Robot Spray Teaching by Force-Sensed Hand Guidance
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Solution Overview
Problem
Current teaching techniques for robotic devices used in ceramic enamelling, such as point-to-point programming and off-line programming, are laborious, complex, and inefficient for small and medium-sized batches, requiring significant operator effort and robot usage, which can lead to production downtime and physical strain.
Innovation Solution
A method and plant that utilize a robotic arm with a sensor to detect forces and torques applied by the operator, allowing for intuitive and efficient programming through a control system that adjusts the robotic arm's movements and spraying head operations, enabling precise and repeatable surface treatment without the need for extensive robot programming knowledge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If point-to-point programming is used to program the robot, then the robot can be taught to perform surface treatment movements, but the programming process becomes laborious and requires significant operator effort and time
Solution Approach 1:
The patent replaces manual mechanical programming operations with an automated optical system. A camera captures images of the workpiece, and image processing algorithms automatically generate robot movement paths, substituting the mechanical process of manually moving and programming the robot with an automated visual recognition and path generation system.
Solution Approach 2:
The system enables the robot to program itself by automatically generating movement paths from captured images. The robot observes the workpiece through the camera, processes the visual information, and autonomously determines the spraying paths without requiring external operator intervention for path planning.
2Ease of operation
If off-line programming is used to plan robot actions, then programming can be done remotely using a programming language, but the process becomes complex and laborious
Solution Approach 1:
The patent replaces complex programming language operations with intuitive image-based programming. Instead of requiring operators to write and debug programming code, the system uses camera images to automatically generate movement paths, replacing the complex software programming process with simplified visual programming.
Solution Approach 2:
The patent introduces image processing as an intermediary between the operator and the robot control system. The camera and image processing algorithms serve as a mediator that translates visual information into robot movement commands, eliminating the need for direct programming language interaction.
3Ease of operation
If self-learning programming is used with a robot provided with balancing systems, then the programming becomes simpler and more intuitive, but the robot becomes complex and costly to produce
Solution Approach 1:
The patent extracts the balancing function from the robot's mechanical structure and relocates it to the control system through software algorithms. The control system compensates for gravity and inertia effects computationally, eliminating the need for complex mechanical balancing systems while maintaining programming simplicity.
Solution Approach 2:
The patent replaces mechanical balancing systems with computational methods in the control system. Instead of using physical counterweights and mechanical compensators, the system uses software algorithms to calculate and compensate for gravitational and inertial forces, reducing mechanical complexity.
4Productivity
If the operator moves the robot to each point of the path and saves its position, then the robot can be programmed to replicate movements, but the operator sustains significant physical effort
Solution Approach 1:
The patent replaces manual physical manipulation of the robot with automated image-based path generation. The camera captures the workpiece geometry, and processing algorithms automatically determine the robot's movement path, eliminating the need for the operator to physically move and position the robot at each point.
Solution Approach 2:
The system enables automatic path generation from captured images, allowing the programming process to serve itself without continuous operator intervention. The image processing system autonomously determines movement paths based on the visual information, reducing the operator's physical involvement to initiating the process.
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 simplifies the programming process, reduces operator effort, and enhances precision and repeatability, making it suitable for small and medium-sized batches while minimizing production downtime and physical strain on the operator.
Implementation Method 1
a sensor (10), connected to said handling device (9), and designed to detect the force and torque (Fs) applied to said handling device (9)
Data Source
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AI summary
A method for the surface treatment of an article (2) by means of a robotic device (3) comprising a robotic arm (5) and a spraying head (4) fitted on the robotic arm (5); the method comprises a learning step, during which the operator moves the spraying head (4) by means of a handling device (9) and the movements made by the spraying head (4) are stored by a storage unit (8); and a reproduction step, which is subsequent to the learning step and during which the robotic arm (5) is operated so that the spraying head (4) repeats the movements stored by the storage unit (8).