Repeatable Robotic Machining Alignment for Determinant Assembly
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Solution Overview
Problem
Conventional machining methods in production environments, such as the aerospace industry, face challenges with precision and efficiency due to large and cumbersome machinery, which leads to significant machining time and inability to achieve small, precise tolerances, and are limited by force-related movement issues and deterministic deformation limitations.
Innovation Solution
The system employs a process that generates spatial representations of machining tool orientations using imaging devices and sensors to adjust for rotational and translational differences, enabling accurate machining by compensating for movement during the machining process, and uses a two-pass or one-pass machining process to ensure precision without requiring large machinery or complex drilling jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional large and cumbersome machinery is used for machining, then machining operations can be performed, but machining time increases significantly and assembly throughput decreases
Solution Approach 1:
The patent replaces conventional large mechanical machining systems with a robotic system that performs machining operations. The robot equipped with a machining tool is controlled by a processor to automatically position and machine parts, eliminating the need for large cumbersome machinery and significantly reducing machining time while increasing assembly throughput.
Solution Approach 2:
The patent changes the operational parameters by using a robotic system with programmable motion control instead of fixed mechanical systems. The processor controls the robot's position, speed, and machining parameters dynamically, allowing for faster cycle times and improved productivity compared to conventional mechanical machining systems.
2Manufacturing precision
If conventional machining methods are used, then parts can be machined, but small precise tolerances cannot be achieved due to force-related movement and deterministic deformation
Solution Approach 1:
The patent implements a feedback mechanism where the processor monitors the robot's position and machining operations in real-time. The system uses measured data from the machining process to adjust and compensate for force-related movements and deterministic deformations, ensuring consistent small precise tolerances are achieved while maintaining reliability.
Solution Approach 2:
The patent performs preliminary positioning and measurement operations before the actual machining. The robot system pre-positions the machining tool and part with high precision, and the processor calculates compensation values for anticipated force-related movements and deformations, allowing small precise tolerances to be achieved consistently.
3Adaptability or versatility
If conventional tooling equipment is used, then machining operations can be performed, but the equipment remains limited and cumbersome
Solution Approach 1:
The patent employs a universal robotic system that can perform multiple machining operations on different parts. The robot equipped with a machining tool can be programmed to perform various machining tasks, replacing multiple specialized conventional tooling equipment with a single versatile system that increases adaptability while managing complexity through software control.
Data Source
AI summary
Systems, methods, and apparatus are disclosed for machining a part. Methods include generating a first spatial representation identifying a first orientation of a machining tool, and mechanically coupling an end effector to the part at a first position, the end effector including the machining tool and a coupling tool. Methods include generating a second spatial representation identifying a second orientation of the machining tool relative to the part, the first and second spatial representations being generated based on images captured by at least one imaging device and measurements from a plurality of sensors. Methods include identifying a plurality of differences that result from the coupling and that include a rotational distance and translational distance, the identifying being based on a comparison of a first image and a second image. Methods include adjusting the machining tool to return the machining tool to the first orientation at the first position.