Robotic Surface Processing Path Control for Curved Worksurfaces
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Solution Overview
Problem
Automating clear coat repair and other surface processing operations in the automotive industry is challenging due to the difficulty in handling curved surfaces and surface features, which limits the efficiency of robotic systems and requires significant manual intervention.
Innovation Solution
A robotic system that includes a surface inspection system, a robotic arm with a surface processing tool, and a process mapping system to approximate surface topography, modify robotic arm trajectories, and generate control signals for precise surface processing on non-flat surfaces with edges or curvature, allowing for automated defect repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robotic system is used for surface processing, then automation extent and productivity are improved, but the system cannot effectively handle curved surfaces and surface features
Solution Approach 1:
The robotic system dynamically adapts its trajectory and tool orientation in real-time based on the detected surface topography. The control system modifies the robotic arm's path and the surface processing tool's engagement angle dynamically as it moves across the workpiece, allowing effective processing of curved surfaces and complex geometries while maintaining full automation.
2Adaptability or versatility
If a robotic system processes non-flat surfaces, then adaptability is improved, but manufacturing precision and surface processing quality deteriorate due to trajectory inaccuracies
Solution Approach 1:
The system performs preliminary scanning of the workpiece surface to create a detailed digital model of the surface topography before processing. Based on this pre-acquired information, the control system pre-calculates and pre-adjusts the robotic trajectory and tool orientation to compensate for surface irregularities, ensuring precise processing even on curved surfaces without real-time feedback delays.
3Manufacturing precision
If manual intervention is used for surface processing on complex surfaces, then manufacturing precision is maintained, but productivity and automation extent are reduced
Solution Approach 1:
The robotic system incorporates real-time feedback through sensors that continuously monitor the actual surface topography during processing. The control system compares the measured surface features with the planned trajectory and dynamically adjusts the robotic arm's path and tool engagement parameters to maintain manufacturing precision, achieving both high precision and full automation simultaneously.
Data Source
AI summary
A robotic system is presented that includes a surface inspection system that receives a plurality of sampled points within a region of a worksurface. The system also includes a robotic arm, coupled to a surface processing tool, the robotic repair arm being configured to cause the surface processing tool to engage the region of the worksurface. The system also includes a process mapping system configured to, based on the plurality of sampled points: approximate a surface topography of the region of the worksurface, modify a trajectory for the robotic arm, based on the approximated surface topography, and generate a control signal for the robotic arm that includes a path for the robotic arm into the region.