Robot Assembly TCP Stability via Matched Intermediate Flange
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Solution Overview
Problem
The existing methods for replacing application devices on painting robots are time-consuming and complex, leading to inconsistent painting results due to changes in the tool center point's path when switching between different types of atomizers, and the need for lengthy intermediate flanges that can't accommodate all necessary connections without shifting the tool center point.
Innovation Solution
Adapting the intermediate flange and application device pairs to match the required connection configurations and overall lengths, using additive manufacturing to create a hose-free, tubeless intermediate flange that maintains a constant total length and adjusts lateral offsets, ensuring the tool center point remains on the programmed path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual supply lines are detached at separation points behind the mounting flange to replace application devices, then application devices can be replaced, but the replacement process becomes extremely time-consuming and complex
Solution Approach 1:
The system is segmented into modular components: a standardized robot flange with all possible connections, interchangeable intermediate flanges with specific connection configurations, and application devices. This segmentation allows the application device and intermediate flange to be replaced as a pre-assembled unit, eliminating the need to disconnect individual supply lines during replacement.
Solution Approach 2:
The intermediate flange is pre-configured with the specific connection configuration required for a particular application device type before the device is installed on the robot. This preliminary preparation of the flange-device assembly enables quick replacement without on-site connection work.
2Adaptability or versatility
If the intermediate flange is made longer to accommodate all necessary connections, then all supply lines can be connected, but the tool center point position shifts and painting results become inconsistent
Solution Approach 1:
Each intermediate flange is designed with local quality - a specific connection configuration tailored to the requirements of a particular application device type. This allows the flange to provide exactly the needed connections without requiring excessive length, maintaining the tool center point position within acceptable tolerances.
Solution Approach 2:
The robot flange serves as a universal interface with all possible connections available. Different intermediate flanges with specific connection configurations can be interchangeably mounted on this universal robot flange, allowing the system to adapt to different application device requirements while maintaining consistent tool center point positioning.
3Adaptability or versatility
If different types of atomizers are installed to test different application devices, then device performance can be evaluated, but the tool center point path changes leading to non-comparable painting results
Solution Approach 1:
Different intermediate flanges have asymmetric, device-specific connection configurations that precisely match their corresponding application devices. This asymmetric design allows each flange-device pair to be optimized for its specific function while maintaining a standardized interface with the robot flange, ensuring consistent tool center point positioning across different device types.
Solution Approach 2:
The intermediate flange acts as an intermediary component between the universal robot flange and the specific application device. It mediates the connection requirements of different device types while maintaining a consistent interface with the robot controller, ensuring that the tool center point path remains unchanged when switching between different application devices.
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3A~3D
AI summary
The invention relates to a robot assembly having an exchangeable application device (1), which application device is connected and exchangeable by means of an intermediate flange (4). According to the invention, the construction lengths (LZ, LF) of the application device (1) and of the intermediate flange (4) are matched to each other as a pair such that an exchange of the application device (1) together with the associated and individually matched intermediate flange (4) does not lead to a shift of the tool center point (TCP).