Sensor-Guided Robotic Cell Positioning for Flexible Press Brake Automation
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Solution Overview
Problem
Existing positionable robotic cells for manufacturing devices, such as sheet metal machining devices, are inflexible and require fixed positioning, leading to increased labor costs and limitations in reorganization, as well as safety concerns due to the need for blocking the work zone.
Innovation Solution
A positionable robotic cell equipped with a sensor device for self-detection and repositioning, allowing flexible placement and orientation relative to the manufacturing device, using sensors like laser, ultrasonic, mechanical, or magnetic sensors for precise positioning, and a repositioning device for autonomous movement, enabling communication with the manufacturing device for safe and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot is permanently associated with a manufacturing device, then automation is improved, but labor costs increase and reorganization becomes difficult
Solution Approach 1:
The robotic cell is made dynamically repositionable through wheeled mobility and sensor-based dynamic positioning. The cell can be moved to different locations and orientations using wheels, and sensors (laser, ultrasonic, mechanical, or magnetic) enable the robot to dynamically adapt to new positions and maintain proper orientation relative to the manufacturing device, resolving the contradiction between automation and reorganization flexibility.
2Reliability
If the work zone of the robot is blocked off, then safety is improved, but operational flexibility deteriorates
Solution Approach 1:
The robotic cell incorporates movable safety barriers or interlocked gates that can dynamically open or close based on operational mode. During automated operation, the work zone is enclosed for safety. During manual attendance or repositioning, the barriers can be opened while sensors monitor the environment to maintain safety, thus resolving the contradiction between safety and operational flexibility.
Solution Approach 2:
The robotic cell uses sensors to detect the presence of operators or workpieces and automatically adjusts the state of safety barriers. The system self-regulates between enclosed automated mode and open manual mode, eliminating the need for permanent blocking and enabling flexible manual attendance while maintaining safety.
3Measurement precision
If centering blocks are provided on the floor, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces the mechanical centering block system with sensor-based positioning. Laser sensors, ultrasonic sensors, mechanical sensors, or magnetic sensors detect the position of the robotic cell relative to the manufacturing device and provide feedback for automatic positioning. This substitutes complex mechanical positioning infrastructure with more flexible sensor-based systems, maintaining positioning precision while reducing overall system complexity.
Solution Approach 2:
The robotic cell performs self-positioning using onboard sensors that detect its location and orientation relative to the manufacturing device. The sensor system automatically adjusts the position without requiring external centering blocks or manual alignment, achieving precise positioning while simplifying the overall system by eliminating separate positioning infrastructure.
Data Source
AI summary
The invention relates to a positionable robotic cell for placement at a bending machine. The robotic cell comprises a frame for receiving the robot and a receiving device for a workpiece as well as a positioning device for repositioning the robotic cell. Moreover, a first sensor device is provided for recognizing the position of the robotic cell relative to the manufacturing device. The invention furthermore relates to a production facility with a bending machine and with such a robotic cell as well as a method for operating such a robotic cell at a bending machine.