Robotic Kitting Alignment for Tight Slot Insertion
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Solution Overview
Problem
Current robotic systems face challenges in assembling kits with parts that require fine motor control and handling fragile or irregularly shaped items, as they struggle with precise placement and alignment due to tight tolerances, which can lead to damage and inefficiency in manufacturing processes.
Innovation Solution
A robotic kitting system that utilizes a combination of position control, force control, and computer vision to pick and place parts into corresponding slots within a tote or carrier, using a suction-type end effector and cameras for precise alignment and insertion, allowing for automated assembly of kits without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a robotic system uses tight tolerances for slot insertion to protect fragile parts, then part protection is improved, but the difficulty of insertion and positioning increases
Solution Approach 1:
The system performs preliminary actions by using vision systems to locate slots and parts before insertion, pre-aligning the robotic end effector to the correct position and orientation, and preparing the insertion path in advance. This allows the robot to approach the tight-tolerance slot with precise positioning already established, making the actual insertion easier while maintaining protection for fragile parts.
Solution Approach 2:
The patent replaces traditional mechanical positioning and alignment mechanisms with vision-based guidance and control systems. Cameras and image processing algorithms substitute for mechanical alignment fixtures, allowing the robotic system to achieve precise positioning through software-controlled adjustment rather than rigid mechanical guides, thereby facilitating easier insertion into tight slots.
2Manufacturing precision
If a robotic system implements force control for precise placement, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system introduces vision systems and sensors as intermediary elements between the robotic controller and the placement operation. These intermediaries provide real-time feedback on position and orientation, enabling precise placement through closed-loop control without requiring complex force control mechanisms. The vision system acts as a mediator that translates visual information into positioning commands.
Solution Approach 2:
The patent implements feedback mechanisms where vision systems continuously monitor the position of parts and slots, and this information is fed back to the robotic controller for real-time adjustment of placement operations. This feedback loop enables precise manufacturing without requiring complex force control hardware, as the system uses visual feedback to achieve accurate positioning.
3Ease of operation
If a robotic system uses suction-type end effectors for handling, then ease of operation is improved, but the ability to handle irregularly shaped items deteriorates
Solution Approach 1:
The system achieves universality by combining suction-type end effectors with vision-based positioning and multiple gripper configurations. The suction cups provide a universal gripping mechanism for various materials, while the vision system and interchangeable grippers provide adaptability for different shapes and sizes. This multi-functional approach allows a single robotic system to handle diverse items effectively.
Solution Approach 2:
The patent employs asymmetric or specially shaped suction cups and grippers that are designed to accommodate irregularly shaped items. Rather than using symmetric, generic grippers, the system employs asymmetric gripping surfaces and multiple suction points that can be positioned to match the specific geometry of each part, thereby maintaining both ease of operation and handling versatility.
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, accurate, and safe handling of parts by ensuring precise alignment and insertion into tight slots, reducing the risk of damage and improving the speed and efficiency of kit assembly processes, even with fragile or irregularly shaped items.
Implementation Method 1
using 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.