Automated manufacturing using modular structures and real time feedback for high precision control
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Solution Overview
Problem
Current manufacturing technologies face challenges in achieving high precision for large objects due to limitations in motion control systems, which are often incompatible for large or very large structures, and require costly and non-modular solutions for submicron accuracy across extensive distances.
Innovation Solution
The implementation of modular structures with computer-controlled motion systems and real-time feedback using sensors, such as tape scales, proximity detectors, and optical sensors, to synchronize and adjust multiple motion systems for precise positioning and motion control across large distances, allowing for scalable and high-precision manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If standard rigid frame structures with motion control systems are used for large objects, then the structure can cover large distances (meters to hundreds of meters), but the manufacturing precision deteriorates to tolerances of hundreds of microns to millimeters instead of submicron precision
Solution Approach 1:
The system divides the large-scale manufacturing task into multiple coordinated motion systems (first gantry system for X-Y movement, second gantry system for Z-axis movement, third motion system for head positioning). Each subsystem operates within a smaller precision envelope while collectively achieving large-span manufacturing capability with high precision
Solution Approach 2:
The system implements real-time feedback through sensors (tape scales, proximity detectors, optical sensors) that continuously monitor the position and motion of each gantry system. This feedback enables dynamic error compensation and coordination between subsystems, maintaining submicron to millimeter precision across the entire large-span structure
2Measurement precision
If tape scale feedback with nanometer resolution is used for motion control, then positioning precision is improved to nanometer level, but the cost increases significantly and the system becomes non-modular and non-scalable
Solution Approach 1:
Instead of using expensive nanometer-resolution tape scales across the entire large-span structure, the system segments the feedback function across multiple sensors positioned at critical points of each gantry subsystem. This distributed sensing approach achieves sufficient precision at lower cost and maintains modularity
Solution Approach 2:
The sensor system is designed to serve multiple functions: tape scales provide both position feedback and motion synchronization, proximity detectors enable collision avoidance and positioning, and optical sensors provide additional verification. This multi-functionality reduces the need for dedicated high-cost sensors throughout the system
Data Source
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AI summary
An apparatus includes a rigid frame or girder system, a first computer controlled motion system associated with the rigid frame or girder system and configured to move in coordinated positions, a second computer controlled motion system associated with a part to be worked on and configured to move in coordinated positions, and a plurality of sensors associated with the first motion system and the second motion system. The first computer controlled motion system and the second computer controlled motion system use information from the plurality of sensors to assist in coordination between the first computer controlled motion system and the second computer controlled motion system.