Reconfigurable Robot Cell Control With Dynamic Safety Zones
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Solution Overview
Problem
Current robot cells face challenges in reconfiguration, safety, and efficient control, particularly when handling complex and large workpieces like aircraft parts, as they require coordinated control of multiple robots and dynamic adjustment to changing workpiece dimensions and robot positions, which complicates safety and manufacturing 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, and a controller to dynamically arrange the safety system and coordinate robot movements, allowing for real-time reconfiguration and enhanced safety by defining safe paths for human operators and optimizing robot interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robots are used to simultaneously assemble large workpieces, then productivity is improved, but device complexity increases due to coordinated control requirements
Solution Approach 1:
The control system is segmented into individual robot controllers, each managing a specific robot's movements and operations. This modular approach allows each robot to be controlled independently while still contributing to the overall assembly process, reducing the complexity of centralized control for multi-robot systems
Solution Approach 2:
The control system is designed with universal coordination capabilities that can manage multiple robots with different functions and configurations. This multi-functional control architecture enables the system to handle various robot types and assembly tasks through a unified control framework, improving productivity without proportionally increasing complexity
2Manufacturing precision
If robot positions are dynamically adjusted to match workpiece dimensions, then manufacturing precision is improved, but safety risks increase due to unpredictable robot movements
Solution Approach 1:
The system incorporates feedback mechanisms that continuously monitor robot positions, workpiece dimensions, and operational parameters. This real-time feedback enables dynamic adjustment of robot positions to match workpiece variations while maintaining safety through continuous verification of operational parameters and automatic correction of deviations
Solution Approach 2:
The control system employs dynamic safety zones that automatically adjust based on real-time robot positions and workpiece dimensions. This dynamic approach allows manufacturing precision to be improved through flexible positioning while safety is maintained through adaptive boundary enforcement that responds to changing operational conditions
3Reliability
If safety zones are dynamically updated based on robot positions, then safety is improved, but device complexity increases due to real-time coordination requirements
Solution Approach 1:
The control system pre-calculates and establishes safety zones based on expected robot positions and workpiece dimensions before operations begin. This preliminary configuration of safety boundaries reduces the complexity of real-time safety management while maintaining high safety standards through proactive rather than reactive control
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 and accessible by a human operator, is described. The robot cell 1 comprises: a set of robots 110, including a first robot 110A, having respective bases 111 (111A), end effectors 112 (112A) and working envelopes 113 (113A) 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 safety system 160, configured to alert the human operator; 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.