Robot Teaching Workspace Mapping for Low-Volume Automation
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Solution Overview
Problem
Conventional automated robotic manufacturing processes, such as robotic sealing, require extensive preprogramming, which is time-consuming and expensive, making it impractical for high-mix, low-volume parts like those in the aerospace industry.
Innovation Solution
A robot automation system that replicates a teaching workspace in an augmented reality environment, tracks manual simulations, and automatically generates robot instructions based on the tracking data, allowing for the configuration of a robotic assembly to perform automated manufacturing processes without extensive preprogramming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional preprogramming methods are used for robotic manufacturing processes, then automation capability is achieved, but programming time and cost increase significantly
Solution Approach 1:
The system creates a digital copy of the physical workspace by capturing images and generating a three-dimensional virtual model. This virtual model serves as a replica that can be manipulated and programmed independently, eliminating the need for time-consuming conventional preprogramming while maintaining full automation capability
Solution Approach 2:
The patent replaces traditional mechanical programming methods with an image-based virtual modeling system. Instead of manually programming robot movements through complex mechanical interfaces, operators use captured images to construct virtual workspace models, which are then automatically converted into robot control instructions
2Extent of automation
If conventional preprogramming methods are used for robotic manufacturing processes, then automation capability is achieved, but programming cost increases significantly
Solution Approach 1:
By creating a virtual copy of the workspace through image capture and three-dimensional modeling, the system eliminates expensive conventional programming processes. The virtual model can be reused and adapted for different manufacturing tasks without incurring additional programming costs
Solution Approach 2:
The system enables operators to perform their own workspace modeling and robot programming using captured images and automated processing. This self-service capability eliminates the need for expensive specialized programming services while maintaining full automation functionality
3Productivity
If automated robotic processes are implemented for high-mix, low-volume parts, then productivity is improved, but programming complexity increases
Solution Approach 1:
The programming process is segmented into distinct phases: image capture, virtual model construction, path planning, and execution. Each phase handles specific tasks independently, reducing overall programming complexity while enabling automated processes for high-mix, low-volume parts
Solution Approach 2:
The virtual workspace model serves as an intermediary between the physical workspace and the robot control system. This intermediate representation simplifies the programming process by providing a standardized, easily manipulable model that can be adapted to different manufacturing scenarios without increasing complexity
Data Source
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AI summary
A robot automation system facilitates automated robotic manufacturing processes by employing a teaching subsystem including a tracking assembly that tracks movement of the mapping tool in a teaching workspace. A computing device in communication with the tracking assembly and the mapping tool receives tracking data from the tracking assembly and the mapping tool indicating movement of the mapping tool along a working path. Based on the tracking data, the computing device automatically generates robot instructions. A robot controller receives the robot instructions from the computing device and executes the robot instructions whereby the robot controller controls a robot and an end effector to conduct the automated robotic manufacturing process.