Traveling Robot Calibration for Bent Aircraft Workpiece Positioning
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Solution Overview
Problem
Current methods for manufacturing aircraft bodies face challenges in achieving high accuracy in positioning and calibration of fuselage connections, particularly when dealing with large and bent workpieces, which can lead to reduced precision and increased errors.
Innovation Solution
A robot system equipped with a position detection sensor, calibration members, and a support member that allows for calibration of the robot's and workpiece's position coordinates using reference and calibration positions, enabling accurate positioning even when the workpiece is bent, by dividing the workpiece into sections and performing calibration based on detected coordinates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the robot performs calibration and positioning operations on large bent workpieces, then the work coverage and adaptability are improved, but the positioning accuracy deteriorates due to workpiece deformation
Solution Approach 1:
The patent divides the large bent workpiece into multiple sections, each with its own local coordinate system. The robot performs calibration separately for each section by detecting calibration members positioned at different locations along the workpiece. This segmentation allows the system to handle workpiece deformation locally while maintaining overall positioning accuracy across the entire workpiece span.
Solution Approach 2:
The patent introduces calibration members as intermediary objects that facilitate accurate positioning. These calibration members are positioned at specific locations on or near the workpiece and serve as reference points for the robot's position detection sensor. By calibrating against these stable intermediary references rather than directly against the bent workpiece geometry, the system achieves high positioning accuracy despite workpiece deformation.
2Manufacturing precision
If traditional positioning methods are used for fuselage connection, then the equipment cost is reduced, but the positioning accuracy and connection precision deteriorate
Solution Approach 1:
The patent uses calibration members and reference positions as intermediary elements that enable high-precision positioning without requiring complex expensive equipment. The calibration members serve as simple yet effective references that bridge the gap between the robot's coordinate system and the workpiece coordinate system, achieving sub-millimeter accuracy through software-based calibration rather than through complex hardware mechanisms.
Solution Approach 2:
The patent replaces complex mechanical positioning mechanisms with a sensor-based detection and software calibration system. Instead of using precision mechanical guides or fixtures to ensure accurate positioning, the system uses position detection sensors to detect calibration members and reference positions, then calculates coordinate transformations through calibration algorithms. This substitution of mechanical systems with sensing and computation achieves higher precision at lower equipment cost.
3Manufacturing precision
If the robot calibrates position coordinates without supporting the workpiece, then the device complexity is reduced, but the positioning accuracy deteriorates when the workpiece is bent
Solution Approach 1:
The patent introduces support members as intermediary structures that hold the workpiece in a stable reference configuration during calibration. These support members provide a stable geometric reference framework against which the calibration members and reference positions can be accurately positioned. By supporting the workpiece to prevent bending during calibration, the system achieves high positioning accuracy without requiring complex active control systems.
Solution Approach 2:
The patent performs support and stabilization of the workpiece before the calibration process begins. The support members are positioned and the workpiece is secured in its reference configuration prior to detecting calibration members and establishing coordinate systems. This preliminary action ensures that the workpiece remains stable and undeformed during subsequent calibration and positioning operations, eliminating the need for complex real-time compensation mechanisms.
Data Source
AI summary
A robot system includes a robot that self-travels along a traveling shaft and is provided with a position detection sensor at a distal end, a support member that has a plurality of reference positions juxtaposed and supports a workpiece, a plurality of calibration members that are juxtaposed along the traveling shaft, and a control device, in which the calibration members each have a calibration position, and the control device is configured to cause the robot to move by a predetermined first distance along the traveling shaft, calibrate position coordinates of the robot based on position coordinates of the calibration positions detected by the position detection sensor, and subsequently calibrate position coordinates of the workpiece based on position coordinates of the reference positions detected by the position detection sensor.