Robotic End-Effector Positioning with Laser Tracking Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing precision manufacturing systems, such as those used in aircraft assembly, face challenges with high costs, long lead times, and inflexibility due to the use of specialized and inaccurate positioning devices, which hinder high-speed and accurate operations.
Innovation Solution
An apparatus and method that includes a positioning unit, a sensing unit, and an error determining device to accurately locate an end-effector with respect to a work site on a workpiece, utilizing a low-cost robotic machine tool by pre-positioning the end-effector and employing laser tracking technology to adjust its position with high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic mechanisms are used for positioning, then flexibility and speed are improved, but positioning accuracy and stiffness deteriorate
Solution Approach 1:
A laser tracking system serves as an intermediary between the robotic mechanism and the work site. The laser tracker measures the actual position of the end-effector with high precision, and this measurement feedback is used to calculate and apply position corrections, thereby compensating for the robotic mechanism's inherent positioning errors while maintaining operational flexibility and speed
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the laser tracking system continuously monitors the end-effector's actual position, compares it with the desired position, and generates correction signals that are fed back to the robotic mechanism. This feedback loop enables real-time compensation for positioning errors, allowing the system to achieve high manufacturing precision while maintaining the speed and flexibility advantages of robotic mechanisms
2Manufacturing precision
If specialized positioning devices are used, then positioning accuracy is improved, but cost and lead time increase
Solution Approach 1:
The invention replaces complex, expensive specialized mechanical positioning devices with a combination of a standard robotic mechanism and a laser tracking system. The robotic mechanism provides the physical positioning capability, while the laser tracking system provides the precision measurement and correction function, eliminating the need for costly specialized mechanical positioning equipment
Solution Approach 2:
The system uses optical copying through laser tracking to create a digital representation of the end-effector's actual position. This optical copy is then processed to generate correction data, allowing the system to achieve high positioning accuracy through software-based correction rather than through expensive specialized mechanical positioning hardware
3Manufacturing precision
If manual placement of positioning device is used, then positioning accuracy is improved, but operation speed deteriorates
Solution Approach 1:
The system implements self-service through automated laser tracking and feedback control. The laser tracking system automatically acquires the end-effector's position, the control system automatically calculates corrections, and the robotic mechanism automatically applies position adjustments without requiring manual intervention. This automation maintains high positioning accuracy while enabling fast, continuous operation
Solution Approach 2:
The automated feedback loop continuously monitors the end-effector's position via laser tracking and automatically generates and applies corrections in real-time. This eliminates the slow manual placement process while maintaining positioning accuracy, as the system self-corrects any deviations during operation at high speed
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
Enables high-speed and accurate manufacturing operations using lower-cost robotic machine tools, improving precision and reducing the need for expensive Numerical Control (NC) machine tools by leveraging the flexibility of robotic systems and precise error correction.
Implementation Method 1
employing laser tracking technology to adjust its position with high precision
Data Source
AI summary
An apparatus coupled with a mechanism and cooperating with the mechanism to locate an end-effector within a predetermined distance of a work site for situating the end-effector with respect to the work site includes: (a) a positioning unit coupled with the end-effector for moving the end-effector an adjustment distance with respect to the workpiece; (b) a sensing unit coupled with the apparatus for sensing extant locus of the end-effector with respect to at least one reference locus; and (c) an error determining device coupled with the sensing unit and the positioning unit; the error determining device determining a difference between the extant locus and the work locus. The positioning unit moves the end-effector in response to the difference indicating signal to reduce the difference.