Autonomous Sanding Head Repair Using Defect Imaging Feedback
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Solution Overview
Problem
Existing automated finishing systems lack the capability to autonomously detect and repair defects in workpieces efficiently, leading to suboptimal surface finishes and increased manual intervention.
Innovation Solution
A method and system that utilize an end effector with a sanding head and optical sensors to capture images of a workpiece, compile them into a virtual model, detect defects, and generate repair toolpaths, allowing for autonomous defect detection and repair during the processing cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated finishing systems are used, then productivity is improved, but the capability to autonomously detect and repair defects deteriorates
Solution Approach 1:
The system enables the workpiece to undergo self-repair through automated defect detection and correction. The robotic finishing system autonomously identifies defects using imaging systems and applies targeted material removal or surface modification to repair them, allowing the workpiece to correct its own imperfections without manual intervention.
Solution Approach 2:
The system implements closed-loop feedback by continuously monitoring the workpiece surface during finishing operations. Imaging systems capture real-time data about surface conditions, which is processed to identify defects, and the system automatically adjusts finishing parameters or applies corrective actions based on this feedback to maintain surface quality.
2Measurement precision
If manual defect inspection and repair is performed, then defect detection accuracy is improved, but productivity deteriorates
Solution Approach 1:
The system replaces manual mechanical inspection with automated imaging systems and computer vision algorithms. Optical sensors, cameras, and machine learning-based image processing automatically detect and classify defects with high accuracy, eliminating the need for manual visual inspection while maintaining or improving detection capability.
Solution Approach 2:
The system creates digital copies of the workpiece surface through high-resolution imaging and 3D scanning. These digital models are then analyzed by software algorithms to identify defects, allowing virtual inspection and planning of repair operations before physical correction is applied.
3Manufacturing precision
If comprehensive defect detection is implemented, then manufacturing precision is improved, but device complexity deteriorates
Solution Approach 1:
The robotic finishing system is designed with multi-functionality, integrating defect detection, classification, and repair capabilities into a single platform. The same robotic manipulator that applies finishing operations also positions repair tools, and the imaging system serves both inspection and process monitoring functions, reducing the need for separate specialized devices.
Solution Approach 2:
The system merges previously separate processes—defect inspection, defect classification, repair decision-making, and repair execution—into an integrated automated workflow. The imaging system, processing software, and robotic finishing system are combined to create a unified system that handles the complete defect management cycle without requiring separate manual intervention stages.
Data Source
AI summary
A method includes: compiling lower-resolution images, captured during a global scan cycle executed over a workpiece, into a virtual model; defining a nominal toolpath and a nominal target force for the workpiece based on a the virtual model; detecting a defect indicator on the workpiece based on the lower-resolution images; accessing a higher-resolution image captured during a local scan cycle over the defect indicator; characterizing the defect indicator as a defect reparable via material removal based on the higher-resolution image; defining a repair toolpath for the defect based on the virtual model; navigating a sanding head over the workpiece according to the repair toolpath to repair the defect; and, during a processing cycle: navigating the sanding head across the workpiece according to the nominal toolpath and deviating the sanding head from the nominal toolpath to maintain forces of the sanding head on the workpiece proximal the nominal target force.