Modular End-Effector Control with Nested Local Controllers
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Solution Overview
Problem
Conventional manufacturing systems rely on centralized control systems for robotic end-effectors, leading to complex and bulky setups, high maintenance costs, and inefficiencies due to the need for extensive programming and calibration, as well as the requirement for multiple spare parts and large test environments.
Innovation Solution
A self-contained modular manufacturing device with local processors that can control end-effectors independently, reducing reliance on a central control system by embedding processors within each module, allowing for modular design, simplified communication, and self-calibration, thereby decreasing downtime and repair costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a centralized control system is used to control robotic end-effectors, then the control functionality is unified and coordinated, but the system complexity increases and maintenance costs rise
Solution Approach 1:
The patent divides the centralized control system into distributed intelligent modules, where each end effector contains its own processor and control logic. This segmentation allows each module to operate independently while maintaining coordination through standardized communication protocols, thereby reducing overall system complexity while preserving control coordination.
Solution Approach 2:
The patent implements a nested control architecture where intelligent modules are embedded within robotic end-effectors, which themselves are part of larger robotic systems. Each nested level maintains its own processing capabilities while interfacing with higher levels through standardized protocols, enabling modular complexity management.
2Manufacturing precision
If extensive programming and calibration are required for centralized control, then control precision is improved, but the time and resources required for setup and maintenance increase
Solution Approach 1:
The patent enables intelligent modules to perform self-calibration and self-diagnosis functions. Each module contains its own processor that can automatically adjust calibration parameters and detect faults without requiring extensive external programming or manual intervention, thereby maintaining precision while reducing setup and maintenance time.
Solution Approach 2:
The patent pre-programs intelligent modules with baseline control logic and calibration routines during manufacturing. This preliminary configuration allows modules to operate with acceptable precision immediately upon deployment, with further calibration occurring automatically during operation rather than requiring extensive initial setup.
3Reliability
If multiple spare parts and large test environments are required for centralized systems, then system reliability is maintained, but the cost and space requirements increase
Solution Approach 1:
The patent segments the robotic system into independent intelligent modules that can be individually replaced rather than requiring spare entire robotic systems. Each module contains its own processor and control logic, allowing faulty modules to be swapped out independently, thereby maintaining reliability while reducing the need for extensive spare parts inventories and large test environments.
Solution Approach 2:
The patent enables quick replacement of faulty intelligent modules with identical or upgraded modules. The standardized interfaces and self-diagnosis capabilities allow for rapid identification and replacement of failed components, recovering system operation quickly without requiring complex testing infrastructure or multiple spare robotic systems.
Data Source
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AI summary
A system and method for a self-contained modular manufacturing device having self-contained modular tools configured to collectively accomplish a specific task or function in a hierarchical control manner. In an embodiment, the modular device includes a housing that has a mount configured to engage a robotic arm or other form of maneuvering actuator (such a crane or gantry). The housing may provide a base by which additional modules may be mounted and coupled. The modular device also includes an interface configured to communicate with a remote master control system capable of control the robotic arm. The modular device also includes one or more other modules that are configured to accomplish a particular task or function. Such modules are sometimes called end-effectors and work in conjunction with each other to accomplish tasks and functions. In a self-contained modular manufacturing device, individual processors disposed in the housing may be configured to control the functional tools (e.g., each end-effector) independent of the overall manufacturing control system and pass control of the self-contained modular device between local controllers in a hierarchical manner.