Autonomous Robotic Sanding With Force-Controlled Toolpath Planning
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Solution Overview
Problem
Existing automated finishing systems lack the ability to autonomously process parts with high accuracy and efficiency, particularly in determining the appropriate sanding force and toolpath based on the part's surface contours and material properties.
Innovation Solution
A robotic system equipped with an optical sensor and sanding head that autonomously scans a part, captures optical images, and generates a toolpath by defining target sanding forces based on tool characteristics and surface contours, allowing for precise sanding operations.
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 surface processing quality deteriorate due to inability to adapt to varying surface contours
Solution Approach 1:
The robotic system dynamically adjusts sanding head position and orientation in real-time based on feedback from optical sensors and force sensors, deviating from the nominal toolpath to maintain target sanding force on surfaces with varying contours. This dynamic adaptation resolves the contradiction by enabling automated operation while maintaining precision through continuous real-time control adjustments.
Solution Approach 2:
The system implements closed-loop feedback control where optical sensors capture surface geometry, force sensors monitor applied sanding force, and the controller adjusts toolpath and sanding parameters accordingly. This feedback mechanism allows the automated system to adapt to actual surface conditions, maintaining manufacturing precision while operating autonomously.
2Manufacturing precision
If high-precision scanning and processing are performed, then manufacturing precision improves, but execution time increases
Solution Approach 1:
The system performs a preliminary scan to capture the part geometry and generate a nominal toolpath before actual sanding. This preliminary action allows the system to plan the processing route in advance, enabling faster execution during the actual sanding operation while maintaining precision through real-time deviations from the pre-planned toolpath.
Solution Approach 2:
The system uses dynamic real-time adjustments during sanding based on force sensor feedback, allowing it to maintain precision without requiring excessively slow scanning speeds. The dynamic control enables the system to process surfaces efficiently while adapting to contour variations, reducing overall execution time compared to static high-precision approaches.
3Device complexity
If fixed toolpath sanding is used, then device complexity is reduced, but adaptability to different surface contours deteriorates
Solution Approach 1:
The system uses force sensor feedback to detect variations in sanding force and automatically adjusts the toolpath in real-time to maintain target sanding force on surfaces with varying contours. This feedback-based adaptation enables the system to handle diverse surface geometries without requiring complex pre-programming for each contour type.
Solution Approach 2:
The system dynamically changes sanding parameters including toolpath deviations, sanding head position, and orientation based on real-time feedback from optical and force sensors. This parameter adaptation allows the system to maintain simplicity in overall device architecture while achieving high adaptability to different surface contours through controlled parameter variations.
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.