Robotic Screw Pickup Control for Reliable Automated Transfer
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Solution Overview
Problem
Existing automated screwing processes lack reliability and efficiency in the automated transfer of screws from a storage container to a screwing tool, leading to potential screw loosening issues.
Innovation Solution
A screwing device equipped with a reservoir, a robotic manipulator with a tailored effector, and a control unit that executes specific control programs to guide the effector along precise trajectories for force-controlled or impedance-controlled movements to pick up and insert screws into a thread, ensuring successful screw transfer and driving within predefined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional automated screw transfer mechanisms are used, then the process is simple, but the reliability of screw transfer is low leading to potential screw loosening
Solution Approach 1:
The patent implements feedback control by using sensors to detect the actual position and orientation of the screw during transfer, comparing it with the desired trajectory, and adjusting the robotic manipulator's movements in real-time to compensate for deviations, ensuring reliable screw placement
Solution Approach 2:
The patent replaces traditional mechanical screw transfer mechanisms with a robotic manipulator system that uses controlled movement and force regulation to handle and position screws, eliminating the reliability issues of mechanical wear and misalignment
2Manufacturing precision
If force-controlled movements are implemented for precise screw picking, then the picking accuracy improves, but the control complexity increases
Solution Approach 1:
The robotic manipulator performs self-adjustment during screw picking by using force sensors to detect contact with the screw and automatically regulating its gripping force and position, eliminating the need for complex external control mechanisms
Solution Approach 2:
The patent dynamically adjusts control parameters such as gripping force, movement speed, and trajectory during the screw picking process based on real-time sensor feedback, enabling precise manipulation without requiring overly complex control architecture
3Productivity
If automated screw transfer is implemented, then productivity increases, but the reliability of subsequent screwing process decreases
Solution Approach 1:
The patent performs preliminary verification of screw quality, position, and orientation during the transfer process before the actual screwing operation, ensuring that only properly positioned screws are transferred to the screwing tool, thereby maintaining high reliability while achieving automation
Data Source
Figure 1~2
AI summary
The invention relates to a screwing device, comprising a storage container (101) for screws, a robot manipulator (103) with an effector that matches the screws and is embodied and designed to receive and handle such screws, a separating unit (102) that is connected to the storage container and places the screws from the storage container (102) on an interface such that they are separated in a known position, in such a way that each screw head can be accessed by the effector, and a control unit (104) for controlling/regulating the robot manipulator, the control unit being embodied and designed to implement the following first control programs: the effector is guided by the robot manipulator along a pre-defined trajectory T1 with a nominal orientation Osoll,T1(RT1) towards the screw head of a screw placed on the interface, a nominal orientation Osoll,T1(RT1) of the effector being defined along the trajectory T1 for locations RT1 on the trajectory T1. In order to receive the screw head in the effector, translatory motion patterns and/or rotational movements and/or tilting movements of the effector, that are force-regulated and/or impedance-regulated and/or admittance-regulated by the robot manipulator, are carried out until a pre-defined threshold value condition G1 for torque acting on the effector and/or a pre-defined threshold value condition G2 of a force acting on the effector and/or a threshold value condition G3 for a time for carrying out the rotational and/or tilting movements is reached or exceeded and/or a provided force/torque signature and/or a position/speed/acceleration signature are reached or exceeded on the effector, that indicate that the screw is successfully received by the effector within pre-defined tolerances.