Robotic Sanding Toolpaths from Part Scans and Force Feedback
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Solution Overview
Problem
Current automated finishing systems lack the ability to autonomously and accurately process parts with varying surface contours and materials, leading to inefficiencies and inconsistencies in surface finishing.
Innovation Solution
A robotic system equipped with a sanding head and optical sensor that autonomously scans a part, generates a toolpath, and adjusts the sanding force in real-time to match target values based on surface contours and tool characteristics, allowing for precise and efficient processing of parts with diverse geometries and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-resolution scanning is performed across the entire part surface, then measurement precision is improved, but loss of time increases due to the extended scan duration
Solution Approach 1:
The part surface is divided into multiple scan regions, with high-resolution scanning applied only to identified feature regions of interest while other areas receive lower-resolution scanning. This segmentation allows the system to maintain measurement precision for critical features while reducing overall scan time by not applying high-resolution scanning uniformly across the entire surface.
Solution Approach 2:
Different scanning resolutions are applied to different regions of the part based on local feature importance. High-resolution scanning is concentrated on regions containing geometric features that require precise measurement, while lower-resolution scanning is used for areas with less critical geometry, thereby optimizing the balance between measurement precision and scan duration.
2Manufacturing precision
If the sanding head deviates from the toolpath to align force values, then manufacturing precision is improved, but device complexity increases due to real-time force monitoring and adjustment mechanisms
Solution Approach 1:
A force sensor mounted on the sanding head provides real-time feedback on the contact force between the sanding pad and part surface. The controller continuously monitors this force data and automatically adjusts the sanding head position relative to the pre-defined toolpath to maintain optimal contact force, ensuring consistent surface finishing quality without requiring complex manual intervention.
Solution Approach 2:
The system replaces complex mechanical positioning adjustments with automated control based on force sensor feedback. Instead of using complex mechanical mechanisms to maintain precise force contact, the system uses electronic sensing and control to dynamically adjust the sanding head position, substituting mechanical complexity with sensor-based control.
3Adaptability or versatility
If the system processes parts with diverse geometries and materials, then adaptability is improved, but device complexity increases due to the need for versatile scanning and processing capabilities
Solution Approach 1:
The robotic system is equipped with universal scanning and processing capabilities that can handle diverse part geometries and materials through software-based adaptation. The optical sensor and sanding head are designed to work across multiple part types, with the controller adjusting scan parameters and toolpaths based on detected feature regions, eliminating the need for specialized equipment for each part type while maintaining versatility.
Solution Approach 2:
The system adapts to different part types by dynamically changing operational parameters such as scan resolution, scan speed, sanding force, and toolpath density based on detected surface features and material characteristics. This parameter-based adaptation allows the same physical equipment to process diverse geometries and materials effectively without requiring complex mechanical reconfiguration.
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 achieves high-resolution surface processing with high repeatability and throughput by combining low-resolution scans with real-time force adjustments, enabling efficient processing of multiple part types and processes across varying surface conditions.
Implementation Method 1
capture a set of optical images
Data Source
AI summary
One variation of a method 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.