Removable Robot Base Coupling With Threshold-Based Operation Lockout
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Solution Overview
Problem
Traditional robotic systems for manufacturing operations, such as welding, are expensive and inflexible due to large permanent mounting systems required for high precision, limiting their applicability to various workpiece sizes and shapes.
Innovation Solution
A robotic system with a removably coupled robotic arm and base, equipped with an electromagnetic member, fluid actuated clamp, or vacuum holder, that includes a controller to disable operations if the coupling parameter with the mounting surface falls below a threshold, allowing for flexible and cost-effective deployment on different surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large permanent mounting systems are used to enable high precision location control, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The system divides the mounting function into two parts: a simple removable base that can be easily attached/detached, and a control system that monitors coupling parameters. This segmentation allows the mounting structure itself to be simple while maintaining precision through active monitoring and control.
Solution Approach 2:
The controller continuously monitors coupling parameters (such as magnetic field strength, vacuum pressure, or clamp force) and provides feedback to determine whether the base is properly coupled to the mounting surface. This feedback mechanism ensures high precision location control without requiring complex permanent mounting structures, as the system can detect and respond to coupling status in real-time.
2Manufacturing precision
If large permanent mounting systems are used for high precision operations, then manufacturing precision is improved, but adaptability to different workpiece sizes and shapes deteriorates
Solution Approach 1:
The removable base is designed to be universally applicable to different workpiece configurations. By using coupling mechanisms (magnetic, vacuum, or mechanical) that can adapt to various surfaces, the same base can be used across different workpiece sizes and shapes while maintaining precision through controller monitoring.
Solution Approach 2:
The system transitions from static permanent mounting to dynamic removable coupling. The base can be easily attached and detached, and the controller dynamically monitors coupling parameters to ensure precision is maintained regardless of workpiece variations. This dynamic approach enables adaptability while preserving manufacturing precision.
3Adaptability or versatility
If removable coupling mechanisms are used to increase flexibility, then adaptability is improved, but reliability of coupling deteriorates
Solution Approach 1:
The controller continuously monitors coupling parameters to detect whether the base is properly coupled to the mounting surface. If coupling is insufficient or lost, the system can issue warnings or prevent operation, thereby maintaining reliability despite the removable nature of the coupling mechanism.
Solution Approach 2:
The system takes preliminary action by monitoring coupling parameters before operations begin and during operation. This prevents unreliable coupling from causing problems, as the controller can detect coupling issues in advance and take corrective action, ensuring reliability is maintained throughout the operation.
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
Enables reliable and cost-effective manufacturing operations by allowing the robotic system to be transported and coupled to various surfaces without large mounting structures, reducing operational costs and increasing flexibility in workpiece handling.
Implementation Method 1
The base (104) may include an electromagnetic member (122) to facilitate a coupling of the base (104) with the mounting surface (202)
Implementation Method 2
The base (104) may include a vacuum holder (126) to facilitate a coupling of the mounting surface (202) with the robotic arm (102)
Data Source
AI summary
A robotic system includes a robotic arm, a base couple coupled to the robotic arm, and a controller. The robotic supports a work implement and is configured to move the work implement to perform an operation on a workpiece. The base is configured to be removably coupled to a mounting surface. The controller is in communication with the robotic arm, the work implement, and the base. Further, the controller is configured to disable the operation of at least one of the robotic arm and the work implement if a coupling parameter between the base and the mounting surface is below a threshold value.