Reconfigurable Robot Cell Layout for Multi-Robot Assembly Control
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Solution Overview
Problem
Existing robot cells face challenges in efficiently reconfiguring and controlling multiple robots for the assembly of complex workpieces like aircraft, requiring improved coordination and flexibility to handle changing dimensions and tasks.
Innovation Solution
A robot cell with a cell floor defining a two-dimensional coordinate system and detectors to locate and control robots using a master three-dimensional coordinate system, allowing dynamic reconfiguration and coordinated movement of robots based on detected locations and bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robots are employed to simultaneously assemble a workpiece within a single robot cell, then productivity is improved through parallel assembly operations, but device complexity increases due to the need for coordinated control of multiple robots
Solution Approach 1:
A master coordinate system acts as an intermediary reference framework that all robots use for positioning and coordination. This mediator enables multiple robots to operate simultaneously without complex inter-robot communication, as each robot independently references the master coordinate system defined by the workpiece or cell structure.
Solution Approach 2:
Detectors continuously monitor the actual positions and orientations of robots, providing feedback to the control system. This feedback mechanism enables real-time coordination and collision avoidance, allowing multiple robots to operate in parallel while maintaining safety and precision through dynamic adjustment of their trajectories.
2Manufacturing precision
If robot bases are fixed to specific locations on the cell floor, then manufacturing precision is maintained through stable positioning, but adaptability decreases when reconfiguration is needed for different workpieces or tasks
Solution Approach 1:
The system transitions from static fixed positions to dynamic reconfigurable positioning. Robot bases can be relocated to different nodes on the cell floor, and the master coordinate system is updated accordingly. This dynamic adaptation allows the same physical infrastructure to support different workpiece geometries and assembly tasks while maintaining precision through coordinate transformation.
Solution Approach 2:
The cell floor is segmented into discrete nodes where robots can be positioned. This segmentation enables modular reconfiguration - robots can be moved between nodes to adapt to different workpiece sizes and shapes, while each node provides a stable, precision reference point for robot placement.
3Reliability
If detectors are used to continuously monitor robot locations and bearings, then safety is improved through real-time collision detection, but use of energy increases due to continuous operation of detection systems
Solution Approach 1:
Instead of continuous monitoring, detectors operate periodically at key moments such as before robot movement, during trajectory execution, and after completion. This periodic detection maintains safety by checking critical states while significantly reducing energy consumption compared to continuous operation.
Solution Approach 2:
Detection resources are allocated partially - full detection capability is activated only when needed (e.g., during critical assembly operations or when robots are in close proximity), while reduced or idle detection modes are used during less critical periods, optimizing the balance between safety and energy consumption.
Data Source
AI summary
A robot cell, having a cell floor defining an array of nodes corresponding with a predetermined two-dimensional coordinate system and defining a volume for receiving a workpiece W therein, is described. The robot cell comprises: a set of robots, including a first robot, having respective bases, end effectors and working envelopes and defining respective three-dimensional coordinate systems, located according to the array of nodes; a set of detectors, including a first detector, configured to detect respective locations and/or bearings of the set of robots using a set of targets disposed on and/or in the cell floor; and a controller, communicatively coupled to the set of robots and to the set of detectors, configured to control movement of the set of robots using the detected respective locations and/or bearings of the set of robots.