Robotic Dispensing Repair Using Vision-Based Defect Coordinates
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Solution Overview
Problem
Robotic dispensing operations often encounter defects such as air pockets in sealant materials, leading to gaps in the dispensed path, which existing systems struggle to prevent or efficiently repair due to the unpredictable nature of the materials.
Innovation Solution
A method that captures images of the dispensing operation, identifies defects, transforms their locations into the robot's coordinate system, and moves the robot to repair these defects directly, allowing for efficient filling of gaps and other defects without needing to follow the original dispensing path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the robot follows the original dispensing path to repair defects, then the repair process is simple and continuous, but the repair time is excessive and productivity is reduced
Solution Approach 1:
The patent segments the repair process into two distinct phases: (1) defect detection and location identification using vision systems during or after dispensing, and (2) targeted repair operations where the robot jumps directly to defect locations rather than following the continuous original path. This segmentation allows the system to maintain operational simplicity while dramatically reducing repair time by eliminating unnecessary travel along the complete dispensing path.
Solution Approach 2:
The patent implements skipping by allowing the robot to jump directly to identified defect locations without traversing the intermediate sections of the original dispensing path. The system records defect coordinates during detection and uses these coordinates to position the nozzle directly at repair points, effectively rushing through the repair process by eliminating redundant motion while maintaining precision through coordinate-based positioning.
2Reliability
If defects are detected and repaired immediately, then the consistency of dispensing operations is improved, but the system complexity increases due to additional detection and coordinate transformation requirements
Solution Approach 1:
The patent applies multi-functionality by integrating multiple capabilities into the robotic system: the vision system serves both as a detection device for identifying defects and as a measurement device for capturing coordinate information; the robot controller performs both the original dispensing operations and the subsequent repair operations; the coordinate transformation system handles both real-time detection data and repair positioning data. This universal approach improves dispensing consistency without requiring entirely separate specialized systems.
Solution Approach 2:
The patent introduces coordinate transformation as an intermediary process that bridges the vision system's detection coordinate system and the robot's execution coordinate system. This intermediary layer processes defect location data from the vision system, transforms it into robot-compatible coordinates, and provides it to the control system for precise positioning. This mediator enables reliable defect repair while managing system complexity by providing a structured data translation layer rather than requiring direct integration of all subsystems.
3Manufacturing precision
If manual intervention is used to repair defects, then the repair quality can be high, but the productivity is reduced and manual labor is required
Solution Approach 1:
The patent implements self-service by enabling the robotic system to automatically detect, locate, and repair its own dispensing defects without human intervention. The vision system autonomously identifies defects, the coordinate transformation system processes defect location data, and the robot automatically positions and repairs defects using the same dispensing mechanism. This self-service capability maintains high repair quality through precise robotic control while dramatically improving productivity by eliminating slow manual repair processes.
Solution Approach 2:
The patent replaces manual mechanical repair operations with automated robotic mechanisms. Instead of human operators physically inspecting and repairing defects by hand, the system uses vision-based detection, automated coordinate processing, and robotic positioning with precision control. This substitution maintains or improves repair quality through consistent automated execution while increasing production speed by eliminating the limitations of manual operation.
Data Source
AI summary
A method of inspection and repair of a robotic operation is provided. The robotic operation preferably includes dispensing material onto a surface of a component. A camera is used to capture an image of the robotic operation and identify defects in the robotic operation in the captured image. The locations of the defects are then transformed from the image coordinate system to the robot coordinate system. The robot may then be moved to the defect locations in the robot coordinate system to repair the defects, e.g., by dispensing additional material at the defect.