Robot File Translation for Window Frame Weld Flash Cleaning
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Solution Overview
Problem
Existing window frame and sash cleaning systems face challenges in consistently removing weld flash due to variances in profile dimensions and misalignment during the welding process, leading to inconsistent removal of weld flash and potential damage to the frame or machinery.
Innovation Solution
A file translator system integrated with an articulating robotic arm that allows for flexible tool utilization and product recognition, enabling operators with minimal training to edit tool paths and recover tool positions, ensuring precise cleaning operations while minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cleaning machines are used to remove weld flash, then cleaning operations can be performed, but consistency of weld flash removal is poor due to profile dimension variances and misalignment
Solution Approach 1:
The system employs dynamic adjustment mechanisms that allow the cleaning tools to adapt their position and orientation in real-time based on detected profile variations. The articulating arm can dynamically reposition tools to compensate for misalignment, ensuring consistent weld flash removal across varying profile dimensions.
Solution Approach 2:
The system changes operational parameters such as tool position, angle, and movement trajectory based on detected profile characteristics. By adjusting these parameters dynamically, the system maintains consistent cleaning performance despite variations in frame profile dimensions and welding alignment.
2Adaptability or versatility
If operators need to edit tool paths and recover tool positions, then flexibility in customization is improved, but operator training requirements and system complexity increase
Solution Approach 1:
The system incorporates automatic tool path recovery functionality that allows the articulating arm to autonomously recalculate and restore optimal cleaning paths after interruptions. This self-service capability reduces the burden on operators, as the system handles complex path reconstruction without requiring deep programming knowledge.
Solution Approach 2:
The system introduces an intermediary software layer that simplifies the interface between operators and the complex robotic control system. This intermediary provides user-friendly tools for editing and recovering tool paths, shielding operators from underlying system complexity while maintaining flexibility.
3Manufacturing precision
If precise cleaning operations are implemented, then weld flash removal quality is improved, but risk of damaging frame or machinery increases
Solution Approach 1:
The system implements protective measures in advance by using sensors to detect frame characteristics and potential vulnerability points before cleaning operations begin. The articulating arm is programmed with cushioning protocols that reduce tool engagement forces and allow for gentle, controlled contact, preventing damage while maintaining cleaning precision.
Solution Approach 2:
The system continuously monitors cleaning operations through feedback from sensors that detect tool contact forces, position accuracy, and frame response. This real-time feedback allows the control system to adjust operational parameters dynamically, maintaining precise cleaning while preventing excessive forces that could cause damage.
Data Source
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AI summary
A disclosed robot system enables an operator of an articulating arm used in fabricating window or door frames to recover the position of the tools during the cleaning process with minimal knowledge or training on a robot. The disclosed robot system also gives the operator the ability to edit a tool cleaning path with simple commands from an operator interface (e.g., HMI) to bring flexibility in customizing the use of the articulating arm.