Robotic Tile Placement System with Profile Sensors
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Solution Overview
Problem
Current automated systems for placing objects on surfaces, such as tiles, are unable to efficiently operate in confined spaces and achieve precise placement due to limitations in sensor technology and mechanical design, leading to inaccuracies and the inability to handle narrow, residential-scale installations effectively.
Innovation Solution
A system comprising a robotic arm with an end effector and sensor units that can sense two-dimensional profiles of both the object and the surface, allowing for precise alignment and placement with sub-millimeter accuracy, using a combination of suction cups and profile sensors to manage the object's pose and orientation in three-dimensional space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large and heavy machinery is used for automated tile placement, then productivity is improved, but the system cannot operate in narrow, confined spaces such as residential floor plans
Solution Approach 1:
The system divides the automated placement task into modular components: a robotic arm with multiple joints for positioning, an end effector for gripping tiles, and separate sensor units for detection. This segmentation allows the system to be compact enough for residential spaces while maintaining automated functionality.
Solution Approach 2:
The robotic arm system is designed with universal applicability to handle various tile sizes and shapes through programmable control. The end effector can adapt to different tile geometries, and the sensor system can detect diverse boundary configurations, making the system versatile for different residential applications without requiring specialized heavy machinery for each case.
2Productivity
If traditional machinery is used for tile placement, then placement speed is improved, but measurement precision deteriorates due to inability to detect complex boundary portions
Solution Approach 1:
The system replaces traditional mechanical alignment methods with optical/electronic sensor-based detection. The sensor units use light-based measurement to detect boundary portions of tiles, providing sub-millimeter precision without the mechanical limitations of traditional alignment tools. This substitution enables both high-speed automated placement and precise detection of complex boundary geometries.
Solution Approach 2:
The sensor units provide real-time feedback on tile position and orientation by detecting boundary portions. This feedback is processed by the control system to calculate pose information and adjust the robotic arm positioning, enabling continuous refinement of placement accuracy while maintaining high productivity through automated closed-loop control.
3Manufacturing precision
If automated systems with sensor feedback are implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The complex sensing and control functions are segmented into separate modular units: sensor units for detection, a robotic arm for positioning, an end effector for manipulation, and a control system for processing. This segmentation allows each component to be optimized independently while simplifying the overall system integration and maintenance.
Solution Approach 2:
The sensor units autonomously detect boundary portions and the control system automatically calculates pose information and controls positioning without requiring complex manual intervention. The system performs self-calibration and self-adjustment, reducing the operational complexity despite the advanced capabilities for high-precision placement.
Data Source
AI summary
A system for placing objects on a surface. The system may include a base, a robotic arm coupled, at an end thereof, to the base, an end effector coupled to the other end of the robotic arm. The end effector may be configured for releaseably coupling to an object to be placed on the surface. The system may further include one or more sensor units on a sensor frame. The one or more sensor units may be configured for sensing a two-dimensional profile data including at least two two-dimensional profiles together comprising at least three boundary portions of the object to be placed and at least three boundary portions of objects on the surface. At least two of the three boundary portions of the object to be placed may be from substantially non-parallel sides. At least two of the three boundary portions of the objects on the surface may be from substantially non-parallel sides. The system may further include a processor configured to determine at least three degrees of freedom of the object to be placed with respect to the sensor frame and six degrees of freedom of the sensor frame with respect to the objects on the surface in a three-dimensional space for determining a current pose of the object to be placed with respect to the objects on the surface based on the two-dimensional profile data. Further, the system may be configured to place the object based on differences between the current pose and a desired pose of the object to be placed determined from a model of objects on the surface in the three-dimensional space.