Robotic Door Gripper with Laser-Guided Position Correction
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Solution Overview
Problem
Existing grippers for door panels in smart factories face issues such as position errors due to twisted or deformed dividers, leading to line interruptions and increased maintenance costs, and are heavy, affecting robot operation efficiency and requiring extensive teaching management.
Innovation Solution
A gripper with a bundle type pin locator and laser sensor system that adjusts pressure and position to accommodate position errors and shape variations, using lightweight components to improve operation rates and reduce maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional gripper with electric cylinder and guide rail is used to clamp door panels, then the gripper can provide sufficient clamping force, but the weight of the gripper increases and affects robot operation efficiency
Solution Approach 1:
The patent replaces the electric cylinder and guide rail mechanism with a pneumatic cylinder that directly drives the clamping arms. The pneumatic system provides sufficient clamping force through compressed air pressure while significantly reducing the mechanical structure weight, thereby improving robot operation efficiency without sacrificing clamping capability
Solution Approach 2:
The patent removes the heavy guide rail component from the traditional gripper structure, retaining only the essential clamping function through a simplified pneumatic mechanism. This extraction of unnecessary heavy components reduces overall gripper weight while maintaining the core clamping functionality
2Productivity
If a fixed picking position is used for the gripper, then the robot can efficiently extract door panels, but line interruptions occur when dividers are twisted or deformed causing position errors
Solution Approach 1:
The patent replaces the fixed picking position with a dynamic position adjustment mechanism. The gripper can automatically adjust its picking position based on the actual door panel location, accommodating divider deformation and position errors. This dynamic adaptation maintains high operation rates while preventing line interruptions caused by positioning failures
Solution Approach 2:
The patent incorporates a feedback mechanism that detects the actual position of door panels and adjusts the gripper's picking position accordingly. This closed-loop control system compensates for divider deformation and ensures reliable door panel extraction even when position errors occur
3Device complexity
If point contact clamping is used for door panels, then the gripper structure is simple, but the gripper cannot adapt to position changes and hinders operation rate
Solution Approach 1:
The patent divides the single point contact into multiple distributed contact points along the clamping arms. This segmentation allows the gripper to adapt to position variations and shape differences in door panels while maintaining a relatively simple overall structure. The multiple contact points provide better tolerance to positioning errors without significantly increasing structural complexity
4Measurement precision
If pallet teaching management work is performed to maintain pallet precision, then picking position accuracy is maintained, but high maintenance costs and periodic checking are required
Solution Approach 1:
The patent implements a self-service positioning system where the gripper automatically detects and compensates for position errors without requiring external teaching or manual calibration. The system self-adjusts to maintain picking accuracy, eliminating the need for periodic pallet teaching management and reducing maintenance costs while preserving position precision
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 gripper effectively corrects position errors, prevents line interruptions, reduces teaching management costs, and decreases robot load by using lightweight components.
Implementation Method 1
a control unit adjusting a moving distance of the robot by measuring a distance difference between the side clamping unit and the inner panel by using a laser sensor
Implementation Method 2
a pressure control valve adjusting the pressure of guide air cylinders each applied to the picking unit
Data Source
AI summary
A gripper mounted on a robot is used in a smart factory to pick a door loaded on a pallet. The gripper includes: a frame mounted on a tool changer of the robot; a picking unit mounted on a front of the frame and applying pressure to and regulating each of upper and lower points of an opening formed in an inner panel of the door through a bundle pin locator; and a pressure control valve adjusting the pressure of guide air cylinders. The gripper further includes: a side clamping unit mounted on the frame and holding a side point of the opening by a fixing locator and a clamper operating with a driving force of a clamping cylinder; and a control unit adjusting a moving distance of the robot based on a distance difference between the side clamping unit and the inner panel.