Robot Screw Gauge Insertion With Lateral Force Alignment
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Solution Overview
Problem
Existing thread inspection devices face challenges in accurately aligning the limit gauge with the screw hole, leading to incomplete inspections and potential damage to the screw hole due to misalignment or eccentricity, and require separate devices for rotating the limit gauge.
Innovation Solution
A control device and method using a robot arm with a force detector to precisely align and insert a screw gauge into a screw hole by performing force control perpendicular to the screw hole's axis, allowing for accurate alignment and insertion without damaging the screw hole, and enabling rotation of the screw gauge without additional devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the limit gauge is rotated with a rotary motor while vertically moving it with a reciprocation device, then the inspection can be performed, but the device complexity increases and the alignment between the limit gauge and screw hole becomes difficult to maintain
Solution Approach 1:
The patent combines the rotary motor and reciprocation device into a single robot arm that performs both rotational and linear movements. This integration eliminates the need for separate devices, reducing overall system complexity while maintaining full automation capability for the inspection process
Solution Approach 2:
The robot arm is designed to perform multiple functions: it can rotate the screw gauge, move it vertically for insertion, and position it with high precision. This multi-functional design replaces multiple specialized devices with a single versatile robot system, simplifying the overall device architecture
2Reliability
If the positions of the limit gauge and screw hole do not completely coincide, then the inspection cannot be performed, but achieving complete coincidence requires high manufacturing precision
Solution Approach 1:
The robot system incorporates sensors and control systems that provide real-time feedback on the position and orientation of the screw gauge relative to the screw hole. This feedback mechanism allows the robot to make automatic adjustments to achieve precise alignment, ensuring reliable inspection without requiring extremely high initial manufacturing precision
Solution Approach 2:
The robot arm provides dynamic positioning capability, allowing real-time adjustment of the screw gauge position and orientation during the inspection process. This dynamic adjustment capability compensates for any initial misalignment and ensures precise coincidence between the gauge and screw hole
3Object-affected harmful factors
If there is eccentricity in the limit gauge or inspection device, then damage or breaking of the screw hole may occur, but preventing damage requires additional control mechanisms
Solution Approach 1:
The robot system uses force sensors and position feedback to monitor the insertion process in real-time. When resistance or misalignment is detected that could lead to damage, the system automatically adjusts the insertion force and position, preventing damage to the screw hole without requiring complex additional control mechanisms
Solution Approach 2:
The robot system dynamically changes insertion parameters such as speed, force, and position during the inspection process. By adjusting these parameters based on real-time conditions, the system prevents damage from eccentricity while maintaining a relatively simple control structure
4Ease of operation
If a separate device is used for rotating the screw gauge, then the rotation can be controlled, but the device size and complexity increase
Solution Approach 1:
The patent integrates the rotation function directly into the robot arm, eliminating the need for a separate rotary device. The robot arm's built-in rotational capability provides sufficient control for the inspection process while reducing the overall number of components and simplifying the system structure
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 enables easy and accurate insertion of the screw gauge into the screw hole, prevents damage, and allows for efficient inspection of both penetrating and non-penetrating screw holes without additional equipment, reducing the size and complexity of the robotic system.
Implementation Method 1
detect force applied to the screw gauge using the force detector
Data Source
AI summary
A control device adapted to control a robot including a robot arm provided with a force detector includes a processor that is configured to execute computer-executable instructions so as to control the robot, wherein the processor is configured to: operate the robot arm to move a screw gauge which is disposed on a tip side of the force detector of the robot arm, used for an inspection of a screw hole, and provided with an external thread, to make the external thread have contact with the screw hole; then detect force applied to the screw gauge using the force detector to perform force control in a direction perpendicular to a direction of an axis of the screw hole based on detection information of the force detector; and operate the robot arm to move the screw gauge based on the force control.