Robotic Part Alignment With Measurement-Based Assembly Correction
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Solution Overview
Problem
Existing 3-D printing methods face challenges in accurately aligning and adhering complex geometries due to manufacturing inaccuracies and the expansion or contraction of adhesives during curing, leading to misalignment and faulty connections.
Innovation Solution
A system and method involving robots, measurement instruments, and controllers for precise positioning and adjustment of parts, using digital simulations and quick-cure adhesives to ensure accurate alignment and bonding, with mechanical features for retention and adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If 3-D printing is used to create complex geometries, then design flexibility and geometric complexity are improved, but manufacturing precision deteriorates due to layer-by-layer accumulation errors
Solution Approach 1:
The patent applies preliminary action by defining a reference frame and planning the assembly sequence before actual assembly begins. The system pre-calculates adhesive application positions and robot movement paths, allowing compensation for expected dimensional variations in 3-D printed parts before the assembly process starts.
Solution Approach 2:
The patent implements feedback by using measurement instruments to detect the actual positions of 3-D printed parts during assembly. The system continuously monitors part locations and adjusts robot movements in real-time based on measured deviations, compensating for manufacturing precision errors through active feedback control.
2Productivity
If robots are used for automated assembly, then productivity is improved, but device complexity worsens due to multiple robots and coordination requirements
Solution Approach 1:
The patent applies universality by designing a reference frame system that can be used by multiple different robots for positioning and alignment. The measurement instruments and control system serve multiple functions including part detection, position verification, and real-time adjustment, reducing the need for separate specialized systems for each robot.
3Ease of manufacture
If adhesives are used to bond parts, then ease of manufacture is improved, but reliability deteriorates due to expansion and contraction during curing causing misalignment
Solution Approach 1:
The patent applies preliminary action by pre-positioning parts using robotic manipulation and measurement-based alignment before adhesive application. The system establishes precise initial positions and creates mechanical retention features that maintain alignment during the adhesive curing process, preventing misalignment caused by adhesive expansion and contraction.
Solution Approach 2:
The patent introduces measurement instruments and control systems as intermediaries between the adhesive bonding process and the final assembly quality. These intermediaries monitor and adjust part positions during assembly, compensating for the harmful effects of adhesive curing on alignment accuracy.
Data Source
AI summary
Systems, methods, and computer-readable media for robotic joining of components, parts, and structures are disclosed. A method in accordance with an aspect of the present disclosure comprises determining a target first position and a target second position in a reference frame, controlling robotic arms to move a first part to the target first position and a second part to the target second position, measuring the parts at the target first and second positions to obtain a measured first and second positions, performing a first operation to determine differences between the measured positions and the target positions, and when the differences exceeds desired tolerances, controlling the robotic arms to move the parts to compensate for the differences, and controlling at least the first or second robotic arm to join the first and second parts after the first and second operations are concluded.