Modular Tool Control With Local Processing and Self-Calibration
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Solution Overview
Problem
Conventional robotic manufacturing systems rely on centralized control systems, which are complex, costly, and inefficient, requiring extensive updates and calibration, leading to high maintenance costs and downtime due to the lack of localized processing and control in end-effectors.
Innovation Solution
A self-contained modular manufacturing device with a local processor that controls end-effectors independently, allowing for self-calibration and communication with a master control system, reducing the need for bulky central control systems and enabling modular device updates and calibration without disrupting the entire manufacturing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If centralized control systems are used to control end-effectors, then control functionality is centralized, but processing speed and power requirements on the master control system increase significantly
Solution Approach 1:
The control system is segmented into a master control system and local processors embedded in end-effectors. The local processors handle tool-specific control functions independently, while the master control system manages high-level coordination. This segmentation reduces the processing burden and power requirements on the master control system by distributing control functionality to localized units.
2Reliability
If centralized control systems are used, then master logic programs control all tools, but system downtime and maintenance costs increase due to lack of localized processing
Solution Approach 1:
Local processors in end-effectors are pre-configured with tool-specific control logic and can operate autonomously. This preliminary setup allows the system to continue operating with localized control even if the master control system experiences issues or requires maintenance, thereby reducing system downtime and improving overall reliability.
3Ease of operation
If conventional controllable tools are mounted to robotic arms, then tools can be controlled, but the tools lack self-contained processing ability and require extensive calibration
Solution Approach 1:
End-effectors are equipped with embedded local processors that provide self-contained processing ability. These local processors enable the tools to perform self-calibration and self-diagnosis functions, eliminating the need for extensive manual calibration and reducing the complexity of tool setup and maintenance operations.
4Extent of automation
If master programs control all end-effectors, then centralized control is achieved, but processing speed requirements on the master control system increase
Solution Approach 1:
The automated control system is divided into hierarchical levels: the master control system handles high-level automation coordination, while local processors in end-effectors handle real-time tool control and processing. This segmentation enables high-speed localized processing without overwhelming the master control system, maintaining high automation levels while managing processing speed requirements effectively.
Data Source
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AI summary
A system and method for a self-contained self-calibrating modular manufacturing device having modular tools and parts configured to collectively accomplish a specific task or function. 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 control system capable of controlling the robotic arm. Such modules work in conjunction with each other to accomplish tasks and functions. In a self-contained self-calibrating modular manufacturing device, a processor disposed in the housing may be configured to control the functional tools (e.g., each end-effector) independent of the overall manufacturing control system as well as use local sensors to determine aspects of an underlying manufactured items for calibration purposes.