Robot Nozzle Tip Alignment Using a Collinear Fixture Check
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Solution Overview
Problem
Conventional methods for troubleshooting nozzle tip alignment on robotic arms are time-consuming and inefficient, leading to application errors and costly downtime due to bent or damaged nozzle tips, with operators unable to accurately determine the direction or extent of misalignment.
Innovation Solution
A system and method to align a nozzle tip on a robotic arm by positioning it adjacent to an alignment fixture, verifying collinearity of the nozzle tip's axis with the alignment fixture's axis, and adjusting or replacing the nozzle tip if misaligned, ensuring alignment in six degrees of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operators use conventional troubleshooting methods to check nozzle tip alignment, then they can identify that the nozzle tip is bent, but the process is time-consuming and operators cannot determine the direction or extent of misalignment, leading to guesswork in recalibration
Solution Approach 1:
A laser alignment tool is introduced as an intermediary device between the nozzle tip and the operator's visual inspection. The laser tool provides a visible reference line that directly indicates misalignment, eliminating the need for operators to guess the direction or extent of bending. This intermediary tool transforms subjective visual assessment into objective, quantifiable alignment data.
Solution Approach 2:
The manual visual inspection method is replaced with an optical measurement system (laser alignment tool). Instead of relying on operators' eyes and judgment, the system uses laser physics to provide precise alignment indicators. This substitution transforms a qualitative, time-consuming process into a quantitative, rapid measurement process.
2Manufacturing precision
If operators manually recalibrate bent nozzle tips without precise alignment tools, then they can attempt to fix the alignment issue, but the lack of accurate measurement leads to mistakes and non-uniformity between calibrations
Solution Approach 1:
The laser alignment tool provides real-time feedback during the calibration process. As operators adjust the nozzle tip, the laser indicator immediately shows whether the alignment is improving or worsening, and by how much. This continuous feedback loop enables operators to make precise adjustments and verify results, ensuring consistent and accurate calibration across different nozzle tips and operators.
Solution Approach 2:
The system changes the measurement parameter from subjective visual assessment to objective laser-based alignment measurement. By using the laser's precise optical reference, the calibration process transitions from approximate adjustments to precise, quantifiable alignment corrections, ensuring uniformity across all calibrations.
3Measurement precision
If operators perform detailed alignment checks and recalibration procedures, then calibration accuracy may improve, but the process becomes time-consuming with average downtime increasing from 1 minute to 20 minutes
Solution Approach 1:
The laser alignment tool enables preliminary detection of alignment issues before they become critical problems. By quickly identifying misalignment during routine checks, operators can perform minor adjustments on-the-spot rather than waiting for complete calibration cycles. This preliminary action prevents small alignment drifts from developing into major issues requiring extensive recalibration.
Solution Approach 2:
The laser alignment tool allows operators to rapidly assess alignment status and skip unnecessary calibration steps. When the laser indicates proper alignment, operators can immediately proceed to production without performing full calibration procedures. This ability to skip redundant steps maintains high measurement precision while minimizing downtime and maximizing productivity.
Data Source
AI summary
A nozzle tip on a vehicle manufacturing robot remains on the robot while being checked for alignment. A robotic arm is moved to a pre-programmed alignment position such that the nozzle tip is adjacent to an alignment fixture secured to a stationary member. Then, a determination is made as to whether the nozzle tip is aligned with the alignment fixture such that an axis of the nozzle tip is collinear with an axis of the alignment fixture.