Spherical Alignment Tool for Robotic Arm End-Effector Positioning
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Solution Overview
Problem
The existing methods for aligning robotic arms with end-effectors are cumbersome and prone to errors due to limited visibility of universal or quick-change connectors, requiring manual alignment with six degrees of freedom, which complicates the teaching process and increases the likelihood of misalignment.
Innovation Solution
A spherical tool and receiver system is introduced, where the spherical tool has a distal base portion that couples to the end-effector and a receiver with arms and indicators that couple to the robotic arm, allowing for precise alignment tracking and feedback through indicators to ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment of robotic arm with end-effector is performed using conventional connectors, then the robotic arm can be taught spatial poses for autonomous operation, but the alignment process becomes complex and error-prone due to limited visibility of connectors
Solution Approach 1:
A spherical alignment tool with visible indicators is introduced as an intermediary device between the robotic arm's connector and the end-effector's connector. This mediator provides visual feedback through indicators that extend or retract based on alignment status, making the alignment process observable and controllable without requiring direct visibility of the hidden connectors themselves.
Solution Approach 2:
The alignment indicators utilize visual color or position changes to communicate alignment status. When the robotic arm achieves proper alignment with the end-effector, indicators extend or change appearance to provide clear visual feedback to the operator, eliminating the need for complex measurement procedures and reducing alignment errors.
2Productivity
If conventional alignment methods are used, then the teaching process can be completed, but the process requires six degrees of freedom manual alignment which increases time and reduces productivity
Solution Approach 1:
The spherical alignment tool incorporates real-time visual feedback through indicators that immediately respond to alignment status. As the operator maneuvers the robotic arm, the indicators provide continuous feedback on alignment progress, enabling rapid convergence to the correct position without requiring time-consuming trial and error or complex measurement procedures.
Solution Approach 2:
The alignment system is designed to be self-guiding through its visual indicators. The indicators automatically extend or retract based on the relative positions of the connectors, providing self-service alignment guidance that reduces the operator's cognitive load and time requirement compared to conventional methods that require manual measurement and calculation.
3Measurement precision
If alignment pins are provided on connector plates, then some alignment assistance is provided, but visibility remains limited and alignment accuracy is insufficient
Solution Approach 1:
The alignment indicators extend in a dimension perpendicular to the connector interface plane, transitioning from a two-dimensional connector surface to a three-dimensional visual indicator. This dimensional extension makes the alignment status visible from a distance and from multiple angles, overcoming the visibility limitations of conventional alignment pins that remain hidden within the connector plane.
Data Source
AI summary
A device for aligning a robotic arm with an end-effector is provided. The device may include a spherical tool and a receiver. The spherical tool may include a spherical end portion and a distal base portion configured to releasably couple to the end-effector. The receiver may include a plurality of arms and a proximal base portion configured to releasably couple to the robotic arm. Furthermore, the arms may be configured to receive the spherical end portion and include one or more indicators configured to track alignment between the robotic arm and the end-effector.