Robotic Sanding Toolpaths With Optical Scanning and Force Feedback
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Solution Overview
Problem
Existing automated finishing systems lack the ability to autonomously process parts with high precision and accuracy, particularly in terms of force control and surface contour adaptation, leading to inefficiencies and inconsistencies in finishing processes.
Innovation Solution
A robotic system equipped with an optical sensor and sanding head that autonomously scans and processes parts by generating a part model, defining toolpaths, and controlling sanding force based on surface contours and tool characteristics, allowing for real-time force adjustments to achieve target values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional automated finishing systems are used, then automation is achieved, but manufacturing precision and force control are insufficient
Solution Approach 1:
The system employs force sensors to continuously monitor the contact force between the sanding head and part surface, comparing measured values with target forces. The controller automatically adjusts sanding head position and force application in real-time based on this feedback, achieving precise force control while maintaining full automation. This closed-loop control system resolves the contradiction by enabling both high automation and precision force control.
Solution Approach 2:
The system replaces traditional mechanical positioning and force control mechanisms with an integrated system combining optical scanning, computational modeling, and sensor-based control. The part model generated from optical scans and the force control algorithms substitute for conventional mechanical fixtures and manual operation, achieving superior precision while maintaining automation.
2Manufacturing precision
If traditional finishing systems are used, then processing can be performed, but manufacturing precision and surface contour adaptation are insufficient
Solution Approach 1:
The system performs optical scanning and part model generation before the actual sanding operation. Surface contours are characterized and toolpaths are planned in advance based on the digital part model. This preliminary characterization enables precise adaptation to complex surface contours during processing without requiring complex real-time mechanical adjustments, resolving the contradiction between precision and complexity.
Solution Approach 2:
The system transitions from direct physical measurement and adjustment to a digital dimension by creating a part model from optical scans. Surface contours are represented and manipulated in the digital domain through coordinate transformations and model-based control, enabling precise adaptation to complex geometries while keeping the physical system relatively simple.
3Manufacturing precision
If high-precision scanning is performed, then manufacturing precision is improved, but execution time increases
Solution Approach 1:
The system performs comprehensive optical scanning and part model generation as a preliminary step before processing. Once the digital part model is created, it can be reused for toolpath planning and force control calculations without requiring repeated high-precision scanning. This separates the one-time precision measurement from the repeated processing operations, reducing overall execution time while maintaining scanning accuracy.
Solution Approach 2:
The system creates a digital copy (part model) of the physical part through optical scanning. This digital model serves as a virtual representation that can be manipulated, analyzed, and used for control without requiring continuous physical measurement. The copy enables precise control during processing while eliminating the time cost of repeated high-precision scanning.
4Manufacturing precision
If real-time force control is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system implements force sensors that provide real-time feedback on contact force between the sanding head and part surface. The controller continuously compares measured forces with target forces and automatically adjusts positioning and force application. This feedback mechanism achieves precise force control through a relatively simple closed-loop control structure, resolving the contradiction between precision and complexity.
Solution Approach 2:
The system replaces complex mechanical force control mechanisms with sensor-based electronic control. Instead of using elaborate mechanical systems to physically control and maintain force, the system uses force sensors and electronic controllers to measure and adjust force application, achieving precise control with simpler overall system architecture.
Data Source
AI summary
One variation of a method S100 for autonomously scanning and processing a part includes: collecting a set of images depicting a part positioned within a work zone adjacent a robotic system; assembling the set of images into a part model representing the part. The method includes segmenting areas of the part model—delineated by local radii of curvature, edges, or color boundaries—into target zones for processing by the robotic system and exclusion zones avoided by the robotic system. The method includes: projecting a set of keypoints onto the target zone of part model defining positions, orientations, and target forces of a sanding head applied at locations on the part model; assembling the set of keypoints into a toolpath and projecting the toolpath onto the target zone of the part model; and transmitting the toolpath to a robotic system to execute the toolpath on the part within the work zone.