Sensor-Based Tool Orientation Feedback for Precise Positioning
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Solution Overview
Problem
Current automated manufacturing systems, particularly those using robots, are expensive, impractical for space-limited facilities, and inefficient in determining and maintaining the precise orientation and positioning of tools, which affects the quality of fabricated articles.
Innovation Solution
A tool positioning system comprising tool sensors and a control module that communicate to determine and indicate the orientation and position of tools relative to a substrate, using sensors like accelerometers, gyroscopes, and GPS for accurate calibration and operation, allowing for retrofitted or integrated solutions to existing tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated manufacturing systems use robots to determine and maintain tool orientation and positioning, then manufacturing precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical robotic systems with electronic sensor-based orientation determination. Tool sensors (accelerometers, gyroscopes, magnetometers) electronically detect tool orientation and position relative to substrate, eliminating the need for mechanical robotic positioning systems while achieving comparable precision.
Solution Approach 2:
The patent introduces sensor systems as intermediaries between the tool and the manufacturing process. These sensors act as mediators that provide orientation and positioning data without requiring direct mechanical intervention from complex robotic systems, simplifying the overall system architecture.
2Manufacturing precision
If automated manufacturing systems use robots for tool positioning, then manufacturing precision is improved, but ease of operation deteriorates due to programming requirements
Solution Approach 1:
The tool sensors automatically determine their own orientation and position relative to the substrate without requiring external programming or control systems. The sensors self-calibrate and provide real-time feedback, eliminating the need for operator programming while maintaining positioning accuracy.
Solution Approach 2:
The system implements real-time feedback through tool sensors that continuously monitor tool orientation and position. This feedback mechanism allows automatic adjustment and correction without programming, as the system self-regulates based on sensor data, improving both precision and ease of operation.
3Manufacturing precision
If traditional robotic systems are used for tool positioning, then manufacturing precision is improved, but adaptability deteriorates due to space requirements and deployment limitations
Solution Approach 1:
The patent replaces bulky mechanical robotic systems with compact electronic sensor systems that can be integrated into existing tools. This substitution enables deployment in space-limited facilities while maintaining orientation control precision, as the sensor-based system requires minimal space compared to mechanical robots.
Solution Approach 2:
The sensor-based tool positioning system can be applied across multiple manufacturing contexts and facility types without requiring specialized infrastructure. The system adapts to different tool types and manufacturing environments, providing universal applicability that mechanical robotic systems cannot achieve.
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
Enables precise and efficient orientation and positioning of tools, improving manufacturing quality and usability by providing real-time feedback to users, making the system more economical and deployable in various settings, including space-limited facilities.
Implementation Method 1
using sensors like accelerometers, gyroscopes, and GPS for accurate calibration and operation
Implementation Method 2
using sensors like accelerometers, gyroscopes, and GPS for accurate calibration and operation
Data Source
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AI summary
Systems and methods for tool orientation and/or position determining system are described herein. In one example, a plurality of tool sensors can be coupled to a tool. The tool sensors can provide data to a control module or system controller. The orientation and/or position of the tool can accordingly be determined from the data. If the orientation and/or position of the tool matches a desired orientation, the tool and/or control module can provide an indication that the tool is in the desired orientation.