Robotic Forming of Non-Planar Workpieces With Adaptive Deformation Control
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Solution Overview
Problem
Existing methods for forming and shaping three-dimensional non-planar workpieces, such as cylinders or tubes, are limited by high costs, long lead times, low precision, and complexity in determining deformation paths, making them unsuitable for precise applications like aeronautical engineering.
Innovation Solution
A robotic shaping and forming system with multiple robotic arms, a work platform, and a computer system that uses sensors, interchangeable tools, and artificial intelligence to control the robotic arms, allowing precise manipulation of non-planar workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydroforming is used to form three-dimensional workpieces, then manufacturing precision can be improved, but device complexity and cost increase significantly due to expensive tooling and development requirements
Solution Approach 1:
The patent replaces traditional mechanical hydroforming systems with robotic arms that use controlled mechanical forces to deform workpieces. The robotic system substitutes complex hydraulic tooling with programmable robotic manipulation, achieving precise forming without expensive dedicated tooling while maintaining manufacturing precision through computer control
Solution Approach 2:
The robotic forming system is designed to be universal and adaptable to different workpiece geometries and forming operations. Unlike hydroforming which requires dedicated tooling for each component, the robotic system can reconfigure for different tasks through programming and tool changes, reducing device complexity while maintaining precision across multiple applications
2Adaptability or versatility
If multi-stage forming is used to create complex shapes, then adaptability improves, but manufacturing precision deteriorates due to accumulation of errors across multiple stages
Solution Approach 1:
The system performs preliminary planning and simulation of the entire forming process before actual execution. The robotic system calculates optimal deformation paths and intermediate states in advance, allowing complex shapes to be achieved through coordinated single-stage or multi-stage operations while maintaining precision by pre-coordinating all movements and forces
Solution Approach 2:
The robotic forming system incorporates sensors and control systems that provide real-time feedback during the forming process. This allows the system to monitor and adjust forces, positions, and deformation rates dynamically, maintaining manufacturing precision even when forming complex three-dimensional shapes that would require multiple coordinated stages
3Ease of operation
If traditional robotic systems are used on flat planar sheets, then ease of operation improves, but manufacturing precision deteriorates when forming non-linear three-dimensional shapes due to uncontrolled strain and deformation
Solution Approach 1:
The robotic system transitions from static, pre-programmed paths to dynamic, adaptive control during forming operations. The system continuously adjusts robotic arm positions, tool forces, and deformation rates based on real-time sensor feedback, enabling precise control of strain and deformation when forming non-linear three-dimensional shapes while maintaining ease of operation through automated adaptation
Solution Approach 2:
The system dynamically changes forming parameters such as force magnitude, application rate, and tool position during the deformation process. By adjusting these parameters in real-time based on material response and desired geometry, the system maintains manufacturing precision for complex three-dimensional forming while keeping the operation simple through automated parameter optimization
4Manufacturing precision
If complex deformation paths are determined for three-dimensional shaping, then manufacturing precision can be improved, but device complexity and calculation requirements increase
Solution Approach 1:
The patent replaces complex mechanical calculation and measurement systems with computer-based simulation and control. The system uses software to calculate optimal deformation paths and control robotic movements, substituting mechanical complexity with programmable computation while maintaining high deformation path accuracy through precise digital modeling and control algorithms
Data Source
AI summary
A robotic shaping and forming system comprising a plurality of opposing robotic arms, a work platform for supporting a non-planar workpiece and a computer system, the plurality of opposing robotic arms having multiple degrees of freedom and an end effector for holding a tool, and wherein at least one robotic arm being mounted on a radially extending rail, the computer system being connected to the plurality of robotic arms, the computer system controlling the movement of the robotic arms, so that at least a pair of robotic arms work together to shape and form a non-planar workpiece that is mounted upon a work platform.