Robotic Kitting Alignment Using Vision and Force Feedback
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Solution Overview
Problem
Existing robotic systems struggle to efficiently assemble kits of parts with varying shapes, sizes, and materials, particularly those requiring fine motor control and handling fragile or irregularly shaped items.
Innovation Solution
A robotic kitting machine system that uses a combination of position control, force control, and computer vision to pick and place parts into corresponding slots in a tote, employing a suction-type end effector and cameras for precise alignment and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robots are used to perform assembly tasks, then productivity and consistency are improved, but the ability to handle fragile items and perform fine motor control deteriorates
Solution Approach 1:
The robotic system dynamically adjusts control parameters including force thresholds, insertion speeds, and compliance settings based on real-time feedback from force sensors and vision systems. This allows the robot to handle fragile items with appropriate care while maintaining high productivity for robust components.
Solution Approach 2:
The system incorporates force sensors, torque sensors, and vision systems that provide real-time feedback during pick-and-place operations. This feedback enables closed-loop control where the robot adjusts its actions based on sensed forces and positions, ensuring fragile items are handled gently while maintaining assembly precision.
2Reliability
If tight tolerance slots are used to protect parts, then part protection is improved, but the difficulty of robotic insertion deteriorates
Solution Approach 1:
The robotic system employs dynamic insertion strategies where insertion speed, force, and angle are continuously adjusted based on real-time feedback from force sensors and vision systems. The robot can slow down and apply precise forces when approaching tight tolerance slots, then speed up for more tolerant insertions, optimizing both part protection and operational simplicity.
Solution Approach 2:
The system replaces traditional mechanical positioning and alignment mechanisms with sensor-based guidance. Vision systems capture images of slot positions, and force sensors detect alignment and insertion forces, allowing the robot to adapt to variations in slot positions without requiring complex mechanical alignment fixtures.
3Adaptability or versatility
If multiple part types with varying shapes and materials are assembled, then kit versatility is improved, but the complexity of robotic manipulation deteriorates
Solution Approach 1:
The robotic system uses a universal end effector with interchangeable grippers and adaptive compliance mechanisms that can handle multiple part types. The vision system and force sensors provide universal detection capabilities that work across different materials and geometries, allowing a single robotic system to assemble diverse kit configurations without requiring specialized mechanisms for each part type.
Solution Approach 2:
The system dynamically adjusts manipulation parameters such as gripper force, insertion speed, approach angle, and compliance settings based on real-time identification of part properties from vision systems and force feedback. This allows the same robotic manipulator to handle fragile electronics, robust mechanical parts, and irregularly shaped components by changing its control parameters rather than its physical structure.
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 efficient and accurate assembly of kits without human intervention, ensuring parts are securely placed and protected from damage, even in tight tolerances, thereby improving manufacturing efficiency and reducing part damage.
Implementation Method 1
employing a suction-type end effector and cameras for precise alignment and insertion
Data Source
AI summary
A robotic kitting machine is disclosed. In various embodiments, a robotic arm is used to move an item to a location in proximity to a slot into which the item is to be inserted. Force information generated by a force sensor is received via a communication interface. The force sensor information is used to align a structure comprising the item with a corresponding cavity comprising the slot, and the item is inserted into the slot.