Robotic Tool Changer Alignment Using Spatial Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing method of teaching a robot controller the location and spatial orientation of robotic tools is limited by human visual perception, leading to inaccuracies and inefficiencies, especially when handling large or heavy tools, and requires impractical use of multiple teaching aid plates.
Innovation Solution
The use of a three-axis spatial orientation sensor and an optical position indicator, such as a cross line laser beam, to align the robot arm with the tool unit, allowing precise adjustment and recording of the tool's location without relying on human visual alignment, and enabling automation of the alignment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If teaching aid plates with alignment marks are used for manual alignment, then the robot controller can be taught tool locations, but the alignment accuracy is limited by human visual perception
Solution Approach 1:
The patent replaces the manual visual alignment system with an automated optical sensing system. A sensor assembly detects alignment marks on teaching aid plates, and a processor automatically calculates and adjusts the robot arm's spatial orientation and position, eliminating reliance on human visual perception and manual adjustment.
Solution Approach 2:
The system performs self-alignment through automated feedback. The sensor assembly detects the alignment marks, the processor computes the required adjustments, and the robot arm automatically positions itself, creating a closed-loop self-correcting system that improves both accuracy and ease of operation.
2Manufacturing precision
If multiple teaching aid plates are used for large or heavy tools, then alignment can be achieved, but the process becomes impractical and complex
Solution Approach 1:
The patent extracts the alignment information from multiple physical teaching aid plates and encodes it into a single digital representation. The sensor assembly reads alignment marks that represent the tool's location and orientation data, allowing the system to process complex spatial information without requiring multiple physical plates to be manually manipulated.
Solution Approach 2:
The system transforms physical alignment parameters (multiple plates, manual positioning) into digital parameters (sensor readings, computed coordinates). By changing from mechanical alignment parameters to optical and computational parameters, the system achieves high precision for large or heavy tools without increasing physical complexity.
3Reliability
If conical pins and tapered holes are used for alignment, then the master and tool units can be mechanically aligned, but the robot arm must shift or rotate the tool in its tool holder
Solution Approach 1:
The patent performs preliminary alignment of the robot arm to the tool's spatial orientation and position before the coupling operation. By using the sensor assembly to detect alignment marks and pre-positioning the robot arm accurately, the system ensures that the master and tool units are already aligned when brought together, eliminating the need for post-positioning shifts or rotations during coupling.
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 method ensures precise and efficient alignment of the robot arm with the tool unit, reducing human error and simplifying the process for large or heavy tools, allowing for high precision and repeatability in tool attachment and detachment.
Implementation Method 1
An optical source, such as a cross line laser beam, may be activated to project an optical signal from one alignment module to the other along a coupling axis centered on the tool unit.
Data Source
AI summary
Alignment modules attached to a robotic tool changer assist spatial orientation and alignment of a robot arm relative to a robotic tool for location training. A three-axis spatial orientation sensor is first attached to an alignment module affixed to a tool unit. The sensor is “zeroed,” or calibrated to the spatial orientation of the tool unit. The sensor is transferred to a corresponding surface of an alignment module affixed to a master unit. The orientation of the robot arm is adjusted to eliminate sensor error signals indicating deviations from the zeroed orientation of the tool unit. An optical signal, such as a cross line laser beam, is then projected between the alignment modules. The x- and y-axis position of the robot arm is adjusted to align the optical signal with alignment markings. When the master and tool units are aligned, the robot arm is advanced in the z-axis direction until the master unit abuts the tool unit.