Sensor-Controlled Robot Damping for Machining Vibration
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Solution Overview
Problem
Conventional manufacturing robots experience vibrations during machining operations, which affect surface quality and robot integrity, and passive counterbalances are insufficient in damping these vibrations, especially when high accuracy is required, such as in aircraft construction.
Innovation Solution
A robotic system with a multi-axis robot arm equipped with sensors (vibration, strain gauge, and temperature sensors) and a controller that actively controls a damping system, such as a hydraulic damper, to resist movement and damp vibrations dynamically, allowing for improved accuracy and reduced wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If passive counterbalances are used to support robot weight, then robot control is improved, but vibration damping during machining operations remains insufficient
Solution Approach 1:
The patent transforms the static passive counterbalance into a dynamic active damping system that continuously adjusts its characteristics based on real-time robot state and external forces, enabling the system to adapt to varying operating conditions and effectively damp vibrations during machining operations
Solution Approach 2:
The patent implements a feedback control loop where sensors detect robot position, velocity, and acceleration, the controller processes this information to determine external forces, and the damping system adjusts accordingly, creating a closed-loop system that actively compensates for vibrations
2Productivity
If robot speed and positioning accuracy are increased, then machining productivity is improved, but vibrations and surface quality deteriorate
Solution Approach 1:
The patent converts the harmful vibrations generated during high-speed machining into controllable dynamic responses by using the vibration sensors to detect oscillations and the active damping system to generate counter-forces, thereby transforming the harmful effect into an opportunity for active compensation and improved surface quality
3Strength
If robot arm stiffness is increased to reduce vibrations, then vibration resistance is improved, but robot adaptability to dynamic forces deteriorates
Solution Approach 1:
The patent dynamically changes the damping parameters of the active damping system based on real-time detection of robot state and external forces, allowing the system to optimize its stiffness and damping characteristics adaptively rather than relying on fixed mechanical stiffness, thereby maintaining both vibration resistance and adaptability
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
The active damping system effectively reduces vibrations and improves machining accuracy and surface finish by dynamically adjusting resistance to match changing machining forces, enhancing the robot's integrity and efficiency.
Implementation Method 1
a damping system configured to apply a resistive force to the robot arm, thereby to resist movement of the robot arm
Implementation Method 2
The damping system may comprise a hydraulic damper or gas spring
Data Source
AI summary
A robotic system comprising: a multi-axis robot; one or more sensors located on the multi-axis robot; a damping system configured to apply a resistive force to the multi-axis robot, thereby to resist movement of the multi-axis robot; and a controller coupled to the one or more sensors and the damping system, the controller being configured to: receive sensor measurements from the one or more sensors; and control, based on the received sensor measurements, the damping system thereby to control the resistive force applied by the damping system to the multi-axis robot.