Reconfigurable Robot Cell Layout for Multi-Robot Assembly Safety
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Solution Overview
Problem
Existing robot cells face challenges in improving reconfiguration, positioning, assembly, safety, and coordinated control of robots, particularly in manufacturing complex workpieces like aircraft parts, which require efficient and safe integration of multiple robots.
Innovation Solution
A robot cell with a cell floor defining a two-dimensional coordinate system, equipped with detectors to locate and orient robots, a safety system, and a controller to manage robot movements and safety alerts, enabling dynamic reconfiguration and coordinated control of robots based on detected locations and working envelopes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robots are employed to simultaneously assemble a workpiece within a single robot cell, then assembly productivity is improved, but coordination control complexity increases
Solution Approach 1:
The patent combines multiple robot control functions into a single centralized controller that manages all robots within the cell. This unified control architecture coordinates multiple robots simultaneously, enabling improved assembly productivity while managing control complexity through integration rather than distributed control systems.
Solution Approach 2:
The controller is designed with universal functionality to manage diverse robot types and operations within the same cell. It provides multi-functional capabilities including position control, safety monitoring, and coordination of different robot systems, thereby simplifying the overall control architecture while supporting high-productivity multi-robot assembly.
2Reliability
If a safety system is implemented to alert human operators, then operator safety is improved, but system complexity increases
Solution Approach 1:
The safety system is integrated with the existing controller rather than being a separate standalone system. The controller combines both production control and safety monitoring functions, thereby improving operator safety through comprehensive monitoring while avoiding the added complexity of multiple independent safety systems.
Solution Approach 2:
The controller is designed with universal functionality that encompasses both operational control and safety monitoring. It provides multi-functional capabilities including real-time position tracking, safety zone monitoring, and operator alerting, thereby achieving improved safety without proportionally increasing system complexity through dedicated separate safety hardware.
3Measurement precision
If detectors are used to detect robot locations and bearings, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The detection functionality is merged into the existing controller system rather than being implemented as separate external detection equipment. The controller integrates detection capabilities that monitor robot positions and bearings, thereby achieving improved positioning precision while reducing overall system complexity through functional integration.
Solution Approach 2:
The controller is designed with universal multi-functional capabilities that include both production coordination and precise position detection. It provides integrated detection of robot locations and bearings alongside control functions, thereby achieving high positioning precision without the added complexity of dedicated separate detection systems.
4Reliability
If the safety system is dynamically arranged based on detected robot locations, then safety reliability is improved, but control complexity increases
Solution Approach 1:
The safety system configuration is made dynamic rather than static. The controller continuously updates safety arrangements based on real-time robot positions detected by the integrated detection system. This dynamic adaptation improves safety reliability by ensuring safety zones accurately reflect current robot locations, while the centralized control architecture manages the complexity of dynamic updates efficiently.
Solution Approach 2:
The system implements feedback mechanisms where detected robot locations are continuously fed back to the controller, which then dynamically adjusts safety system arrangements. This closed-loop control improves safety reliability by ensuring safety configurations respond to actual robot positions, while the integrated controller manages the feedback processing without proportionally increasing overall system complexity.
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 and accessible by a human operator, 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; a safety system, configured to alert the human operator; 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.