Switchgear Mounting Plate Alignment for Robotic Wiring Precision
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Solution Overview
Problem
Existing arrangements for assembling and wiring electronic components in switchgear require high precision, leading to manual intervention in critical steps due to submillimeter error tolerances, which limits automation in precise processing tasks.
Innovation Solution
An optical imaging system with a stereo camera detects the orientation of the mounting plate relative to the robot, calculates an offset from detected deviations, and adjusts position data for further processing steps, enabling automated high-precision tasks like component placement and wiring without precise initial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mounting plate is positioned with high precision relative to the robot, then reliable component arrangement and wiring is achieved, but the system complexity and calibration requirements increase significantly
Solution Approach 1:
The patent replaces the mechanical positioning and calibration system with an optical imaging system. Instead of using complex mechanical calibration procedures to achieve submillimeter precision, the system uses optical fields (cameras and imaging devices) to detect the mounting plate's position and orientation, then compensates through software-based coordinate transformations. This substitutes mechanical precision requirements with optical detection and computational correction.
Solution Approach 2:
The patent changes the reference frame parameters dynamically. Rather than fixing the mounting plate in a precise position, the system detects the actual position and orientation parameters of the mounting plate, then transforms all component position data into the detected reference frame. This parameter transformation approach allows the system to adapt to any mounting plate configuration while maintaining manufacturing precision.
2Manufacturing precision
If frequent readjustment or manual intervention is used for high precision processing steps, then reliable cable feeding and wiring is achieved, but productivity and automation extent decrease
Solution Approach 1:
The patent implements a feedback loop where the optical imaging system continuously detects the mounting plate's position and orientation during assembly operations. The detected information is fed back to the controller, which automatically adjusts the robot's movements and component placement positions. This closed-loop feedback system maintains high precision for cable feeding and wiring without requiring manual readjustment, thereby preserving productivity and enabling full automation.
Solution Approach 2:
The system enables the robot to self-correct its positioning automatically. Through the optical imaging system's detection and the controller's coordinate transformation, the robot autonomously compensates for any mounting plate misalignment or drift during the assembly process. This self-service capability eliminates the need for operator intervention in precision-critical steps like cable feeding, maintaining both high precision and continuous productivity.
3Manufacturing precision
If manual intervention is required for processing steps, then high precision wiring tasks can be performed, but the extent of automation and labor requirements worsen
Solution Approach 1:
The patent replaces manual mechanical positioning and alignment operations with an optical detection and computational correction system. The optical imaging system captures images of the mounting plate and components, and the controller automatically calculates the transformation between the detected reference frame and the robot's reference frame. This substitution enables the robot to perform precision wiring tasks autonomously without manual intervention, achieving full automation while maintaining high wiring precision.
Solution Approach 2:
The system creates a digital copy of the mounting plate's actual position and orientation through optical imaging. Instead of physically measuring and manually inputting coordinates, the imaging system captures visual information and the controller generates a digital representation of the mounting plate's configuration. This digital copy is then used to automatically calculate offset values and guide the robot's precision movements, enabling automated high-precision wiring without manual measurement and positioning.
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
This solution allows for fully automated processing of electronic components, including drilling, cutting, assembly, and wiring, by compensating for deviations in mounting plate alignment, thereby increasing automation and reducing manual intervention in switchgear construction.
Implementation Method 1
the robot has an optical imaging system which is configured to detect an orientation of a mounting plate with respect to the robot
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an arrangement for fitting and wiring electronic components (11, 15) in switchgear engineering, wherein the arrangement contains a robot (10) having an end effector in the form of a gripper (1), a mounting plate holding device (18) by way of which a mounting plate (12) is held in a mounting position in relation to the robot (10), and a component supply (13) within access of the robot (10), by way of which components (11, 15) to be mounted on the mounting plate (12) are provided for retrieval by the robot (10), wherein a controller (2) of the robot (10) contains machine data for actuating the robot (10), including position data for arranging components (11, 15) on a mounting plane (E) of a mounting plate (12) to be populated, characterized in that the robot (10) has an optical imaging system (3) that is designed to record an orientation of a mounting plate (12) in relation to the robot (10), wherein the controller (2) of the robot (10) is designed, depending on the recorded orientation, to provide the position data with an offset representing the orientation of the mounting plate (12) in relation to the robot (10). A corresponding method is also described.