Sensor-Guided Multi-Robot Assembly for Precise Welding
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Solution Overview
Problem
Conventional single-manipulator robotic solutions for assembly tasks are limited in the types of assemblies they can handle, require high setup and operational costs, and are inflexible, often needing human intervention for modifications, leading to increased downtime and operational costs.
Innovation Solution
A robotic system with multiple robots and sensors that autonomously locate, pose, and couple objects, using a controller to coordinate their movements and perform manufacturing tasks like welding, with adaptive capabilities to accommodate changes in manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single robot with rigid fixture is used for assembly tasks, then positional accuracy is maintained, but system flexibility and adaptability deteriorate
Solution Approach 1:
The patent replaces static rigid fixtures with dynamic robotic manipulators that can adapt their position and orientation. The robotic system uses real-time sensor feedback and control algorithms to maintain positional accuracy while being reconfigurable for different assembly tasks, thus achieving both precision and flexibility.
Solution Approach 2:
The patent employs multiple robotic manipulators that can perform various assembly operations. Each manipulator is equipped with interchangeable end effectors and can be programmed for different tasks, allowing a single system to handle multiple assembly configurations without requiring task-specific rigid fixtures.
2Manufacturing precision
If rigid fixtures are used to account for positional uncertainties, then assembly precision is maintained, but setup and operational costs increase
Solution Approach 1:
The patent replaces mechanical rigid fixtures with an automated robotic system equipped with sensors and control systems. The robotic manipulators use vision systems and force sensors to detect and compensate for positional uncertainties, eliminating the need for expensive custom-designed rigid fixtures while maintaining assembly precision.
Solution Approach 2:
The robotic system performs self-calibration and self-adjustment through sensor feedback. The manipulators automatically detect positional deviations and compensate for them through closed-loop control, eliminating the need for manual setup and adjustment of rigid fixtures for each assembly task.
3Ease of operation
If teach pendant devices are used for robot control, then assembly tasks can be performed, but human intervention is required increasing operational costs and downtime
Solution Approach 1:
The patent implements a closed-loop control system where sensors continuously monitor the assembly process and provide feedback to the controller. This enables the robotic manipulators to automatically adjust their movements and compensate for deviations in real-time, eliminating the need for human operators to intervene with teach pendants during production, thus reducing downtime and increasing productivity.
Solution Approach 2:
The robotic system autonomously performs assembly tasks without requiring human operators to program or adjust the robots during operation. The system uses pre-programmed sequences combined with real-time sensor feedback to handle variations, making the operation fully autonomous and eliminating productivity losses associated with human intervention.
Data Source
AI summary
This disclosure provides systems, methods, and apparatuses, including computer programs encoded on computer storage media, for operation of an assembly robotic system. In one aspect of the disclosure, the assembly robotic system includes a tool coupled to a robot device and configured to be selectively coupled to a first object. The assembly robotic system also includes a welding tool, one or more sensors configured to generate sensor data, and a controller. The controller is configured to control the tool to couple the tool to the first object based on the sensor data, control the robot device to bring the first object into a spatial relationship with a second object, and generate a weld instruction to cause the weld tool to weld a seam formed between the first and second objects. Other aspects and features are also claimed and described.