Mobile Robot Path Planning for Reconfigurable Mandrel Cleaning
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Solution Overview
Problem
Current automated systems for cleaning large layup mandrels are costly, require significant infrastructure, and are not scalable or reconfigurable for different sizes and configurations, often necessitating manual customization and occupying valuable manufacturing space.
Innovation Solution
A robotic system with autonomous robots equipped with a processor that generates a master plan based on CAD models, allowing for registration, trajectory construction, and execution of cleaning operations on layup mandrels without the need for dedicated infrastructure, using fiducial markers and sensors for navigation and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a dedicated mandrel cleaning room is constructed, then cleaning automation is achieved, but non-recurring cost increases significantly
Solution Approach 1:
The mobile robotic system is designed to perform multiple functions including cleaning, inspection, and preparation of layup mandrels of various sizes. The robot can be reconfigured with different end effectors and tools to handle diverse mandrel configurations, eliminating the need for dedicated infrastructure for each cleaning task.
Solution Approach 2:
The system employs a mobile robot that can dynamically reposition itself around mandrels of different sizes and configurations. The robotic arm and end effector can be dynamically adjusted to reach different surfaces, allowing the same system to adapt to varying cleaning requirements without permanent installation.
2Extent of automation
If a mandrel cleaning station is installed on the shop floor, then cleaning automation is achieved, but floor space is occupied and infrastructure requirements increase
Solution Approach 1:
The mobile robot can move freely throughout the facility and position itself at different mandrel locations as needed. This dynamic capability eliminates the need for a fixed cleaning station, allowing the system to utilize existing floor space for other manufacturing purposes while maintaining automation.
Solution Approach 2:
The cleaning function is extracted from a fixed station and transferred to a mobile platform. This extraction allows the cleaning capability to be deployed flexibly throughout the facility without occupying dedicated floor space for a permanent installation.
3Manufacturing precision
If automated cleaning systems are designed for specific mandrel configurations, then cleaning effectiveness is improved, but adaptability to different sizes and configurations decreases
Solution Approach 1:
The robotic system is designed with universal capabilities to handle various mandrel configurations. The system can be programmed with different cleaning paths and parameters for different mandrel types, and the end effector can be reconfigured to accommodate different cleaning requirements, maintaining effectiveness across diverse applications.
Solution Approach 2:
The system adjusts cleaning parameters such as speed, pressure, and orbital patterns based on the detected mandrel configuration. This allows the same physical system to optimize its cleaning effectiveness for different mandrel sizes and surface characteristics through software-controlled parameter changes rather than hardware reconfiguration.
4Manufacturing precision
If manual customization of cleaning process is performed for each mandrel configuration, then cleaning quality is maintained, but labor cost increases significantly
Solution Approach 1:
The robotic system automatically detects mandrel configuration through sensors and markers, then self-configures the cleaning parameters and paths based on pre-programmed knowledge bases. This eliminates the need for manual customization for each mandrel type, maintaining consistent cleaning quality while removing the associated labor costs.
Solution Approach 2:
The system uses sensors and vision systems to detect mandrel configuration and provides feedback to the control system, which automatically adjusts cleaning parameters accordingly. This closed-loop approach ensures consistent cleaning quality across different mandrel configurations without requiring manual intervention for customization.
Data Source
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AI summary
A robotic system includes a robot and a processor configured to autonomously generate a master plan for movement of an end effector of the robot for operating on an operating surface of a workpiece in a physical environment. The master plan is based on a computer aided design (CAD) model of the workpiece and defines movement paths of the end effector based on a reach distance of a robotic arm of the robot at each of a plurality of working waypoints defined in the master plan and corresponding to fiducial markers on the workpiece. The processor registers the robot to the workpiece, iteratively adjusts an approximate workpiece position in a world map until matching an actual workpiece position in the physical environment, and constructs and executes a robotic arm trajectory causing the end effector to operate on the operating surface along the movement paths defined in the master plan. (Fig. 1)