Reconfigurable Robot Cell Control With Shared Coordinate Tracking
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Solution Overview
Problem
Current robot cells face challenges in efficiently reconfiguring and controlling multiple robots to assemble complex workpieces, such as aircraft, due to limitations in coordinate systems and interdependencies between robots, which affect precision and efficiency.
Innovation Solution
A robot cell with a cell floor defining a two-dimensional coordinate system, equipped with detectors to track robot locations and bearings, sensors to sense poses, and a controller to guide robots within three-dimensional working envelopes, allowing for dynamic reconfiguration and improved coordination among robots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robots are employed to simultaneously assemble a workpiece, then productivity is improved, but device complexity increases due to coordinated control requirements
Solution Approach 1:
A master coordinate system acts as an intermediary reference framework that all robots share. Each robot's controller references this common coordinate system to determine its position and orientation, enabling coordinated control without complex inter-robot communication. The detectors and sensors provide feedback to the controller, which adjusts robot positions based on deviations from the master coordinate system, simplifying the control architecture while maintaining synchronization.
2Adaptability or versatility
If robot positions are fixed according to a predetermined coordinate system, then device complexity is reduced, but adaptability deteriorates when reconfiguring for different workpieces
Solution Approach 1:
The system transitions from static fixed positions to dynamic positioning. Robots can be relocated to different nodes on the cell floor and their coordinate systems can be adjusted based on detectors and sensors feedback. The master coordinate system remains fixed while individual robot coordinate systems are dynamically transformed to match the workpiece geometry, enabling reconfiguration for different workpieces while maintaining a simple overall framework.
Solution Approach 2:
The system allows changing coordinate system parameters (origin, orientation, scale) for each robot based on detected workpiece features. When a new workpiece is introduced, detectors identify its geometry and the controller adjusts robot coordinate systems accordingly, while robots remain positioned on the predetermined node array. This enables adaptability without requiring a complete redesign of the coordinate infrastructure.
3Manufacturing precision
If detectors and sensors are added to track robot positions and poses, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The detectors and sensors serve multiple functions: they track robot positions and orientations, detect workpiece geometry and position, provide feedback for coordinate system transformation, and enable collision avoidance. This multi-functionality justifies the added complexity by delivering comprehensive precision control across multiple operational aspects simultaneously.
Solution Approach 2:
Detectors and sensors continuously monitor robot positions and workpiece characteristics, feeding this information back to the controller. The controller compares actual positions with expected positions based on the master coordinate system and makes real-time adjustments to maintain precision. This closed-loop feedback system ensures high manufacturing precision while keeping the control logic relatively simple through standardized feedback processing.
Data Source
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AI summary
A robot cell 1, having a cell floor 10 defining an array of nodes 100 corresponding with a predetermined two-dimensional coordinate system and defining a volume for receiving a workpiece W therein, is described. The robot cell 1 comprises: a set of robots 110, including a first robot 110A, having respective bases 111, end effectors 112 and working envelopes 113 and defining respective three-dimensional coordinate systems, located according to the array of nodes 100; a set of detectors 120, including a first detector 120A, configured to detect respective locations and/or bearings of the set of robots 110; a set of sensors 150, including a first sensor 150A, configured to sense respective poses of the set of robots 110; and a controller 130, communicatively coupled to the set of robots 110 and to the set of detectors 120, configured to control movement of the set of robots 110 using the detected respective locations and/or bearings of the set of robots 110.