Electromagnetic Surface Processing Force Control on Complex Surfaces
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Solution Overview
Problem
Variations in the pressing force applied by surface processing tools can lead to inconsistencies in the final surface quality, particularly when dealing with complex surfaces with manufacturing tolerances, such as car bodies, causing discrepancies between the actual shape and the programmed path.
Innovation Solution
An electromagnetic actuator is used to control the pressing force of the surface processing device, allowing for precise and constant force application by adjusting the electric current, and a dual control loop system to maintain the desired force and displacement, enabling the device to compensate for shape mismatches and operate at high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a rigid connection is used between the robot and the surface processing device, then the robot can operate at high speed, but the pressing force varies significantly due to shape mismatches
Solution Approach 1:
The patent introduces an electromagnetic actuator as an intermediary element between the robot and the surface processing device. This actuator actively compensates for shape mismatches by adjusting the pressing force in real-time, allowing the robot to maintain high speed operation while the actuator ensures consistent pressing force application despite variations in surface geometry
Solution Approach 2:
The patent implements a feedback control mechanism where the actual pressing force is continuously measured and compared with the target pressing force. The electromagnetic actuator receives feedback signals and adjusts its output accordingly to maintain the desired pressing force, enabling the system to operate at high speeds while maintaining manufacturing precision
2Productivity
If the robot operates at high speed, then productivity increases, but the pressing force control becomes difficult due to shape variations
Solution Approach 1:
The electromagnetic actuator serves as a mediator that decouples the robot's high-speed motion from the pressing force application. It absorbs the disturbances caused by high-speed operation and shape variations, maintaining accurate pressing force control independent of robot speed
Solution Approach 2:
The patent employs a dynamic control approach where the electromagnetic actuator continuously adjusts the pressing force in real-time based on feedback signals. This dynamic adjustment capability allows the system to maintain precision even during high-speed operation when shape variations occur
3Manufacturing precision
If a pneumatic cushion element is used to reduce pressing force variations, then surface quality improves, but the system complexity increases
Solution Approach 1:
The patent replaces the passive pneumatic cushion element with an active electromagnetic actuator. This substitution transforms the compliance mechanism from a passive mechanical/pneumatic system to an active electromagnetic system with feedback control, achieving better pressing force consistency while reducing overall system complexity
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 ensures consistent surface quality by maintaining a constant pressing force, reducing discrepancies, and allowing high-speed operation while minimizing wear and electric losses, thus improving the processing efficiency and surface finish.
Implementation Method 1
The mover may comprise permanent magnets to generate an electromagnetic force by interacting with the magnetic field of the stator
Data Source
AI summary
A surface processing apparatus comprises a surface processing device to process a surface, a robot to move the surface processing device with respect to the surface, an electromagnetic actuator to electromagnetically apply an actuator force to the surface processing device, so as to cause the surface processing device to press against the surface with a controlled pressing force, and a control unit to control the pressing force by adjusting an electric current of the electromagnetic actuator.