Robotic Assembly Feedback Control for Error Accrual Mitigation
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Solution Overview
Problem
Robotic systems face challenges in producing physical structures due to variations and errors introduced during the production process, which can deviate from the intended design, and existing methods lack sufficient flexibility to accommodate these issues effectively.
Innovation Solution
A robotic system equipped with sensors and a control system that monitors each step of the production process, takes measurements, and dynamically adjusts parameters to mitigate variations and errors, ensuring the final structure aligns with the designer's intent by modifying production process parameters within defined constraints and weightings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a robotic system follows strict specifications from a model to produce a physical structure, then manufacturing precision is improved, but the system cannot accommodate variations and errors introduced during the production process
Solution Approach 1:
The robotic system dynamically adjusts production parameters in real-time based on sensor measurements. The control system modifies end-effector positions, orientations, and operational parameters during the production process to accommodate variations while maintaining manufacturing precision. This dynamic adaptation allows the system to respond to actual physical conditions rather than rigidly following pre-defined specifications.
Solution Approach 2:
The system employs sensors to continuously measure the physical structure being produced and feeds this information back to the control system. The control system compares measurements against specifications, identifies variations and errors, and automatically adjusts production parameters to compensate. This closed-loop feedback mechanism enables the system to maintain precision while adapting to real-world variations.
2Adaptability or versatility
If the robotic system dynamically adjusts production parameters to accommodate variations, then adaptability is improved, but manufacturing precision may deteriorate due to deviations from the original design specifications
Solution Approach 1:
The control system continuously monitors production through sensor measurements and automatically adjusts parameters to maintain precision. By comparing real-time measurements against design specifications and implementing corrective adjustments, the system ensures that adaptability does not compromise manufacturing precision. The feedback loop maintains conformity to specifications even when dynamic adjustments are necessary.
Solution Approach 2:
The system modifies production parameters such as end-effector position, orientation, speed, and tool path deviations to accommodate physical variations. These parameter changes are calculated to preserve the intent of the design while adapting to actual conditions. The control system determines optimal parameter adjustments that maintain manufacturing precision within acceptable tolerances.
3Reliability
If the robotic system monitors each step and makes real-time adjustments, then reliability is improved, but device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The robotic system uses multi-functional sensors and control components that serve multiple purposes. For example, sensors not only measure position and orientation but also detect variations and guide compensation adjustments. The control system integrates monitoring, analysis, and adjustment functions in a unified architecture, reducing the need for separate dedicated components for each function and thereby managing complexity while enhancing reliability.
Solution Approach 2:
The robotic system autonomously monitors its own production process and self-corrects variations without external intervention. The control system automatically analyzes sensor data, identifies deviations, and adjusts production parameters to maintain reliability. This self-service capability reduces the need for complex external monitoring and control infrastructure.
4Measurement precision
If the system uses sensors to take measurements after each step, then measurement precision is improved, but productivity decreases due to additional monitoring and adjustment time
Solution Approach 1:
The measurement and adjustment processes are integrated into the continuous production flow without interrupting the robotic system's operation. Sensors take measurements during or immediately after each production step, and adjustments are made in real-time while production continues. This continuous action approach maintains measurement precision while minimizing productivity loss by eliminating idle time between measurement and correction.
Solution Approach 2:
The system performs preliminary measurements and predictions of required adjustments before completing each production step. By anticipating necessary corrections in advance, the system can prepare adjustment parameters ahead of time, reducing the actual adjustment time and maintaining production speed. This preliminary action ensures measurement precision is achieved without significant productivity penalty.
Data Source
AI summary
A robotic system includes end-effector(s) that combine a plurality of objects in a production process. The system includes sensor(s) that obtain measurement(s) relating to a combination of a first object and one or more other objects during the production process. The system includes a control system communicatively coupled to the sensor(s). The control system stores specifications relating to the combination of the plurality of objects. The control system receives the measurement(s) from the sensor(s), determines a difference based on the measurement(s) and the specifications, determines adjustment(s) to the production process based on the determined difference, and sends, for the end-effector(s), instruction(s) based on the specifications and the one or more adjustment(s). The end-effector(s) combine a second object with the first object and the one or more objects based on the specifications and the one or more adjustment(s).