Robotic Sanding Toolpath Control for Variable Part Surfaces
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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 maintain a target force, using a combination of optical images, tool characteristics, and force sensors to ensure precise processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional automated finishing systems are used, then automation is achieved, but adaptability to varying surface contours and materials is insufficient
Solution Approach 1:
The system performs preliminary scanning of the part surface using optical sensors to capture geometric data and material properties before processing. This preliminary action enables the generation of a customized toolpath that adapts to the specific surface contours and materials, resolving the contradiction by preparing adaptation information in advance while maintaining full automation during execution
Solution Approach 2:
The system dynamically adjusts processing parameters including sanding head position, orientation, and applied force based on real-time feedback from force sensors and optical imaging. The toolpath is not static but adapts during processing to accommodate varying surface contours and material properties, enabling both high automation and adaptability simultaneously
2Manufacturing precision
If complex scanning and processing is performed to achieve high precision, then manufacturing precision improves, but processing time increases
Solution Approach 1:
The system performs comprehensive scanning and part model generation in advance before the actual sanding operation. By capturing all necessary geometric and material information during the scan period and preparing the adaptive toolpath beforehand, the system eliminates the need for time-consuming measurements and adjustments during processing, thus achieving high precision without excessive processing time
Solution Approach 2:
The system maintains continuous useful action by overlapping scan periods with toolpath generation and preparation activities. The robotic manipulator continuously processes the part along the pre-generated adaptive toolpath without interruption, ensuring that the high precision requirements are met through continuous monitoring and adjustment while minimizing idle time
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 enables efficient and accurate surface processing by allowing the robotic system to adapt to different surface contours and materials, reducing processing time and improving throughput while maintaining high resolution and repeatability.
Implementation Method 1
autonomously manipulate the robotic system to move an optical sensor across a part loaded into a work zone; and, at the optical sensor, capture a set of optical images depicting the part
Implementation Method 2
detecting a force value between the sanding head and the part surface
Data Source
AI summary
One variation of a method for autonomously scanning and processing a part includes: accessing a part model representing a part positioned in a work zone adjacent a robotic system; retrieving a sanding head translation speed; retrieving a toolpath for execution on the part defining positions, orientations, and target forces applied by the sanding head to the part. The method includes traversing the sanding head along the toolpath, at the sanding head translation speed; reading a sequence of applied forces from a force sensor coupled to the sanding head at positions along the toolpath; and deviating from the toolpath to maintain the set of applied forces within a threshold difference of a sequence of target forces along the toolpath. In one variation of the method, the robotic system executes a toolpath at a duration less than target duration by selectively varying target force and sanding head translation speed across the part.