Parallel Kinematic Manipulator With Pulsed Visual Feedback
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Solution Overview
Problem
Current robotic manipulator systems are not cost-effective for applications beyond large-scale manufacturing, require numerous sensors that increase weight and cost, and struggle with high-speed operations due to damping and electromagnetic interference, while providing inadequate visual feedback and being noisy.
Innovation Solution
A parallel kinematic manipulator system with three degrees of freedom using three linear coil actuators, magnetic disc swivel joints, and a minimal number of Hall effect sensors, along with a control system that includes a digital control unit and pulsed illumination source, to achieve high-speed and precise movements with reduced noise and sensor interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high-speed delta manipulator operates at high speeds, then productivity is improved, but visual feedback deteriorates because movements appear indistinct to the human eye
Solution Approach 1:
A pulsed illumination source is introduced that emits light in synchronization with the manipulator's operational cycle. The illumination is turned on during critical phases of movement and off during others, creating a periodic lighting pattern that allows the human eye to perceive distinct positional information even at high speeds, thereby maintaining visual feedback quality while preserving high productivity
2Measurement precision
If numerous sensors are used for satisfactory operation, then measurement precision is improved, but weight increases and speed decreases
Solution Approach 1:
The patent extracts and removes unnecessary sensors from the system, retaining only the essential Hall effect sensors needed for basic operation. By eliminating redundant sensing elements, the total sensor count is reduced, which decreases the weight of the manipulator system and removes damping effects that would otherwise limit operational speed, while still maintaining sufficient measurement precision for the application
3Measurement precision
If sensors are located close to the end-effector, then measurement precision is improved, but electromagnetic interference increases under certain working conditions
Solution Approach 1:
The patent introduces magnetic coupling as an intermediary mechanism between the sensors and the end-effector. Hall effect sensors are positioned away from the end-effector, and magnetic coupling elements are used to transmit positional information through the magnetic field. This intermediary approach allows the sensors to remain at a distance from electromagnetic interference sources while still achieving accurate measurement of end-effector position through the magnetic field coupling
4Ease of manufacture
If a Cartesian manipulator structure is used, then ease of manufacture is improved, but speed and precision deteriorate due to damping in flexible couplings
Solution Approach 1:
The patent replaces traditional mechanical flexible couplings with a magnetic coupling system. Instead of using mechanical elements that introduce damping and deformation, magnetic fields are used to transmit motion and force. This substitution eliminates the damping effects that limit speed and precision while maintaining the simplicity of the Cartesian structure, as the magnetic coupling elements can be easily integrated into the existing mechanical framework
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables high-speed and precise manipulations with reduced manufacturing costs, minimal sensor usage, and effective visual feedback, while minimizing noise and sensor interference, thus addressing the limitations of existing systems.
Implementation Method 1
The controller receives sensory signals from the at least one Hall effect sensor
Implementation Method 2
magnetic disc swivel joints
Data Source
AI summary
A parallel kinematic manipulator system having three degrees of freedom and a method of controlling and visualizing work objects using force feedback and oscillation algorithms is provided. Three co-planar linear actuators operate symmetrically and parallel to an effector arm and are pivotally connected by three magnetic disc swivel joints to a base plate. The disc swivel joints each include a convex upper and lower swivel member having two dimensional gear patterns structured into their contacting and non-sliding surfaces. A pulsed illumination source consists of an annular LED array and is synchronized to the oscillation frequencies of the system to provide visual filtering capabilities. A control unit includes a method for keeping a work object balanced by force feedback and without the need for angle sensors at the end-effector, as well as methods for rotation of work objects and control of the pulsed illumination source. Sound trap ridges are included as part of the housing to reduce system noise.