Robotic Expansion Board Insertion With Force-Controlled Tilting
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Solution Overview
Problem
Existing methods for inserting electronic plug-in cards into plug-in couplings lack automation and reliability, often requiring high force and energy, which can lead to material stress and inefficiency.
Innovation Solution
A device and method utilizing a robotic manipulator with impedance- or admittance-controlled tilting movements, guided by a control program, to insert the plug-in card into the coupling, reducing the force required and ensuring precise alignment and contact within predefined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual alignment and insertion methods are used, then the process is simple in structure, but automation and reliability are lacking
Solution Approach 1:
The patent replaces manual mechanical alignment and insertion operations with an automated robotic manipulator system. The robot manipulator, controlled by a control unit executing a control program, performs the plugging operation automatically, eliminating the need for manual intervention while maintaining precision through controlled tilting movements.
Solution Approach 2:
The system incorporates self-alignment capabilities where the robotic manipulator autonomously positions and orients the plug-in card using sensor feedback and control algorithms. The impedance-controlled tilting mechanism automatically adjusts insertion forces and angles, enabling the system to self-regulate during the plugging process without external intervention.
2Reliability
If high force is applied during insertion, then the plug-in connection is secured, but material stress increases and energy consumption rises
Solution Approach 1:
The patent employs dynamic insertion techniques where the robotic manipulator performs controlled tilting movements with varying angles and velocities. The impedance control adjusts insertion forces in real-time based on encountered resistance, applying maximum force only when necessary to overcome insertion barriers while using minimal force during alignment and final seating, thereby reducing overall energy consumption.
Solution Approach 2:
The insertion process utilizes periodic tilting movements where the manipulator oscillates the plug-in card between tilted and horizontal positions. This periodic action helps the card progressively settle into the slot through controlled micro-adjustments, reducing the need for sustained high-force application and lowering energy consumption while ensuring reliable connection.
3Reliability
If high force is applied during insertion, then the plug-in connection is secured, but material stress on plug-in card and coupling increases
Solution Approach 1:
The impedance-controlled robotic manipulator dynamically adjusts insertion forces based on real-time feedback from force sensors and position encoders. The system applies gentle forces during alignment phases and gradually increases force only when necessary to overcome mechanical interference, thereby securing the connection while minimizing stress on the plug-in card and coupling components.
Solution Approach 2:
The control program incorporates pre-calculated force limits and compliance parameters that cushion the insertion process against excessive forces. The impedance control acts as a mechanical cushion, absorbing shock and preventing force spikes that could damage components, while still ensuring adequate insertion force is applied to secure the connection reliably.
4Manufacturing precision
If conventional insertion methods are used, then the process is fast, but precision and alignment accuracy within tolerances are insufficient
Solution Approach 1:
The patent replaces conventional manual or simple mechanical insertion methods with an automated robotic system that uses sensors, control algorithms, and precise motion control to achieve sub-millimeter alignment accuracy. The robotic manipulator can detect and compensate for positional deviations in real-time, ensuring alignment within specified tolerances while maintaining high insertion speeds through automated operation.
Solution Approach 2:
The system incorporates feedback mechanisms where sensors monitor the position, orientation, and force applied during insertion. The control unit processes this feedback information and adjusts the manipulator's movements in real-time to maintain alignment within tolerances. This closed-loop control ensures precision without requiring excessively slow operation, as corrections are made dynamically during the insertion process.
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 solution enables an automated, energy-efficient, and reliable plugging process with reduced material stress, improving the efficiency and accuracy of the plug-in connection.
Implementation Method 1
with the first robot manipulator impedance-controlled and / or admittance-controlled tilting movements of the plug-in area are executed in the plug-in level
Implementation Method 2
with the first robot manipulator impedance-controlled and / or admittance-controlled tilting movements of the plug-in area are executed in the plug-in level
Implementation Method 3
until a specified limit condition G1 for a moment acting on the effector and / or a specified limit condition G2 for a force acting on the effector is reached or exceeded
Implementation Method 4
until a specified limit condition G1 for a moment acting on the effector and / or a specified limit condition G2 for a force acting on the effector is reached or exceeded
Data Source
Figure 1~2
AI summary
The invention relates to a device for plugging a plug-in region of an expansion board into a plug-in coupling, the plug-in coupling having a slot, which has a depth T along a depth axis TA and a length L along a longitudinal axis LA, and the depth axis TA and the longitudinal axis LA defining a plug-in plane, the device comprising: a first interface (101) for providing the plug-in coupling; a second interface (102) for providing the expansion board; a first robot manipulator (103) having an effector; and a control unit (104) for the open-loop/closed-loop control of the first robot manipulator (103), the control unit (104) being configured and designed to execute a control program having the following steps: the first robot manipulator (103) picks up the expansion board at/from the second interface (102) by means of the effector and leads the expansion board along a specified trajectory T with a specified target orientation Osoll(RT) of the plug-in region to the plug-in coupling provided at the first interface, Osoll(RT) defining the target orientation of the plug-in region of the expansion board held by the effector along the trajectory T for locations RT of the trajectory T; in order to plug the plug-in region into the plug-in coupling by means of the first robot manipulator (103), force-controlled and/or impedance-controlled and/or admittance-controlled tilting motions of the plug-in region in the plug-in plane are carried out until a specified limit value condition G1 for a torque acting on the effector and/or a specified limit value condition G2 of a force acting on the effector is reached or exceed and/or a provided force/torque signature and/or a position/velocity/acceleration signature is reached or exceeded at the effector, which signature or signatures indicate that the plugging of the plug-in region into the plug-in coupling is successfully concluded within predefined tolerances.