Robotic End Effector Alignment Using Distance Sensor Feedback
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Solution Overview
Problem
Existing robot programming techniques require high expertise and effort, and are inadequate for adapting to misalignment between robots and target objects, especially in uneven or dynamic environments, as they rely on open-loop methods that lack real-time feedback.
Innovation Solution
The system uses real-time data from multiple distance sensors to compute offset distances and rotational angles, enabling automated alignment of a robotic end effector relative to a target object through a finite-state machine control application, which simplifies motion path planning and adapts to environmental changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard open-loop programming techniques are used, then robot motion sequences can be executed, but the system cannot adapt to misalignment between robot and target object
Solution Approach 1:
The patent implements closed-loop feedback by using distance sensors to continuously measure the actual distance between the end effector and target object, comparing it with the desired distance, and automatically adjusting robot motion to eliminate alignment errors. This feedback mechanism enables the system to adapt to misalignment while maintaining reliable positioning accuracy.
2Measurement precision
If external hardware for continuous closed-loop feedback is used, then alignment accuracy is improved, but system complexity and setup requirements increase
Solution Approach 1:
The patent makes the robot's end effector self-sufficient by integrating distance sensors directly onto it, enabling the end effector to autonomously measure its own position and orientation relative to the target object. This eliminates the need for external motion capture hardware and complex setup procedures while maintaining high measurement precision.
Solution Approach 2:
The distance sensors mounted on the end effector serve multiple functions: they provide continuous distance measurement for alignment feedback, enable adaptation to misalignment, and support various automated operations. This multi-functionality reduces overall system complexity by consolidating measurement capabilities into the end effector itself.
3Ease of manufacture
If on-line or off-line motion programming is performed, then robot path planning can be achieved, but time and specialized training requirements increase
Solution Approach 1:
The system eliminates the need for manual on-line or off-line motion programming by enabling the robot to autonomously plan and adjust its own path using real-time distance sensor feedback. The end effector self-corrects its position and orientation based on measured alignment errors, significantly reducing preparation time and eliminating the need for specialized programming training.
Solution Approach 2:
The patent implements dynamic path planning where the robot continuously adjusts its motion trajectory based on real-time feedback from distance sensors. This dynamic adaptation allows the system to automatically respond to environmental changes and misalignment without requiring time-consuming pre-programming or specialized operator expertise.
Data Source
AI summary
Systems and methods for automating robotic end effector alignment using real-time data from multiple distance sensors to control relative translational and rotational motion. In accordance with one embodiment, the alignment process involves computation of offset distance and rotational angles to guide a robotic end effector to a desired location relative to a target object. The relative alignment process enables the development of robotic motion path planning applications that minimize on-line and off-line motion path script creation, resulting in an easier-to-use robotic application. A relative alignment process with an independent (off-board) method for target object coordinate system registration can be used. One example implementation uses a finite-state machine configuration to control a holonomic motion robotic platform with rotational end effector used for grid-based scan acquisition for non-destructive inspection.