Robot Grinding Tool Velocity Control for Precision
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Solution Overview
Problem
Robot-supported abrasive machining processes, such as grinding and sanding, struggle to maintain high precision and adapt to dynamic changes in contact pressure and tool velocity, requiring significant manual labor for adjustment and monitoring.
Innovation Solution
A robot-supported grinding method where a grinding tool or workpiece is mechanically coupled to a manipulator's tool-center-point, with an actuator controlling the grinding force and adjusting the rotational velocity of the grinding tool based on measured deflections to maintain consistent circumferential velocity, even as the tool wears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot-supported grinding process is used, then productivity is improved, but manufacturing precision deteriorates due to inability to recognize and compensate dynamic changes in contact pressure and tool velocity
Solution Approach 1:
The patent implements a feedback control system where a sensor measures the actual circumferential velocity of the grinding tool during the robot-supported grinding process. The measured velocity is compared with the reference velocity, and the controller adjusts the grinding tool's rotational speed in real-time to compensate for wear and dynamic changes, maintaining manufacturing precision while preserving productivity benefits
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses electronic sensors and controllers to monitor and adjust grinding parameters. This substitution enables the robot-supported system to automatically compensate for dynamic changes, resolving the precision issue while maintaining high productivity
2Manufacturing precision
If manual adjustment and monitoring is used, then manufacturing precision is maintained, but device complexity increases due to deployment of personnel for adjusting and monitoring tasks
Solution Approach 1:
The patent implements a self-service control system where the grinding apparatus automatically monitors its own performance through integrated sensors and adjusts its operating parameters without external intervention. The controller continuously measures actual circumferential velocity and autonomously compensates for tool wear, eliminating the need for manual adjustment and monitoring personnel
3Duration of action of moving object
If the grinding tool wears during operation, then duration of action is extended, but manufacturing precision deteriorates due to reduction in circumferential velocity
Solution Approach 1:
The patent implements a dynamic adjustment system that continuously adapts the grinding tool's rotational velocity based on its wear state. As the tool wears and radius decreases, the controller automatically increases rotational speed to maintain constant circumferential velocity, allowing the tool to remain effective throughout its entire service life without precision degradation
Solution Approach 2:
The patent changes the rotational velocity parameter in response to tool wear. The controller measures the actual circumferential velocity and adjusts the rotational speed parameter dynamically to compensate for reduced tool radius, maintaining manufacturing precision throughout the extended service life of the grinding tool
Data Source
AI summary
A robot-supported grinding method is described. In accordance with one example of the invention, the grinding method includes contacting a surface of a workpiece with a rotating grinding tool, whereby either the grinding tool or the workpiece is mechanically coupled to the tool center point (TCP) of a manipulator. The method further includes controlling an actuator that influences the grinding tool or the workpiece to produce a grinding force between the grinding tool and the workpiece, as well as measuring an actual deflection of the actuator. The rotational velocity of the grinding tool is adjusted depending on the measured actual deflection of the actuator and a reference deflection of the actuator.