Switchgear Mounting Plate Alignment Using Optical Robot Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing arrangements for mounting and wiring electrical components in switchgear construction require high precision, leading to submillimeter error tolerances and necessitate frequent readjustments or manual intervention, especially for complex processing steps like cable feeding.
Innovation Solution
The integration of an optical imaging system with a robot that can detect the orientation of a mounting plate relative to the robot, allowing for the calculation and application of offsets to position data, enabling automated execution of high-precision processing steps without the need for precise initial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high precision alignment of mounting plate with robot is required, then manufacturing precision is improved, but device complexity and ease of operation deteriorate due to frequent readjustments and manual intervention
Solution Approach 1:
The patent replaces mechanical alignment systems with an optical imaging system that uses visual feedback and coordinate transformation algorithms. The system captures images of the mounting plate, detects its actual position and orientation, calculates transformation matrices, and adjusts robot position data accordingly, eliminating the need for mechanical precision alignment mechanisms
Solution Approach 2:
The patent implements a feedback loop where the optical imaging system continuously monitors the mounting plate's position, the controller calculates the deviation from the reference coordinate system, and the robot's position data is dynamically adjusted based on this feedback. This closed-loop control enables automatic compensation for alignment errors
2Manufacturing precision
If high precision alignment is attempted, then manufacturing precision is improved, but loss of time increases due to frequent readjustments and manual intervention
Solution Approach 1:
The system performs self-alignment through automatic detection and compensation. The optical imaging system automatically captures images, the controller automatically calculates transformation matrices, and the robot automatically adjusts its position data, eliminating the need for manual alignment operations and reducing process time
Solution Approach 2:
The patent performs preliminary detection and calculation of the mounting plate's position and orientation before the actual component mounting begins. The transformation matrix is calculated in advance, allowing the robot to immediately use corrected position data without interruption during the manufacturing process
3Ease of operation
If manual intervention is used for complex processing steps, then ease of operation is improved, but extent of automation deteriorates
Solution Approach 1:
The patent creates a universal automated system that handles multiple complex tasks including component placement, cable routing, and crimping through the robot equipped with interchangeable end effectors. The optical imaging system and coordinate transformation approach provide a universal framework that works for various component types and mounting configurations
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 the automation of high-precision processing steps in switchgear construction, reducing the need for manual intervention and improving the reliability and efficiency of the mounting and wiring processes.
Implementation Method 1
the robot is provided with an optical imaging system configured to detect an orientation of a mounting plate with respect to the robot
Data Source
AI summary
An arrangement for the assembly and wiring of electrical components in switchgear construction, the arrangement comprising a robot with an end effector designed as a gripper, a mounting plate holding device, with which a mounting plate is held in a mounting position with respect to the robot, and a component supply in the access area of the robot, via which components to be mounted on the mounting plate are provided for removal by the robot, wherein a controller of the robot has machine data for controlling the robot including position data for the arrangement of components on a mounting plane of a mounting plate to be equipped, wherein the robot has an optical imaging system which is adapted to detect an orientation of a mounting plate with respect to the robot, the controller of the robot being adapted to provide the position data with an offset representing the orientation of the mounting plate with respect to the robot as a function of the detected orientation. A corresponding method is further described.