Multi-Axis Robot End Effector Positioning Against Tool Slippage

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Solution Overview

Problem

Multi-axis robots experience tool slippage or skidding during machining operations due to imbalanced force distribution, leading to imperfections or damage on workpieces.

Innovation Solution

A method and device for controlling the position of a multi-axis robot's end effector using three strain sensors to detect stress imbalances, with automatic controls in multiple directions to maintain balanced force distribution and prevent slippage, employing a control device connected to actuators and optical laser transceivers for precise positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multi-axis robot performs machining operations with high speed and precision, then productivity and manufacturing precision are improved, but tool slippage and workpiece damage occur due to imbalanced force distribution

Engineering Contradiction:

Improvemachining rateVSAvoidtool stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a feedback control system using three strain sensors mounted on the end effector to continuously monitor force distribution during machining operations. The control device receives sensor signals, processes the force distribution data, and automatically adjusts robot positioning to maintain balanced forces, preventing tool slippage while preserving high-speed machining capability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual operator control with an automated control system that uses electronic signal processing to manage force distribution. The control device substitutes human judgment with algorithmic processing of strain sensor data, enabling real-time adjustments to prevent slippage without sacrificing productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If clamping force is increased to prevent tool slippage, then tool stability is improved, but risk of workpiece damage increases

Engineering Contradiction:

Improvetool stabilityVSAvoidworkpiece damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent dynamically adjusts the clamping force parameter based on real-time strain sensor feedback rather than maintaining a fixed high force. The control device modulates the robotic end effector's positioning to optimize force distribution, achieving adequate tool stability while preventing excessive force that could damage the workpiece

Inventive Principle:

Principle #35Parameter changes

3Reliability

If strain sensors and automatic control system are added to detect and correct force imbalances, then tool stability is improved, but device complexity increases

Engineering Contradiction:

Improveforce distribution controlVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the force monitoring function into three separate strain sensors mounted on the end effector, each measuring force in a specific direction. This segmentation allows the control device to process independent sensor signals and adjust positioning along corresponding axes, managing system complexity through functional decomposition

Inventive Principle:

Principle #1Segmentation

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 method effectively reduces the risk of tool slippage by maintaining balanced stress distribution, ensuring precise and reliable machining operations on aeronautical equipment.

Implementation Method 1

at least three strain sensors configured to deliver pieces of information representative of stresses exerted on the end effector in the first direction

Methodology Applied

Scientific EffectStrain measurement: Deformation

Implementation Method 2

at least three optical laser transceiver modules, each configured to measure a distance

Methodology Applied

Scientific EffectOptical measurement: LIDAR

Data Source

PatentUS20250205903A1Method for controlling the position of an end effector of a multi-axis robot and system executing the method

Publication Date: 2025.06.26 AIRBUS OPERATIONS (SAS)

AI summary

A method for controlling the position of an end effector of a multi-axis robot, in particular used to drill aeronautical-equipment parts in a first direction. The method regulates the clamping force of the tool against a workpiece in the first direction while automatically controlling the position of the end effector in two other directions that are perpendicular to each other and each perpendicular to the first direction, based on pieces of information representative of forces oriented in the first direction and obtained from three separate sensors. A control device is configured to execute the method for positioning the end effector. Reducing or preventing slippage of a tool over a workpiece improves the quality of machining operations carried out by the tool-bearing end effector.