Radar Assembly Robot Nesting for Precise 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 assembly system comprising two robotic devices, where a first robotic device with a larger working envelope positions a second, high-precision robotic device to install parts in a radar array chassis, utilizing a cradle and part scanner for accurate and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual processes and tooling are used to perform high torque operations inside a radar structure, then operators can complete assembly tasks, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system equipped with specialized end effectors. The robotic device performs high torque fastening operations that were previously done manually, eliminating the need for operators to physically access hard-to-reach locations and significantly reducing assembly time while maintaining operational capability.
Solution Approach 2:
The automated assembly system is designed to perform tasks independently without continuous human intervention. The robotic device autonomously navigates to target locations, positions fasteners, applies torque, and completes assembly operations on its own, making the system self-sufficient for the assembly process and thereby improving productivity.
2Productivity
If operators work in hard-to-reach locations to complete manual assembly, then high torque operations can be performed, but the process becomes difficult to complete manually
Solution Approach 1:
The robotic system replaces human operators in performing difficult manual operations within the radar structure. The robot's articulated arms and specialized end effectors can access confined and hard-to-reach areas that are difficult for human operators to reach, while maintaining the ability to apply high torque for fastening operations.
Solution Approach 2:
The robotic device approaches the radar structure from external locations rather than requiring operators to work from inside hard-to-reach areas. By positioning the robotic system outside the radar structure and using articulated arms to reach internal fastening points, the system eliminates the need for operators to physically access difficult locations, thereby improving ease of operation while maintaining productivity.
3Manufacturing precision
If a single robotic device is used for assembly, then the system is simpler, but it cannot achieve both large working envelope and high precision simultaneously
Solution Approach 1:
The system divides the assembly task between two specialized robotic devices: a first robotic device with a larger working envelope that handles positioning and macro-movements, and a second robotic device with higher precision that handles fine positioning and precise fastening operations. This segmentation allows each robot to be optimized for its specific function, achieving both large working envelope and high precision without requiring a single overly complex robot.
Solution Approach 2:
The second high-precision robotic device is positioned on or integrated with the first robotic device's workspace, creating a nested configuration where the smaller precision robot operates within the broader workspace of the larger robot. This nested arrangement allows the system to achieve both the large working envelope of the first robot and the high precision of the second robot while minimizing overall system complexity through coordinated operation.
Data Source
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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.