Robotic Sanding Tool with Real-Time Force Control
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Solution Overview
Problem
Current sanding technologies, both manual and automated, face challenges in achieving a consistent material removal rate, especially on surfaces with variable geometries, leading to inconsistent results and increased risk of operator injury in manual sanding and high processing costs in automated systems.
Innovation Solution
A system comprising a sanding tool with a robotic manipulator and a control unit that monitors and adjusts sanding parameters in real-time to maintain a consistent material removal rate by moving the sanding tool to a sanding position with a normal force, setting parameters based on a model rate, and modifying them to achieve an actual rate matching the model rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated robotic sanding is used, then productivity and consistency are improved, but the system cannot identify required sanding degree at particular locations and requires extensive numerical control programming for different surface geometries
Solution Approach 1:
The system changes parameters dynamically by using sensors to detect surface geometry and sanding requirements in real-time, then adjusts sanding parameters (speed, pressure, abrasive selection) accordingly. This eliminates the need for extensive pre-programming while maintaining automated productivity and consistency.
Solution Approach 2:
The robotic sanding system performs self-adjustment by using its own sensors to detect surface characteristics and automatically modifying sanding parameters. The system serves itself by identifying required sanding degree at particular locations through real-time sensing, eliminating the need for external programming for different geometries.
2Adaptability or versatility
If manual sanding is used, then adaptability to different surface geometries and locations is improved, but operator safety deteriorates due to repetitive motion injury risk
Solution Approach 1:
The patent replaces the manual mechanical sanding system with an automated robotic system that uses sensors and controlled mechanisms to perform sanding operations. This substitution eliminates operator exposure to repetitive motion injuries while maintaining adaptability through real-time surface detection and parameter adjustment.
Solution Approach 2:
The robotic system acts as an intermediary between the operator and the sanding process. The operator programs the system once, and the robot executes the sanding operations, mediating the harmful repetitive motion exposure while preserving the ability to handle different surface geometries through sensor feedback.
3Loss of time
If automated sanding is used, then processing time is reduced, but material removal rate consistency deteriorates without real-time parameter adjustment
Solution Approach 1:
The system implements feedback control by using sensors to monitor surface characteristics and sanding progress in real-time, then adjusting sanding parameters accordingly. This feedback loop maintains consistent material removal rate while keeping processing time short, as the system automatically adapts without requiring manual intervention or reprogramming.
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
This approach ensures a consistent material removal depth and surface characteristics across varying surface geometries, improving the quality and accuracy of the sanding process while reducing operator risk and processing time.
Implementation Method 1
a robotic manipulator coupled to the sanding tool and configured to move the sanding tool relative to the structure
Implementation Method 2
a sanding tool including an abrasive surface
Implementation Method 3
the abrasive surface is in contact with the surface and a sanding force is approximately normal to the surface
Implementation Method 4
monitor one or more of the sanding parameters when the sanding tool is in the sanding position; determine an actual material removal rate, based on one or more of the sanding parameters being monitored
Data Source
AI summary
A system for sanding a surface includes a sanding tool, a robotic manipulator to move the sanding tool relative to the surface, and a control unit operatively coupled with the sanding tool and the robotic manipulator. The control unit is operable to: (1) move the sanding tool to a sanding position relative to the surface in which an abrasive surface is in contact with the surface and a sanding force is approximately normal to the surface; (2) set one or more sanding parameters corresponding to a model material removal rate; (3) monitor one or more of the sanding parameters; (4) determine an actual material removal rate, based on one or more of the sanding parameters being monitored; and (5) modify one or more of the sanding parameters until the actual material removal rate is approximately equal to the model material removal rate.