Compliant Robot Arm Transfer for Conveyor Synchronization
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Solution Overview
Problem
Existing 'pick and place' robot systems in production lines face challenges with high investment costs, low flexibility, and error-proneness due to precise timing and synchronization requirements, which limit their ability to handle diverse products and additional processing steps without complex sensor systems and precise conveyor designs.
Innovation Solution
A robot system with compliance control and flexible guide means allows for automatic positioning and movement of objects along a process line, enabling flexible interaction and processing beyond traditional 'pick and place' tasks, reducing the need for precise synchronization and sensor usage by using impedance control and force sensors to guide objects along converging guide surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If 'pick and place' robot systems are integrated into conventional flow processing systems with precisely timed conveying equipment, then high-speed and high-precision tasks can be performed, but significant investment in accuracy and programming is required, introducing susceptibility to errors
Solution Approach 1:
Instead of synchronizing the robot to the conveyor belt's movement, the patent inverts the approach by having the robot arm actively guide and pull the conveyor belt to achieve synchronization. This reverses the traditional control paradigm where the conveyor is the master and robot is the slave, allowing the robot to dictate timing and position, thereby reducing synchronization complexity while maintaining high processing speed
Solution Approach 2:
The robot system performs its own synchronization by using its effector to physically guide the conveyor belt, eliminating the need for external synchronization equipment, sensors, and complex control programming. The robot serves itself by creating the timing reference through its own movements, reducing device complexity and error susceptibility
2Measurement precision
If sensors and complex evaluation electronics are used to accurately determine object positions and detect positional deviations, then precise positioning can be achieved, but the system becomes more complex and expensive
Solution Approach 1:
The patent replaces the optical/electronic sensor-based positioning system with a mechanical guidance system. The robot arm's effector physically contacts and guides the object or carrier device along the process line, using mechanical forces rather than electronic sensing to achieve precise positioning. This eliminates complex sensor systems while maintaining measurement precision through direct mechanical control
Solution Approach 2:
The robot arm's effector acts as an intermediary between the control system and the object, providing direct mechanical guidance and positioning. Instead of using sensors to detect position and then calculating required adjustments, the effector directly imposes the correct position through mechanical contact, simplifying the system by removing the sensing and computation intermediary layer
3Adaptability or versatility
If the workspace is functionally and spatially decoupled from the process line, then robot processing can be performed, but active movement of objects along the production line cannot be achieved
Solution Approach 1:
The patent merges the workspace with the process line by positioning the robot arm along the process line rather than separating them. The robot arm can both process objects at designated work positions and actively guide them along the process line between positions. This integration allows the same mechanical system to perform both processing and transport functions, achieving versatility and productivity simultaneously
Solution Approach 2:
The robot arm is designed with multi-functionality, serving both as a processing tool and a transport mechanism. The same effector that performs processing operations also guides and moves objects along the process line. This universal design eliminates the need for separate transport devices, allowing the robot to adapt to different processing and transport requirements, enhancing both adaptability and productivity
Data Source
Figure 1
Figure 2~2c
Figure 3~3b
AI summary
The invention relates to a robot system (1), to a corresponding method, and to a processing system, wherein, along a process line (2, 19, 22, 26), which is formed by guide rails (20, 23), or on a conveyor belt (6), objects (4, 10, 11, 15) or workpieces are optionally moved or transported on carrier devices (5, 12, 14) having gripping elements (13, 16). The robot arm (7) removes the objects (4, 10, 11, 15) from the process line by pulling or pushing the objects from a plane or surface of the process line into a working chamber (17) compliantly, i.e., in a non-rigid manner by means of force control, wherein the objects are positioned and oriented in the working chamber by means of guiding elements (18). After the processing of the objects (4, 10, 11, 15) in the working chamber (7), the objects are pushed or pulled back onto the process line (2, 19, 22, 26) by means of the robot arm (7). The process line (2, 19, 22, 26) can comprise passive, non-driven rollers or the like instead of an actively driven conveyor belt (6), wherein the robot arm (7) nudges or pushes the objects (4, 10, 11, 15) in order to transport the objects.