Robotic Shape Forming for Precise Non-Planar Workpieces
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Solution Overview
Problem
Existing methods for shaping and forming three-dimensional non-planar workpieces, such as cylinders or tubes, are limited by high costs, long lead times, low precision, and complexity in determining deformation paths, making them unsuitable for precise forming in applications like aeronautical engineering.
Innovation Solution
A robotic shaping and forming system with multiple robotic arms, each with six degrees of freedom, mounted on radially extending rails and controlled by a computer system, uses interchangeable tools and sensors to form non-planar workpieces, incorporating artificial intelligence and visual monitoring for precise shaping and forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hydroforming is used for shaping planar linear sheets, then forming capability is achieved, but cost and lead time increase significantly
Solution Approach 1:
The patent replaces traditional hydroforming mechanical systems with a robotic system that uses controlled force application through specialized tools. The robotic arms with force control replace the complex hydroforming equipment, achieving similar forming capabilities through software-controlled mechanical action rather than high-pressure fluid systems.
Solution Approach 2:
The patent changes the forming parameters from high-pressure hydroforming conditions to controlled robotic force application. By varying force magnitude, direction, and application points through software control, the system achieves different forming outcomes without requiring expensive dedicated tooling for each configuration.
2Adaptability or versatility
If multi-stage/multi-process forming is used, then various shapes can be formed, but quality and precision decrease
Solution Approach 1:
The patent segments the forming process into multiple controlled force application steps, where each robotic arm independently applies precise forces to specific regions. This segmentation allows complex shapes to be formed through coordinated multi-step robotic action rather than sequential multi-process operations, maintaining precision throughout.
Solution Approach 2:
The robotic system provides universal shaping capability through software control, where the same robotic arms can perform different forming operations by changing control parameters. This eliminates the need for dedicated equipment for each forming stage, maintaining consistent precision across all operations.
3Extent of automation
If robots are used for shaping flat planar sheets into non-linear three-dimensional shapes, then automation is achieved, but strain and deformation cause tearing or deforming
Solution Approach 1:
The patent implements force feedback control where sensors monitor the actual forces applied during forming and adjust robotic arm actions in real-time. This feedback mechanism prevents excessive strain that could cause tearing, while maintaining automation. The system continuously adapts force application based on material response.
Solution Approach 2:
The robotic system dynamically adjusts force magnitude, direction, and application points during the forming process. Rather than applying static forces, the system adapts in real-time to material behavior, preventing deformation and tearing while maintaining automated control.
4Ease of manufacture
If traditional methods are used for determining shape prior to deformation, then simplicity is maintained, but complexity increases for curved profiles like cylinders or tubes
Solution Approach 1:
The patent replaces complex manual or analytical shape determination methods with software-based robotic control. The computer system automatically calculates deformation paths and force applications for complex curved profiles, eliminating the need for manual geometric calculations and simplifying the manufacturing process.
Solution Approach 2:
The system performs preliminary computational analysis of the desired final shape and automatically determines the deformation path and force application sequence. This preliminary digital planning simplifies the actual manufacturing process, especially for complex curved profiles like cylinders or tubes.
Data Source
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AI summary
A robotic shaping and forming system (10, 40, 50, 81) comprising a plurality of opposing robotic arms (12a, 12b, 22a, 22b, 41, 42, 52a-52h, 82a-82h), a work platform (15, 25, 34, 45, 55, 85) for supporting a non-planar workpiece (11, 21, 31, 44, 54, 63, 73, 84) and a computer system, the plurality of opposing robotic arms (12a, 12b, 22a, 22b, 41, 42, 52a-52h, 82a-82h) having multiple degrees of freedom and an end effector for holding a tool (14, 24, 61, 62, 71, 72), and wherein at least one robotic arm (12a, 12b, 22a, 22b, 41, 42, 52a-52h, 82a-82h) being mounted on a radially extending rail (13, 23a, 23b, 43, 53a-53h, 83a-83h), the computer system being connected to the plurality of robotic arms (12a, 12b, 22a, 22b, 41, 42, 52a-52h, 82a-82h), the computer system controlling the movement of the robotic arms (12a, 12b, 22a, 22b, 41, 42, 52a-52h, 82a-82h), so that at least a pair of robotic arms (12a, 12b, 22a, 22b, 41, 42, 52a-52h, 82a-82h) work together to shape and form the non-planar workpiece (11, 21, 31, 44, 54, 63, 73, 84) that is mounted upon the work platform (15, 25, 34, 45, 55, 85).