Press Robot Synchronization Using Real-Time Motion Feedback
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Solution Overview
Problem
Current methods for synchronizing press machines and press tending robots are inefficient, leading to suboptimal throughput due to lack of control over robot approach speed, timing, and motion trajectory, requiring manual tuning and being prone to errors when program changes occur.
Innovation Solution
Implementing a system that learns and adjusts robot motion timing and press machine position data in real-time, using encoders and communication networks to synchronize robot movements, ensuring robots enter and exit the press machine at optimal times, and automatically re-learning interlock angles to maintain performance and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PLC communication is used to control robot entry timing, then safety is improved by preventing collisions, but productivity deteriorates due to PLC delays and manual tuning requirements
Solution Approach 1:
The system continuously monitors actual press motion timing through encoders and feedback loops, automatically adjusting robot entry timing based on real-time press position data. This eliminates fixed PLC delays and manual tuning while maintaining collision prevention through dynamic synchronization.
Solution Approach 2:
The patent replaces traditional PLC-based timing control with a motion control system that directly interfaces with robot controllers through encoder feedback. This substitution eliminates software communication delays inherent in PLC systems and provides deterministic timing control.
2Productivity
If robot approach speed is increased to improve throughput, then productivity is improved, but reliability deteriorates due to increased collision risk and robot wear
Solution Approach 1:
The system dynamically adjusts robot approach speed based on actual press motion timing and position feedback. The robot controller continuously optimizes velocity profiles to maximize approach speed while maintaining safe timing margins, eliminating the need for conservative fixed-speed operations.
3Productivity
If manual tuning of robot timing is performed to optimize synchronization, then productivity can be improved, but device complexity increases and adaptability deteriorates when program changes occur
Solution Approach 1:
The system performs self-adjustment by automatically learning press motion characteristics through encoder feedback and autonomously optimizing robot timing parameters. This eliminates manual tuning requirements and ensures automatic adaptation when press programs or robot paths are modified.
4Productivity
If precise motion trajectory control is implemented to optimize robot timing, then productivity is improved, but device complexity increases
Solution Approach 1:
The system optimizes timing by dynamically adjusting velocity and position parameters based on encoder feedback from the press. The motion controller modifies robot motion parameters in real-time to achieve precise synchronization without requiring complex mechanical modifications or additional sensors.
Data Source
AI summary
Methods and systems include ways to synchronize a press machine and tending robots, including a pick robot and a drop robot, where the press machine includes an operating area for pressing a blank into a part. The pick robot and the part are moved out of the operating area while the drop robot carrying the blank is moved into the operating area. At least a portion of the pick robot and/or the part resides within the operating area at the same time at least a portion of the drop robot and/or the blank resides within the operating area. The pick robot is in communication with the drop robot and the movement of the pick robot is synchronized with the movement of the drop robot to prevent the pick robot or part from colliding with the drop robot or the blank.