Reconfigurable Workstation Using Vision-Guided Robotic Arm
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Solution Overview
Problem
Existing robotic assembly processes are inflexible and specific to single apparatus, limiting their ability to handle diverse components and products, and require precise tooling and fixturing, which restricts their adaptability and scalability.
Innovation Solution
A reconfigurable autonomous workstation with a multi-faced superstructure, a controllable robotic arm, conveyor tables, and a vision system, enabled by a programmable controller, allowing for flexible assembly of various components into different products without external input, and capable of being easily transported and reconfigured for different tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision tooling and fixtures are used to present components to the robotic arm, then assembly precision is improved, but device complexity and lack of flexibility increase
Solution Approach 1:
The robotic arm is designed with a universal end effector that can perform multiple assembly operations (screwing, clipping, adhesive application, etc.) without requiring specialized tooling or fixtures for each component type. This multi-functional approach eliminates the need for complex, part-specific tooling while maintaining assembly precision through programmable control.
Solution Approach 2:
The patent replaces traditional mechanical precision tooling and fixtures with a programmable robotic system that uses sensors, vision systems, and software control to achieve precise component positioning and assembly. The robotic arm with its programmable end effector substitutes complex mechanical fixturing with automated mechanical manipulation guided by digital instructions.
2Manufacturing precision
If part-specific tooling is used for robotic assembly, then assembly precision for specific components is improved, but adaptability to different products deteriorates
Solution Approach 1:
The robotic assembly system employs dynamic, programmable control that allows the end effector to adapt its operations in real-time based on the specific component being assembled. The system can be reprogrammed to handle different product types, component orientations, and assembly methods, providing both precision for current tasks and flexibility for future reconfiguration without physical modifications.
Solution Approach 2:
A universal end effector design enables the robotic arm to perform multiple assembly functions (fastening, joining, sealing, etc.) across different product lines. This eliminates the need for part-specific tooling while maintaining assembly precision through programmable control and sensor feedback, allowing the same hardware to adapt to various products.
3Manufacturing precision
If traditional robotic assembly with fixed tooling is used, then assembly accuracy for specific products is improved, but reconfiguration time and productivity for new products deteriorate
Solution Approach 1:
The system performs preliminary programming and setup of the robotic arm's operational parameters, toolpaths, and end effector configurations before actual assembly begins. This allows rapid reconfiguration for new products by simply loading new program instructions, eliminating the need for time-consuming physical retooling while maintaining assembly accuracy through pre-calculated precision movements.
Solution Approach 2:
The robotic system uses dynamic reprogramming capabilities that allow it to be quickly reconfigured for different products through software updates rather than physical modifications. The programmable end effector can adapt its operations in real-time, enabling fast changeover between product types while maintaining assembly accuracy through continuous sensor feedback and controlled movements.
Data Source
AI summary
A reconfigurable autonomous workstation includes a multi-faced superstructure including a horizontally-arranged frame section supported on a plurality of posts. The posts form a plurality of vertical faces arranged between adjacent pairs of the posts, the faces including first and second faces and a power distribution and position reference face. A controllable robotic arm suspends from the rectangular frame section, and a work table fixedly couples to the power distribution and position reference face. A plurality of conveyor tables are fixedly coupled to the work table including a first conveyor table through the first face and a second conveyor table through the second face. A vision system monitors the work table and each of the conveyor tables. A programmable controller monitors signal inputs from the vision system to identify and determine orientation of the component on the first conveyor table and control the robotic arm to execute an assembly task.