughout the machining process, rather than relying on periodic or pre-calculated values. This continuous adaptation allows the system to maintain positioning accuracy even during rapid position changes, as the compensation parameters are constantly being refined based on current conditions.
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 rapid and precise compensation for deviations, optimizing the positioning accuracy of the manipulator by continuously refining the compensation parameters, thereby reducing the discrepancy between target and actual positions.
Implementation Method 1
measuring the actual position of the operating point during workpiece machining
Implementation Method 2
these parameters are not ideally constant but can change, for example, depending on the prevailing temperature
Implementation Method 3
environmental measurements like temperature and pressure
Data Source
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AI summary
The invention relates to a method for compensating for a deviation of an operating point (1) of a manipulator (2) during the machining of a workpiece (3) by an end-effector (4) on the manipulator (2), wherein an instruction sequence for controlling the manipulator (2) for the purpose of machining the workpiece (3) is executed and, based on the instruction sequence, target position information (5) corresponding to a target position (6) is generated, on the basis of which target position information (5) the operating point (1) of the manipulator (2) is adjusted, wherein the target position information (5) is processed using a set of compensation parameters (7) relating to the target position information (5) to determine a compensation value (8), and the target position information (5) is adapted according to the compensation value (8) to compensate for a deviation (9) between an actual position (10) of the operating point (1) and the target position (6). The invention is characterized in that the actual position (10) is measured during the machining of the workpiece (3), in that a correction value (12) is determined based on a comparison between the measured actual position (10) and the target position (6), and in that the set of compensation parameters (7) is adapted, based on the correction value (12), during the machining of the workpiece (3) to reduce the deviation (9).