Robotic Tool Path Control for Variable-Density Material Removal
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Solution Overview
Problem
Robotic systems for removing material from workpieces face inefficiencies when dealing with non-homogeneous materials, as constant feed rates, tool paths, and rotational speeds are not suitable for varying density distributions, leading to inaccurate cuts and prolonged operating times.
Innovation Solution
A robotic system that determines the density distribution of a workpiece using a three-dimensional representation, classifies points or voxels into different density classifications, and generates specific tool paths for each classification to adjust feed rates and rotational speeds accordingly, allowing for precise material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a constant feed rate is used for homogeneous workpieces, then cutting efficiency is improved, but cutting accuracy deteriorates when processing non-homogeneous materials with varying density
Solution Approach 1:
The feed rate is changed from a constant value to a dynamic value that varies based on the local density of the workpiece material. The system continuously adjusts the feed rate according to the density classification of the current voxel being processed, allowing optimal cutting parameters to be applied to each region of the workpiece.
Solution Approach 2:
Different feed rates are applied to different regions of the workpiece based on their local density characteristics. High-density regions receive slower feed rates to maintain accuracy, while low-density regions receive faster feed rates to improve efficiency, with each region processed according to its specific properties.
2Ease of manufacture
If a uniform tool path is applied to homogeneous workpieces, then processing simplicity is improved, but processing effectiveness deteriorates for non-homogeneous materials
Solution Approach 1:
The tool path is divided into multiple segments, each corresponding to a specific density classification of workpiece voxels. The system segments the workpiece into high-density and low-density regions and generates distinct tool path segments for each, allowing optimized processing parameters to be applied to each segment based on its material properties.
Solution Approach 2:
The tool path parameters are changed to reflect the varying density distribution of the workpiece. The system modifies tool path parameters such as feed rate, depth of cut, and tool speed based on the density classification of each voxel, transforming a uniform tool path into an adaptive one that responds to local material properties.
3Ease of operation
If a constant rotational speed is used for homogeneous workpieces, then operational simplicity is improved, but heat generation increases when processing dense regions of non-homogeneous materials
Solution Approach 1:
The rotational speed is changed from a constant value to a dynamic value that adjusts based on the local density of the workpiece. The system continuously modifies the rotational speed according to the density classification of the current voxel, reducing speed in high-density regions to minimize heat generation and maintaining higher speeds in low-density regions for efficiency.
4Manufacturing precision
If slower feed rates are used for dense materials, then cutting accuracy is improved, but operating time increases
Solution Approach 1:
The feed rate is locally optimized for each voxel based on its density classification. High-density regions receive slower feed rates to ensure cutting accuracy, while low-density regions receive faster feed rates to reduce operating time. This local optimization eliminates the need to use a uniformly slow feed rate throughout the entire workpiece.
Solution Approach 2:
The feed rate parameter is changed from a constant value to a variable parameter that adapts to the local density of each voxel. The system dynamically adjusts the feed rate based on the density classification, allowing the parameter to change according to the material properties being processed, thereby optimizing both accuracy and efficiency.
Data Source
AI summary
A method of operating a robotic system to efficiently remove material from a workpiece based on a density distribution of the material of the workpiece. The density distribution of the material of the workpiece is determined from a three-dimensional representation and evaluated by classifying the plurality of points or voxels into a first density classification and a second density classification. A navigation computer generates a first tool path and a second tool path for the tool based on the evaluated density distribution. The first tool path is associated with the first density classification, and the second tool path is associated with the second density classification. The position of the tool relative to the workpiece is tracked with a navigation computer and controlled with a manipulator controller based on the generated tool path to remove material along the first tool path, and remove material along the second tool path.