Robotic Tool Holder Collision Detection With Low-Friction Return
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Solution Overview
Problem
Conventional tool holders for robotic welding systems experience positional accuracy and reliability issues due to high friction forces, leading to degradation in weld quality and the need for re-programming after collisions.
Innovation Solution
The tool holder design incorporates a housing, actuator, pressure plate, springs, and a sensor switch, with dowels in a triangular geometry for line contact and die springs to reduce friction, allowing for accurate and reliable collision detection and return to the reference position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional tool holders are used, then the structure is simple, but friction forces are high causing positional accuracy degradation
Solution Approach 1:
The tool holder is segmented into multiple functional components including actuator, pressure plate, springs, sensor switch, and housing. This segmentation allows each component to perform its specific function independently, reducing overall friction and improving positional accuracy while maintaining manageable structural complexity.
Solution Approach 2:
Springs are introduced as intermediary elements between the actuator and housing to reduce direct contact and friction forces. The springs act as mediators that transmit force while minimizing friction, thereby improving positional accuracy without significantly increasing structural complexity.
2Reliability
If conventional tool holders are used, then the device is simple, but reliability deteriorates after collisions
Solution Approach 1:
A sensor switch is integrated into the tool holder to detect collisions and provide feedback signals. This feedback mechanism allows the system to identify collision events and respond appropriately, significantly improving reliability after collisions while adding only moderate device complexity.
Solution Approach 2:
Springs are positioned to provide beforehand cushioning that absorbs collision forces before they reach critical components. This prior cushioning protects the actuator and other sensitive parts from damage, enhancing reliability while maintaining reasonable device complexity.
3Manufacturing precision
If friction forces are high, then the structure is simple, but weld quality degrades
Solution Approach 1:
Springs serve as intermediary elements that reduce friction forces between the actuator and housing. By introducing these spring-mediated contact points, the system maintains simple structural elements while significantly reducing friction forces that would otherwise degrade weld quality.
4Reliability
If collision detection is added, then reliability improves, but false feedback occurs during high acceleration
Solution Approach 1:
The spring system acts as a counterweight mechanism that balances acceleration forces against collision detection forces. During high acceleration movements, the springs absorb inertial forces, preventing false feedback in the sensor switch while maintaining accurate collision detection capability.
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
The solution effectively reduces friction forces, enhances positional accuracy, and improves the reliability of robotic tool holders, ensuring consistent weld quality by accurately detecting and responding to shocks without false feedback during high acceleration movements.
Implementation Method 1
dowels in a triangular geometry for line contact and die springs to reduce friction
Implementation Method 2
The sensor switch detects a shock force on the actuator and to output a signal in response to detecting the shock force
Implementation Method 3
ones of the plurality of dowels that are in contact are in line contact
Data Source
AI summary
An example robotic tool holder includes an actuator that is disposed within a housing and configured to hold a tool. The housing and the actuator are in contact via dowels to limit movement of the actuator toward a distal end of the housing. Ones of the dowels that are in contact are in line contact and the ones of the dowels that are in contact are in a triangular geometry. The pressure plate is in line contact with the actuator within the housing around a circumference of the pressure plate. The springs are in contact with the pressure plate to bias the actuator toward a proximal end of the housing via the pressure plate. The springs are in contact with the mounting plate opposite the pressure plate. The sensor switch detects a shock force on the actuator and outputs a signal in response to the shock force.