Continuous Robot Motion for Circular Track Diameter Measurement
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Solution Overview
Problem
Existing methods for measuring the diameter of a circular track on components are limited by precision and speed, as they rely on stepper motors that move in discrete steps, leading to inefficiencies and inaccuracies.
Innovation Solution
A method utilizing a robot with a manipulator arm articulated about two axes, equipped with a gripping mechanism, moves the component continuously along the measurement trajectory with constant acceleration, allowing for simultaneous measurement by sensors and image processing to determine the diameter with high precision, and integrates with an assembly line for automated transfer and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a stepper motor is used to move the component in discrete steps, then the measurement can be performed with simple equipment, but the measurement precision and speed are limited
Solution Approach 1:
The patent replaces the stepper motor mechanical system with a robot system that uses servo motors and closed-loop control. The robot moves the component continuously along a circular trajectory with precisely controlled position, velocity, and acceleration, eliminating the discrete stepping limitation and enabling both high precision and high speed measurements.
Solution Approach 2:
The patent implements continuous motion of the component along the measurement trajectory without discrete stops and starts. The robot maintains continuous movement with controlled acceleration and deceleration, allowing measurements to be taken continuously during motion rather than requiring the component to be stationary at each measurement point, thereby increasing measurement speed while maintaining precision.
2Productivity
If the component is moved in discrete steps with stops, then the measurement can be performed with simple control, but the measurement time is excessive
Solution Approach 1:
The robot system moves the component continuously along the circular measurement trajectory without discrete stops. Measurements are acquired during continuous motion, eliminating the time lost in repeated acceleration and deceleration cycles of discrete stepping, thereby significantly reducing measurement cycle time.
Solution Approach 2:
The system performs preliminary positioning and acceleration of the component before measurements begin, and maintains optimal motion parameters throughout the measurement process. This preliminary preparation allows measurements to be taken during steady-state continuous motion, maximizing measurement speed and minimizing total measurement time.
3Measurement precision
If a robot with articulated arm is used for continuous movement, then measurement precision and speed are improved, but the device complexity increases
Solution Approach 1:
The robot system is designed to perform multiple functions: positioning the component, moving it along the measurement trajectory, and holding it during measurement. This multi-functionality reduces the need for separate specialized devices, thereby managing complexity while achieving high precision and speed measurements.
Solution Approach 2:
The patent replaces simple stepper motor positioning with a robot system that uses advanced control algorithms and sensors. The robot's articulated arm with multiple degrees of freedom provides precise positioning and continuous motion control, achieving high measurement precision despite increased device complexity through intelligent control rather than mechanical simplicity.
4Measurement precision
If the robot arm has mass greater than 20 kg, then high-frequency vibrations are eliminated, but the device complexity and cost increase
Solution Approach 1:
The patent specifies a minimum mass for the robot arm (greater than 20 kg) to change the dynamic parameters of the system. This mass parameter is chosen to naturally dampen high-frequency vibrations during acceleration and deceleration, improving measurement precision by reducing vibration-induced measurement errors, while accepting the associated increase in device complexity and cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances measurement precision and speed by maintaining consistent motion and reducing vibrations, enabling accurate diameter determination and streamlining the assembly process through automated component transfer without human intervention.
Implementation Method 1
a source of a collimated light beam capable of projecting a luminous pattern onto the circular track
Implementation Method 2
a camera capable of acquiring an image of the luminous pattern projected onto the circular track
Data Source
AI summary
This method for measuring the diameter of a circular track on a component comprises: a) a step (162) of moving the component along a measurement path, b) as the component is moving along the measurement path, a measurement step (170), for measuring at least one parameter, without contact with the component, c) a step (186) of determining the diameter of the circular track from the parameters measured. During step a) a robot continuously moves the component at an instantaneous speed that is never zero along the measurement path and an instantaneous acceleration that never changes sign along the measurement path.