Radar Metrology System for Robot Arm Positioning
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Solution Overview
Problem
Existing metrology systems for robots, such as SCARA robots, face limitations in accuracy and reliability, particularly for precise position and orientation determination across various orientations, which can be time-consuming and do not provide the desired level of precision for applications like workpiece measurements and manufacturing.
Innovation Solution
A radar metrology system is introduced, comprising a mobile and stationary radar configuration that uses radar signals to determine distances between radar components, enabling precise tracking of the end tool's position and orientation with micron-level accuracy by calculating distances based on phase measurements and wavelength analysis, improving upon traditional encoder-based systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional encoder-based systems are used for position sensing, then the system structure is simple, but the positioning accuracy is limited to hundreds or thousands of microns
Solution Approach 1:
The patent replaces mechanical encoder-based position sensing with a radar-based electromagnetic measurement system. The radar system uses electromagnetic waves to measure distances between the robot arm and reference targets, achieving micron-level accuracy without mechanical contact. This substitution eliminates the fundamental accuracy limitations of mechanical encoders while reducing mechanical wear and maintenance requirements.
Solution Approach 2:
The patent introduces radar waves as an intermediary medium for position measurement. Instead of direct mechanical coupling between the encoder and the robot arm, the radar system uses electromagnetic wave propagation and reflection off reference targets to indirectly measure position. This intermediary approach enables non-contact, high-precision measurement that overcomes mechanical system limitations.
2Measurement precision
If calibration techniques are used to improve robot accuracy, then positioning precision can be enhanced, but the calibration process requires significant time
Solution Approach 1:
The patent performs radar system calibration by moving the robot arm to predetermined positions and measuring distances to reference targets before actual work begins. This preliminary calibration establishes accurate position references that enable high-precision operation throughout subsequent work cycles without requiring repeated calibration, thus minimizing time loss while achieving micron-level accuracy.
3Reliability
If traditional position sensors are used, then the system is easier to operate, but the reliability and repeatability of position determination are insufficient for precise workpiece measurements
Solution Approach 1:
The patent replaces mechanical position sensors with a radar-based measurement system that uses electromagnetic waves for non-contact position determination. This substitution significantly improves reliability and repeatability for precise workpiece measurements by eliminating mechanical wear, contact interference, and the limited resolution of mechanical encoders, while maintaining ease of operation through automated radar measurement processes.
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 radar metrology system enhances the precision and reliability of position and orientation determination, achieving micron-level accuracy over a meter or more, surpassing the limitations of traditional systems by directly measuring distances without reflections and providing improved calibration processes.
Implementation Method 1
A radar metrology system includes a mobile radar configuration including a plurality of mobile radar components that are configured to be coupled to at least one of the end tool or the end tool mounting configuration. A stationary radar configuration includes a plurality of stationary radar components that define at least part of a metrology frame volume. Distances are determined between stationary radar components and mobile radar components based at least in part on radar signals
Data Source
AI summary
A radar metrology system is provided for use with a movement system (e.g., a robot arm) that moves an end tool, and includes mobile and stationary radar configurations. The mobile radar configuration includes mobile radar components that are coupled to the end tool or an end tool mounting configuration. The stationary radar configuration includes stationary radar components (e.g., which define a metrology frame volume that surrounds a movement volume in which the end tool is moved). Distances are determined between stationary radar components and mobile radar components based at least in part on radar signals, wherein the distances indicate (e.g., and may be utilized to determine) a position and orientation (e.g., of the mobile radar configuration and/or end tool). The radar signals are either transmitted from stationary radar components and received by mobile radar components, or transmitted from mobile radar components and received by stationary radar components.