Robot Surface Finishing With Force Feedback for Plane Flatness
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Solution Overview
Problem
Existing surface finishing methods for machine tool beds fail to accurately and efficiently remove micro-irregularities and inclinations from precision-processed plane surfaces, leading to suboptimal processing precision and potential operation failures due to lack of lubrication.
Innovation Solution
A surface finishing apparatus equipped with a robot arm, force sensor, visual sensor, and controller that determines and executes precise surface removal positions using a tool with a flat-plate-like distal end, applying surface inspection agents and controlling force application to remove micrometers from the surface, thereby enhancing precision and preventing operation failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot arm with a scraper tool is used for surface finishing, then automation and productivity are improved, but manufacturing precision and surface flatness deteriorate due to inability to accurately remove micro-irregularities
Solution Approach 1:
The patent replaces the conventional mechanical scraper system with a controlled rubbing system using a metal flat surface and surface inspection agent. The force sensor detects microscopic surface variations, and the controller adjusts the rubbing pressure in real-time to achieve precise surface finishing that maintains both automation and manufacturing precision.
Solution Approach 2:
The patent implements a feedback mechanism where the force sensor continuously monitors the force applied during surface rubbing, and the controller adjusts the arm's movement and pressure based on this feedback. This closed-loop control enables the automated system to achieve the precision previously only attainable through skilled manual operation.
2Ease of manufacture
If conventional scraping methods are used, then surface finishing can be performed, but reliability deteriorates due to potential operation failures from insufficient lubrication
Solution Approach 1:
The patent applies surface inspection agent to the plane surface before the rubbing process, allowing the system to pre-identify high portions that need removal. This preliminary preparation ensures that the subsequent rubbing process reliably creates the necessary lubrication grooves, preventing operation failures.
Solution Approach 2:
The system uses the surface inspection agent itself as both the detection medium and the lubrication source. The agent highlights surface irregularities while also serving as the lubricant that will be distributed by the rubbing process, eliminating the need for separate lubrication application steps.
3Manufacturing precision
If multiple removing positions are determined and processed sequentially, then manufacturing precision is improved, but productivity deteriorates due to increased processing time
Solution Approach 1:
The patent divides the surface finishing process into multiple discrete removing positions that are determined in advance through visual sensor imaging and force sensor analysis. By pre-segmenting the work area into specific target locations, the system can efficiently process each position sequentially without unnecessary movements, maintaining precision while optimizing productivity.
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 apparatus effectively reduces surface irregularities and inclinations, ensuring improved processing precision and preventing operation failures by automatically determining and executing precise surface removal positions with controlled force application, even in the absence of a skilled specialist.
Implementation Method 1
a visual sensor 60 that acquires an image of a plane surface S of a metal member P
Implementation Method 2
a force sensor 30 that detects a force applied to a tool 50
Implementation Method 3
a metal flat surface is rubbed against the plane surface, and thereby the surface inspection agent is distributed over the plane surface
Data Source
AI summary
A surface finishing apparatus includes: an arm to which a tool is attached; a force sensor that detects force applied to the tool; a visual sensor acquiring an image of a plane surface; a storage device storing data indicating a target state of the plane surface; and a controller that performs removing position determination process for determining, by using at least unfinished-surface image data and the data indicating the target state, a plurality of removing positions on the plane surface of the member, and arm control process for controlling the arm to sequentially perform surface removal at the plurality of determined removing positions, wherein a surface inspection agent is applied to the plane surface whose image is to be acquired by the visual sensor, and thereby the surface inspection agent is distributed over the plane surface.