Programmable Robot Pattern Transfer for Precise Template-Based Machining
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Solution Overview
Problem
Existing manual and machine-based processes for machining workpieces with precise feature patterns, such as in the aerospace industry, face inefficiencies and inaccuracies due to the need for templates and potential mechanical inaccuracies, leading to delays and mismatches in feature locations.
Innovation Solution
A programmable robot that can switch between measuring and machining configurations, using a probe to determine coordinate data from reference features in a template and then machining a workpiece without the template, ensuring high accuracy and repeatability by utilizing a common datum for precise positioning and pattern transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a template is used to transfer hole patterns to workpieces, then the location accuracy of features is improved, but the manufacturing time and complexity increase due to manual overlay and fixing processes
Solution Approach 1:
The patent replaces the manual mechanical process of overlaying and fixing templates with an automated robotic system. The robot uses a probe to digitally capture coordinate data from reference features on the template, then uses this data to automatically position and machine the workpiece, eliminating the need for manual template handling while maintaining high location accuracy.
Solution Approach 2:
The robot creates a digital copy of the template's hole pattern by probing reference features and storing their coordinate data. This digital replica is then used to guide the machining process, allowing the robot to reproduce the pattern accurately without physically contacting the template during machining, thus eliminating time-consuming template overlay and fixing steps.
2Loss of time
If design drawing data is used to program the machine, then the physical template is eliminated, but inaccuracies in the data may go undetected resulting in mismatched hole locations
Solution Approach 1:
The system incorporates feedback by using the probe to actually measure the reference features on the physical template before machining. This measured coordinate data serves as feedback that captures any variations or tolerances in the template's actual dimensions, ensuring the digital model reflects the true physical template geometry rather than relying solely on theoretical CAD data.
Solution Approach 2:
The robot performs preliminary probing and measurement of the template's reference features before the machining operation. This preliminary action captures the actual coordinate data of the template, creating an accurate digital representation that accounts for any manufacturing tolerances or variations in the physical template, thereby preventing location mismatches during subsequent machining.
3Manufacturing precision
If manual processes are used for high accuracy machining, then the precision is maintained, but the manufacturing efficiency and assembly line speed decrease
Solution Approach 1:
The robotic system is self-programming, using the probe to automatically capture coordinate data from the template and generate the machining path without external programming intervention. This self-service capability allows the system to maintain high precision while operating automatically at high speed, eliminating the need for slow manual processes while achieving the required feature matching accuracy.
Solution Approach 2:
The robot performs multiple functions: it probes to capture template data, processes the coordinate information, and executes machining operations all in one automated system. This multi-functionality consolidates what would otherwise require separate manual operations into a single automated process, maintaining precision while dramatically improving manufacturing efficiency and assembly line speed.
Data Source
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AI summary
A programmable robot 1 is disclosed. The robot is configurable between a measuring configuration, in which a probe 103 is operable, and a machining configuration, in which a tool 105 is operable. The robot comprises: a carrier 3 for carrying the probe and the tool; a position sensing arrangement 5 for determining coordinate data; and a controller 7. The controller is configured to cause the carrier, in the measuring configuration, to move the probe to each of a plurality of reference features 107 in a template 109 held in a first orientation by a jig 111, wherein feedback via the probe enables the position sensing arrangement to determine coordinate data associated with the reference features. The controller is configured to, on the basis of the determined data, cause the carrier, in the machining configuration, to return to each position corresponding to each reference feature location and machine a workpiece held in the first orientation.