Robot End Effector Sensor Assembly for Drilling Precision
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Solution Overview
Problem
Conventional industrial robots face limitations in accurately positioning and holding tools with respect to work pieces, leading to inefficiencies in operations such as drilling and counterboring.
Innovation Solution
An industrial robot system with an end effector connected to a robot arm, featuring a drive assembly, a controller, and a sensor assembly that includes light sources and a photosensitive array to project and detect light reflections on the work piece, allowing for precise calculation of coordinates and angles to align the drill bit accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional robot positioning methods are used, then the robot structure remains simple, but the positioning accuracy and tool alignment precision are insufficient
Solution Approach 1:
The patent replaces complex mechanical positioning mechanisms with an optical measurement system. A sensor assembly including light sources and photosensitive arrays projects light lines onto the workpiece surface and detects reflection angles to calculate precise tool position and orientation coordinates, substituting mechanical complexity with optical-field measurement methods
Solution Approach 2:
The patent introduces light lines as an intermediary medium between the robot tool and workpiece. By projecting light lines onto the workpiece surface and analyzing their reflection, the system creates an optical intermediary that enables precise measurement of tool position and orientation without direct mechanical contact or complex sensors on the tool itself
2Manufacturing precision
If multiple robot arm movements are used to achieve precise positioning, then positioning accuracy can be improved, but the operation time and productivity decrease
Solution Approach 1:
The patent performs preliminary measurement of the workpiece surface geometry using the optical sensor assembly before the actual machining operation. By calculating the tool center point coordinates and orientation angles in advance through light reflection analysis, the system eliminates the need for multiple iterative robot movements during machining, thereby improving both precision and productivity
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 system enhances the accuracy and speed of tool positioning, reducing the number of robot arm movements and improving the precision of operations like drilling and counterboring by calculating the correct x, y, and z-coordinates and rotational angles based on light reflection data.
Implementation Method 1
The first light source is configured to produce a first fan of light which is projected as a first line of light on the object surface. The second light source is configured to produce a second fan of light, which is projected as a second line of light on the object surface. The photosensitive array is positioned with respect to the first light source and the second light source to detect a first reflection line corresponding to the first line of light and a second reflection line corresponding to the second line of light.
Data Source
AI summary
An industrial robot system includes an end effector connectable to a robot arm, a drive assembly, and a controller. The end effector includes a distal housing, a spindle assembly rotatable about a rotational axis, a drill bit rotatable about the rotational axis, and a sensor assembly. The sensor assembly includes a first light source, a second light source, and a photosensitive array. The first light source produces a first fan of light which is projected as a first line of light on the object surface. The second light source produces a second fan of light, which is projected as a second line of light on the object surface. The photosensitive array detects a first reflection line corresponding to the first line of light and a second reflection line corresponding to the second line of light.