Robot Tool Control via 3D Optical Scanning for Aircraft Component Precision
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Solution Overview
Problem
Conventional robotic systems face challenges in precision and automation when handling large components, particularly those with diameters over 2 meters, due to inaccuracies in positioning and material application, which complicates operations like filling grooves or sealing, and lacks real-time quality control in aviation, architecture, and shipbuilding.
Innovation Solution
A method utilizing an optical 3D measuring system to create a virtual image of the component's surface area, converting point coordinates into a robot coordinate system for precise tool control, enabling automatic and precise robotic operations without manual alignment, and allowing real-time monitoring and regulation of operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automatic control methods are used for large components (diameter > 2 meters), then the robot can be positioned approximately using automated indoor positioning, but positioning accuracy deteriorates and requires time-consuming manual measurement and masking processes
Solution Approach 1:
The patent creates a virtual copy of the large component using an optical 3D measuring system, which captures the actual geometry and position of the component. This virtual model serves as a digital replica that can be processed computationally to determine precise robot tool path coordinates, eliminating the need for physical measurement and masking while maintaining high positioning accuracy.
Solution Approach 2:
The patent replaces the mechanical positioning and measurement system (manual measurement devices, physical masking) with an optical measurement system and computational processing. The optical 3D measuring system captures component geometry optically, and software algorithms convert this data into precise robot control coordinates, substituting mechanical processes with optical and computational ones.
2Measurement precision
If manual measurement and positioning methods are used for each component variant, then positioning accuracy can be maintained, but the process becomes extremely time-consuming
Solution Approach 1:
The patent performs preliminary action by creating the virtual image of the component before the robot operation begins. The optical 3D measuring system captures the component geometry in advance, and the control system pre-calculates the tool path coordinates based on this virtual model. This preliminary data preparation enables the robot to execute operations immediately with high precision without requiring time-consuming measurements during the actual operation.
Solution Approach 2:
By creating a virtual copy of the component, the system eliminates the need for repeated physical measurements for each component variant. Once the virtual model is created, it can be used repeatedly for multiple operations and component variants, significantly reducing the time required for positioning while maintaining accuracy.
3Reliability
If masking material is applied to prevent contamination from imprecise positioning, then quality can be maintained, but the process complexity and time increase due to masking and removal operations
Solution Approach 1:
The patent replaces the mechanical masking process with a computational solution. Instead of physically masking areas to prevent contamination, the system uses the virtual 3D model to precisely calculate and control the robot's tool path, ensuring accurate material application without the need for masking materials or the complex processes of applying and removing masks.
4Manufacturing precision
If the robot is adapted to different processing speeds and precise positioning requirements, then operation quality improves, but the system complexity and setup time increase
Solution Approach 1:
The patent implements dynamics by enabling the robot system to adapt to different processing speeds and positioning requirements through software control rather than physical reconfiguration. The control system can dynamically adjust the robot's movement speed, acceleration, and positioning precision based on the specific operation requirements and the geometry of the component, all controlled through software parameters rather than mechanical 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
Enables precise and automatic robotic operations on large components without the need for manual alignment, reducing inaccuracies and improving material application, and allows for real-time quality control, enhancing the efficiency and accuracy of operations.
Implementation Method 1
creating at least one virtual image... using an optical 3D measuring system; the at least one virtual image captures a surface area of an aircraft component
Data Source
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AI summary
A method according to the invention serves to control an operation of a robot (10). It comprises creating at least one virtual image with an optical 3D measuring system (20) and with respect to a 3D measuring coordinate system (23), wherein the at least one virtual image captures a surface area of a component (30). The method further comprises converting a plurality of point coordinates of the virtual image into point coordinates with respect to a robot coordinate system (13) using a transformation rule and controlling a tool element (11) of the robot (10) based on the point coordinates with respect to the robot coordinate system to perform the operation. A system according to the invention is configured to carry out a method according to the invention.