Mover Trajectory Alignment Using Two-Step Sensor-Guided Turning
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Solution Overview
Problem
Existing mover systems face challenges in achieving precise alignment with trajectories, leading to inaccuracies in navigation and parts mounting processes.
Innovation Solution
A control method and system that utilize multiple sensors and drive wheels to perform a two-step turning process, aligning the mover with a trajectory through a first and second turning step, enhancing alignment accuracy by adjusting the orientation of the drive wheels relative to the trajectory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single sensor and single turning step are used for alignment, then the control system is simple, but the alignment accuracy is insufficient
Solution Approach 1:
The alignment process is segmented into two distinct turning steps: a first turning step that performs rough alignment to bring the mover close to the trajectory, and a second turning step that performs fine alignment to achieve precise alignment. This segmentation allows each step to focus on a specific aspect of alignment, improving overall accuracy while keeping each individual step relatively simple
Solution Approach 2:
The first turning step performs preliminary alignment actions to position the mover in approximate alignment with the trajectory before the second turning step performs the final precise alignment. This preliminary action reduces the workload and complexity required for the final alignment operation
2Measurement precision
If multiple sensors and two-step turning are implemented, then alignment accuracy improves, but the control process becomes more complex
Solution Approach 1:
The trajectory detection function is segmented across multiple sensors positioned at different locations on the mover. Each sensor detects trajectory information within its own detection range, and the control unit processes each sensor's data independently for its respective turning step, reducing the complexity of coordinating all sensors simultaneously
Solution Approach 2:
The system uses feedback from each sensor to continuously monitor the mover's alignment status with the trajectory. The control unit adjusts the turning operations based on real-time feedback from the sensors, enabling precise alignment while managing the complexity through iterative correction rather than complex pre-planning
3Manufacturing precision
If a single turning operation is used, then the control process is simple, but the alignment accuracy with the trajectory is insufficient
Solution Approach 1:
The turning operation is divided into two sequential phases: the first turning step executes a larger rotation to achieve rough alignment with the trajectory, and the second turning step executes a smaller adjustment rotation to achieve precise alignment. This segmentation of the turning control allows each phase to use appropriate control parameters and algorithms, improving overall precision while managing complexity
Solution Approach 2:
The first turning step performs preliminary rotation to position the mover in approximate alignment with the trajectory, reducing the angular distance to be covered in the second turning step. This preliminary action simplifies the control requirements for the final precise alignment operation
Data Source
AI summary
A control method includes a first turning step and a second turning step. The first turning step includes controlling a plurality of drive wheels to make a mover turn around a position where a first detection range overlaps with a trajectory, until a second sensor senses, in a state where the first detection range overlaps with the trajectory, a state where the trajectory is present at a first target position within a second detection range. The second turning step includes controlling, after the first turning step has been performed, the plurality of drive wheels to make the mover turn around the first target position until the third sensor senses a state where the trajectory is present at a second target position within a third detection range.