Rack-and-Pinion Backlash Adjustment for 7th-Axis Robot Drives
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Solution Overview
Problem
Traditional robotic systems used in warehouse operations for tasks like line kitting are inefficient and prone to errors due to their limited movement capabilities, often requiring human intervention which leads to fatigue, injuries, and suboptimal task execution.
Innovation Solution
A robotic system with a 7th linear axis that allows for additional degrees of freedom, enabling the robot to move along a guide rail and operate within a larger solution space, optimizing tray handling and assembly tasks by integrating the 7th axis into the control system to enhance efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional 6-axis robotic systems are used for line kitting operations, then the system structure is simpler and easier to control, but the robot cannot access all locations within the workspace and requires human intervention
Solution Approach 1:
The patent adds a 7th linear axis to the traditional 6-axis robotic system, enabling movement along a guide rail in addition to the six rotational axes. This dimensional extension allows the robot to access all locations within the workspace, eliminating the need for human intervention while maintaining manageable system complexity through modular integration
2Productivity
If human workers perform tray handling tasks, then the system is simpler to implement, but worker fatigue and injuries occur and task execution is suboptimal
Solution Approach 1:
The robotic system with 7th axis performs tray handling tasks autonomously without human intervention. The robot independently navigates the workspace, identifies trays, executes picking and placing operations, and manages its own operation through integrated control systems, thereby eliminating worker fatigue and injuries while maintaining high task execution quality
3Speed
If a 7th linear axis is added to the robotic system, then the robot can access all locations within the workspace and operate at high speed, but the system complexity increases and requires backlash adjustment mechanisms
Solution Approach 1:
The patent incorporates backlash adjustment mechanisms that dynamically modify mechanical parameters of the drive assembly. By adjusting clearance parameters in the rack and pinion connection, the system maintains high-speed operation while compensating for backlash effects, thereby achieving fast tray handling without sacrificing positioning accuracy despite increased system complexity
Data Source
AI summary
The present application discloses a mechanism to adjust backlash in a rack and pinion powertrain assembly. The mechanism to adjust backlash includes a mounting frame having an opening defined therein to receive an operative end of a drive assembly, a shoulder fastener positioned through a first complementary set of holes at a first end of a mounting flange to movably couple the mounting flange to the mounting frame, the fastener being fastened in a manner such that the mounting flange and drive assembly have freedom to pivot about a longitudinal axis of the first complementary set of holes, and an adjustable length coupling device having a first end coupled mechanically to the mounting plate and a second end coupled mechanically to the mounting flange at a location substantially opposite the first end of the mounting flange.