Robotic Arm Tool Positioning Using Projected-Line Feedback
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Solution Overview
Problem
The complexity and large size of wind turbine blades pose challenges for automated manufacturing and testing processes, as they require precise positioning and orientation, which is difficult to achieve with existing technologies relying on manual methods due to the blades' unique geometry and the need for precise control of tools during processes like non-destructive testing.
Innovation Solution
A method using a robotic arm with a projector and camera to project a line onto the workpiece, detect the image, and adjust the tool's position and orientation based on predetermined values, ensuring precise control through motor controllers and feedback loops, allowing for efficient and repeatable positioning and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual production methods are used, then the complexity of handling large and complex blades can be managed by skilled technicians, but automation cannot be reliably implemented due to difficulty in holding blades in precisely the same position and orientation
Solution Approach 1:
The system uses a camera to capture images of the blade, processes these images to determine the actual position and orientation of the blade, and feeds this information back to the control system. This feedback loop enables the automated system to adapt to variations in blade positioning and achieve precise control through continuous adjustment based on real-time measurements.
Solution Approach 2:
The patent replaces traditional mechanical positioning systems with an optical measurement and control system. Instead of relying on fixed mechanical fixtures and manual alignment, the system uses computer vision (camera imaging) and computational algorithms to determine blade position and orientation, substituting mechanical rigidity with optical precision and software-based control.
2Manufacturing precision
If fixed computer inputs and machine pathing are used for automation, then automated systems can be guided, but reliable and repeatable positioning of large complex blades cannot be achieved due to their unique geometry and size
Solution Approach 1:
The system allows the blade to essentially position itself by capturing its actual position through imaging and using that information to guide the automated tool. Rather than requiring the automation system to force the blade into a predetermined position through complex mechanical means, the system adapts to the blade's actual position and adjusts the tool path accordingly, letting the measurement system serve the positioning function.
Solution Approach 2:
The system dynamically changes the control parameters (tool path, positioning coordinates) based on the measured actual position of the blade. Instead of using fixed predetermined coordinates, the system calculates adjusted parameters that account for variations in blade placement, enabling precise control through adaptive parameter modification rather than rigid fixed inputs.
3Manufacturing precision
If manual methods are used for post-production processes like non-destructive ultrasound testing, then flexible handling is possible, but precise control of tool position and orientation cannot be achieved to obtain reliable data
Solution Approach 1:
The imaging system continuously monitors the position and orientation of the testing tool relative to the blade surface and provides feedback to the control system. This enables real-time adjustment of tool positioning to maintain optimal alignment for ultrasound testing, ensuring reliable data collection while operating in an automated manner that improves efficiency over manual methods.
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 accurate and repeatable positioning of tools relative to wind turbine blades, enhancing the quality and efficiency of manufacturing and testing processes by preventing damage from improper alignment or force application.
Implementation Method 1
projecting an image onto the workpiece from a projector mounted on the tool or on the robotic arm, wherein the projected image comprises a line
Implementation Method 2
detecting the projected image using a camera mounted on the tool or on the robotic arm
Data Source
AI summary
Controlling the position of a tool mounted on a robotic arm comprising projecting an image onto the workpiece from a projector and detected using a camera. The camera and projector are mounted on the tool or robotic arm. The image is used to determine a relative position of the tool with respect to a workpiece and the relative position is provided as an input to a controller which is configured to compare the relative position to a predetermined value. If the relative position is not equal to the predetermined value, a control signal is issued to a position controller to move the tool to a new position in which the relative position of the tool is closer to the predetermined value. Or, if the relative position is equal to the predetermined value, a control signal is issued to the position controller to maintain the tool in its current position.