Industrial Robot Passive Centering Elastic Component Insertion
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Solution Overview
Problem
Existing methods for installing components into workpieces, especially those with elastic properties, face challenges in precise positioning and efficient insertion due to unknown component tolerances and the need for complex sensor systems and programming, leading to increased cycle times.
Innovation Solution
A method utilizing an industrial robot with an end effector that increases process forces until a threshold is reached, then switches to impedance control to perform a passive centering movement, leveraging the component's or robot's elasticity to align the component without active joint movement, thus eliminating the need for precise positioning sensors and complex programming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex sensor systems and programming are used to achieve precise positioning, then manufacturing precision is improved, but device complexity and cycle time increase
Solution Approach 1:
The elastic component itself performs the centering function through its own elastic properties. When the component is inserted into the opening, its elasticity causes it to deform and then return to its original shape, passively centering itself within the opening without requiring external sensors or complex control systems. The component serves its own positioning needs through its material properties.
Solution Approach 2:
The invention changes the stiffness parameter of the robotic system dynamically. The robot operates in a compliant mode with reduced stiffness during the insertion phase, allowing the elastic component to perform passive centering. This parameter change eliminates the need for complex positioning sensors while maintaining precision through controlled flexibility.
2Manufacturing precision
If complex sensor systems and programming are used to achieve precise positioning, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The elastic component autonomously performs the centering operation through its elastic deformation and recovery. This self-centering mechanism eliminates the need for time-consuming sensor-based detection and complex control programming, significantly reducing cycle time while maintaining precise positioning.
Solution Approach 2:
The invention replaces complex sensor-based active control systems with a passive elastic mechanical system. The elastic component's natural deformation and recovery behavior substitutes for electronic sensors and complex control algorithms, achieving both precision and speed.
3Measurement precision
If the industrial robot maintains high stiffness during insertion, then positioning accuracy is improved, but the component cannot self-center and insertion fails
Solution Approach 1:
The robotic system dynamically adjusts its stiffness parameter during the insertion process. Initially, the robot operates with reduced stiffness to allow the elastic component to deform and passively center itself within the opening. Once centered, the robot can then apply sufficient force for successful insertion. This dynamic stiffness adjustment resolves the contradiction between maintaining positioning accuracy and enabling self-centering.
Solution Approach 2:
The invention changes the stiffness parameter of the robot controller during the insertion process. The system transitions from a compliant state that enables passive centering to a stiffer state that provides positioning accuracy and insertion force. This parameter change allows the system to achieve both self-centering capability and positioning precision at different stages of the operation.
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
This approach reduces cycle time by utilizing the component's or robot's elasticity to achieve precise alignment and insertion, minimizing search time and energy losses, and is applicable to various shapes and materials, including rubber and metal components.
Implementation Method 1
increasing process forces by means of the industrial robot after the insertion section of the component has come into contact with the workpiece until a process force threshold is reached, the process forces being stored in particular in the form of material stresses
Implementation Method 2
Execution of a passive centering movement of the industrial robot due to the process forces released by a relaxation of the material
Data Source
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AI summary
The invention relates to a method for mounting a component (6), which has an insertion portion (9) and a holding portion (7), in an opening (10) of a workpiece (11) by means of an industrial robot (1), which has an end effector (3), which guides the component (6) on the holding portion (7). The method according to the invention takes place by (S1) making the insertion portion (9) of the component (6) approach the opening (10) by moving the industrial robot (1); (S2) increasing process forces by means of the industrial robot (1) after the insertion portion (9) of the component (6) has made contact with the workpiece (11), until a process force threshold (P) is reached, wherein the process forces are stored in particular in the form of material stresses; (S3) increasing the elasticity of the industrial robot (1) when the process force threshold (P) is reached; and (S4) performing a passive centring movement of the industrial robot (1) on the basis of the process forces released by an expansion of the material.