Tactile Robot Parting Device for Solar Modules
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Solution Overview
Problem
Existing separating devices for trimming solar modules, such as those with multi-axis robots and cutting tools, face challenges in precision, tool wear, and safety, particularly when dealing with fragile overhangs, as they may cause damage and require complex protective measures.
Innovation Solution
A multi-axis tactile robot with force- or torque-controlled axes, integrated edge-scanning sensors, and a vibrating cutting tool, which can detect mechanical resistance and adjust movements to prevent damage, optimize cutting processes, and reduce tool wear by enabling automatic wear compensation and precise edge detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional multi-axis robot with position-controlled axes is used for cutting, then the cutting path can be precisely followed, but the robot cannot react to mechanical resistance and may cause damage to the workpiece
Solution Approach 1:
The patent transforms the static position-controlled robot into a dynamic force-controlled system. The robot axes are equipped with force control that allows real-time adaptation to mechanical resistance during cutting. This enables the robot to maintain precise cutting path following while simultaneously reacting to varying workpiece conditions, thus preventing damage through active force regulation rather than passive position control.
Solution Approach 2:
The patent implements force feedback control where sensors detect mechanical resistance during cutting and feed this information back to the robot controller. This closed-loop feedback system allows the robot to continuously adjust its cutting forces based on actual workpiece conditions, resolving the contradiction between maintaining precise cutting paths and preventing workpiece damage through real-time adaptation.
2Object-affected harmful factors
If heating wires or laser beams are used for cutting, then the cutting process can be performed without contact, but harmful gases or particles may be produced and material wear increases
Solution Approach 1:
The patent replaces thermal cutting methods (heating wires and laser beams) with a mechanical cutting system. Instead of using heat to melt and separate material, a physical cutting tool with cutting edges mechanically separates the workpiece. This substitution eliminates the production of harmful gases and particles associated with thermal processes while using a robust mechanical tool designed to withstand wear.
Solution Approach 2:
The patent changes the fundamental cutting parameter from thermal energy to mechanical force. By transitioning from temperature-based cutting to force-based cutting, the system eliminates harmful thermal byproducts. The cutting tool is designed with specific mechanical properties (hardness, toughness, geometry) optimized for mechanical separation, thereby extending tool life through appropriate material selection and design rather than suffering from thermal degradation.
3Ease of manufacture
If a mechanical cutting tool is used, then the construction and cost are reduced, but the tool is subject to wear
Solution Approach 1:
The patent implements automatic tool wear compensation where the force-controlled robot system continuously monitors cutting forces and adapts to tool wear in real-time. As the cutting tool wears, the force control system adjusts the applied forces and cutting parameters to maintain optimal cutting performance. This self-service approach allows the use of simple, cost-effective mechanical tools while compensating for wear through intelligent control, thereby extending effective tool life without requiring complex or expensive tools.
4Reliability
If complex protective measures are implemented to ensure safety, then safety is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical protective measures with a force-controlled robot system that inherently ensures safety through controlled interaction forces. Instead of using physical barriers, interlocks, and protective enclosures, the system relies on force sensors and control algorithms to detect and respond to workpiece conditions, operator presence, and potential hazards. This substitution reduces device complexity while maintaining or improving safety through intelligent force regulation.
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 enhances precision and safety by allowing the robot to react to mechanical resistance, reducing tool wear, and minimizing damage to the workpiece, while also simplifying the cutting process and reducing the need for protective measures.
Implementation Method 1
A multi-axis tactile robot with preferably force-controlled or force-regulated or torque-controlled or torque-regulated robot axes
Implementation Method 2
The robot is designed to perform a vibration movement, in particular when the cutting tool is advanced
Implementation Method 3
Alternatively or additionally, the separating tool is designed as a vibrator tool, in particular as a vibrator blade
Data Source
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AI summary
A parting device and a parting method are provided, in particular for trimming workpieces (2), in particular solar modules. The parting device has a multi-member (12, 13, 14, 15) programmable robot (6) which is in the form of a tactile robot, in particular a force/torque-regulated robot. The robot guides a parting tool (8) which is in the form of a knife.