Robot Suction Tool Control for Wrinkle-Free Sticker Affixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sticker affixing systems often result in warpage or wrinkling of stickers due to non-uniform force application during the peeling and affixing process, particularly when dealing with non-flat surfaces.
Innovation Solution
A sticker affixing system that uses an articulated robot with a suction tool equipped with multiple holes for uniform suction, combined with a controller that adjusts the posture and traveling direction of the suction tool based on force sensors and position information to maintain consistent force application, ensuring the sticker is peeled and affixed without wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a suction tool is used to peel off the sticker from the release paper, then the sticker can be affixed to the object, but wrinkles or warpage may be generated in the sticker during the process
Solution Approach 1:
The suction tool is divided into multiple suction holes (e.g., 9 holes arranged in a 3x3 grid) instead of a single suction point. This segmentation distributes the suction force across multiple contact points with the sticker, preventing localized deformation and wrinkles while maintaining effective peeling and affixing capability
Solution Approach 2:
The suction forces are made non-uniform across different holes, with stronger suction applied at the leading edge of the suction tool and weaker suction at the trailing edge. This local differentiation in suction intensity matches the stress distribution during sticker affixing, preventing wrinkles while ensuring proper adhesion
2Speed
If the suction tool applies strong force to peel the sticker, then the peeling speed increases, but the sticker may deform or wrinkle
Solution Approach 1:
Multiple suction holes distribute the peeling force across many small contact points rather than one large force concentration, enabling faster peeling speeds without causing localized sticker deformation or wrinkles
Solution Approach 2:
The suction forces are dynamically adjusted with stronger suction at the leading edge (where peeling initiates) and weaker suction at the trailing edge (where peeling completes). This dynamic force distribution maintains high peeling speed while preventing wrinkles through appropriate force gradient
3Device complexity
If the suction tool is held at a fixed posture, then the control system is simple, but uniform force cannot be applied to stickers on non-flat surfaces
Solution Approach 1:
Force sensors mounted on the suction tool provide real-time feedback about the forces applied to the sticker. The control system uses this feedback to dynamically adjust the suction forces and tool posture, ensuring uniform force application across the sticker surface even on non-flat objects while maintaining manageable system complexity
4Device complexity
If the suction tool travels in a straight line, then the path is simple to control, but the traveling direction may not be perpendicular to the object surface on non-flat objects
Solution Approach 1:
Force sensors provide feedback about the contact forces between the suction tool and the object surface. The control system processes this feedback to dynamically adjust the tool's traveling direction, ensuring the tool moves perpendicular to the local surface orientation even on complex non-flat objects, while maintaining straightforward path control through continuous small adjustments
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
The system effectively prevents sticker wrinkling by maintaining uniform force application, allowing for smooth peeling and affixing even on complex surfaces, including corners and non-flat objects.
Implementation Method 1
a suction tool equipped with multiple holes for uniform suction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Generation of a wrinkle is prevented when a sticker (150) is affixed to an object (130). A sticker affixing system (10) includes an articulated robot (100), a controller (200) configured to control the articulated robot (100), a suction tool (110) attached to a distal end of the articulated robot (100), and a force sensor (201) configured to detect force applied to the suction tool (110). The controller (200) causes the articulated robot (100) to execute: an operation of moving the suction tool (110) holding a sticker (150) along a surface of an object (130) to which the sticker (150) is afssfixed; and an operation of adjusting an inclination of the suction tool (110) with respect to a traveling direction (roll axis) of the suction tool (110) and the traveling direction of the suction tool (110) based on a signal from the force sensor (201).