Nested Robot Assembly for Precise Radar Chassis Installation
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Solution Overview
Problem
The manual assembly of large-scale modular radars is labor-intensive and time-consuming, requiring high torque operations in hard-to-reach locations, which are difficult to perform manually.
Innovation Solution
An automated radar assembly system comprising two robotic devices, where a first robotic device with a larger working envelope positions a second robotic device with higher precision and repeatability to install parts in a radar array chassis, synchronized by a controller to facilitate efficient and accurate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly processes are used for large-scale modular radars, then operators can perform high torque operations, but the assembly process becomes labor-intensive and time-consuming
Solution Approach 1:
The robotic assembly system performs assembly operations autonomously without human intervention. The robot navigates the chassis, positions components, and executes fastening operations automatically, eliminating the need for manual labor while maintaining assembly capability
Solution Approach 2:
Manual mechanical assembly operations are replaced with an automated robotic system. The robot uses automated fastening mechanisms and positioning systems to perform tasks that were previously done manually, significantly improving productivity and reducing labor intensity
2Ease of manufacture
If operators work in hard-to-reach locations to perform manual assembly, then parts can be installed, but the process becomes difficult and time-consuming
Solution Approach 1:
The robotic system dynamically adapts to the complex geometry of the radar chassis. The robot can extend its working envelope to reach hard-to-access locations and adjust its positioning dynamically, making part installation easier and faster compared to static manual operations
Solution Approach 2:
The robotic system acts as an intermediary between the assembly process and the hard-to-reach locations. It navigates and positions itself within the chassis structure to access remote fastening points, eliminating the need for operators to physically reach difficult locations
3Measurement precision
If a single robotic device with large working envelope is used, then it can reach all locations, but precision and repeatability are reduced
Solution Approach 1:
The robotic assembly system is segmented into multiple specialized robotic devices. Each robot is optimized for specific tasks with high precision, while the collective system covers the entire working envelope through coordinated operation and repositioning
Solution Approach 2:
The system uses a hierarchical structure where a first robotic device with large working envelope positions a second robotic device with smaller working envelope but higher precision. The precision robot is effectively nested within the workspace of the larger robot, combining the advantages of both
Data Source
AI summary
An automated radar assembly system is disclosed, comprising: a first robotic device coupled to a cradle, the first robotic device having a first working envelope; a second robotic device coupled to the first robotic device via the cradle, the second robotic device having a second working envelope that is smaller than the first working envelope; a part stand coupled to the cradle, the part stand being arranged to carry: a part; and a controller operatively coupled to the first robotic device and the second robotic device, the controller being configured to: cause the first robotic device to position the second robotic device at a first location relative to a radar array chassis, and cause the second robotic device to pick up the part from the part stand and install the part at a second location in the radar array chassis.