Robotic Polishing Tool Head Cleaning and Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Robotic machining systems face inefficiencies in cleaning and calibration, particularly with abrasive belts, leading to reduced performance and accuracy over time due to dust accumulation and belt degradation, which affects the precision and safety of machining operations.
Innovation Solution
A robotic polishing system incorporating a controller with imaging capabilities to identify cleaning and calibration requirements, utilizing a belt cleaning assembly with brushes and air nozzles to clean the tool head and determine the calibration position of the tool center point using image data from artifacts on the tool head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic polishing systems operate continuously without cleaning, then productivity is maintained, but dust accumulation on the tool head degrades manufacturing precision and reliability
Solution Approach 1:
The system performs cleaning operations before dust accumulation significantly impacts precision. The controller monitors operational parameters and triggers cleaning at predetermined intervals or when threshold values are reached, preventing precision degradation rather than correcting it after the fact.
Solution Approach 2:
The cleaning system integrates seamlessly into the polishing operation, allowing the robotic arm to transition between polishing and cleaning without significant downtime. The cleaning assembly remains positioned to enable quick engagement with the tool head, maintaining continuous productive action.
2Manufacturing precision
If manual cleaning of the tool head is performed frequently, then manufacturing precision is maintained, but loss of time and productivity increase
Solution Approach 1:
The robotic system performs its own cleaning automatically. The cleaning assembly, integrated into the robotic structure, engages with the tool head during programmed intervals without requiring removal from the work cell or manual intervention, enabling the system to service itself.
Solution Approach 2:
Manual cleaning operations are replaced with an automated mechanical cleaning system. The robotic arm positions the cleaning assembly against the tool head, and motorized brushes or air jets perform the cleaning function that previously required human operators.
3Productivity
If the tool head is not cleaned regularly, then productivity is maintained, but reliability and safety of machining operations deteriorate due to dust accumulation and belt degradation
Solution Approach 1:
The controller monitors the cleaning cycle and tool head condition, adjusting operational parameters based on accumulated dust levels and cleaning effectiveness. This feedback mechanism ensures cleaning is performed at optimal intervals to maintain reliability without unnecessarily interrupting productivity.
Solution Approach 2:
The system addresses potential reliability issues before they manifest as failures. By cleaning the tool head at predetermined intervals and monitoring belt usage, the system prevents dust-related malfunctions and belt degradation from compromising machining reliability.
4Manufacturing precision
If comprehensive cleaning and calibration procedures are implemented, then manufacturing precision and reliability are improved, but device complexity increases
Solution Approach 1:
The cleaning and calibration functions are integrated into a single coordinated procedure. The robotic arm performs both cleaning operations and calibration measurements during the same tool head engagement, combining multiple maintenance functions into one unified process rather than separate operations.
Solution Approach 2:
The cleaning assembly serves multiple functions: it cleans dust from the tool head, facilitates calibration by providing a reference surface, and may assist in belt alignment. This multi-functionality reduces the need for separate dedicated systems for each maintenance task.
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
The system effectively maintains tool head cleanliness and calibration, ensuring consistent machining performance and safety by automatically identifying and addressing dust accumulation and belt degradation, thereby improving operational precision and reducing the risk of errors and accidents.
Implementation Method 1
The controller includes a processor in communication with a non-transitory memory storing instructions, which instructions when executed by the processor, cause the processor to identify a cleaning requirement for the tool head using the image data
Implementation Method 2
control the robotic polishing assembly to clean the tool head by moving the tool head to engage one or both of the first lateral brush and the second lateral brush
Implementation Method 3
The first lateral air nozzle may be configured to direct a first stream of pressurized air and the second lateral air nozzle may be configured to direct a second stream of pressurized air
Implementation Method 4
The biasing member may be configured to bias the tool extension outward from the tool guide along the lengthwise axis
Data Source
AI summary
A polishing system includes a robotic polishing assembly, a calibration system, a belt cleaning assembly, and a controller. The robotic polishing assembly includes a robotic arm and an end effector. The end effector includes a polishing arm, a motor, and a tool head. The calibration system includes an imaging device. The belt cleaning assembly includes a first lateral brush and a second lateral brush. The controller is in signal communication with the robotic polishing assembly and the calibration system. The controller includes a processor in communication with a non-transitory memory storing instructions, which instructions when executed by the processor, cause the processor to identify a cleaning requirement for the tool head and control the robotic polishing assembly to clean the tool head by moving the tool head to engage the belt cleaning assembly.