Robot Sealant Trajectory Adjustment for CAD-to-Part Seam Variation
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Solution Overview
Problem
Industrial robots face inaccuracies when performing operations on machine-manufactured parts due to discrepancies between their CAD files and actual dimensions or structural properties, leading to errors, delays, and resource wastage.
Innovation Solution
A system that uses sensor input to detect differences between CAD-defined and actual dimensions or structural properties of target objects, allowing for the modification or generation of new trajectories for robots to perform operations accurately, such as applying sealants or welding, by comparing sensor data with CAD file information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robots perform operations based on CAD files, then operational consistency is maintained, but manufacturing variations cause positioning inaccuracies and errors
Solution Approach 1:
The system performs preliminary scanning and detection of the target object's actual dimensions and structural properties before executing the operation. This preliminary action captures manufacturing variations and allows the trajectory to be adjusted in advance, ensuring accurate positioning despite deviations from CAD specifications
Solution Approach 2:
The system uses sensor feedback to detect actual dimensions and structural properties of the target object, compares them with CAD file data, and dynamically adjusts the robot trajectory based on detected deviations. This closed-loop feedback mechanism ensures operational accuracy despite manufacturing variations
2Reliability
If trajectories are modified to accommodate manufacturing variations, then operational accuracy improves, but system complexity increases
Solution Approach 1:
The system integrates multiple functions into a unified trajectory adjustment mechanism that handles various types of manufacturing variations (dimensional deviations, structural property changes, surface irregularities) through a single adaptive framework, reducing overall system complexity despite the diverse nature of corrections needed
3Reliability
If real-time detection and trajectory adjustment is implemented, then error reduction is achieved, but processing time increases
Solution Approach 1:
The system performs detection and trajectory adjustment as preliminary actions before the actual operation begins. By completing the scanning, detection, and trajectory modification in advance, the system minimizes time added to the overall process while ensuring accurate positioning for the subsequent operation
Solution Approach 2:
The detection and trajectory adjustment processes are integrated into the operational workflow in a continuous manner, rather than as separate discrete steps. This allows the system to maintain continuous useful action throughout the process, minimizing idle time and processing delays
Data Source
AI summary
Aspects of the disclosure are directed towards generating a trajectory for use by a robot to perform an operation on a target object. A method includes a robot instructed to traverse a surface of the target object from the starting position and obtain sensor input from a sensor system of the robot using a first trajectory specified by a CAD file for the target object. Sensor input that includes a first height to the target object, a width of the seam, and a depth of the seam may be received. A second trajectory may be generated for traversing the surface of the target object and that modifies the first trajectory based on the sensor input. The robot may be instructed to move to the starting position and traverse the surface of the target object using the second trajectory and apply a sealant to the seam.