Vision-Based Machining Head for Robot Accuracy Correction
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Solution Overview
Problem
Anthropomorphic robots lack the necessary stiffness and accuracy for precise machining tasks due to their low precision, and existing solutions to improve accuracy are either costly or limited in effectiveness, such as high-precision equipment or external measuring systems that require clear line-of-sight and are not always feasible.
Innovation Solution
An automated machining head with vision equipment, including 3D video cameras and a laser projector, connected to a computer and robot controller, which uses specific software to correct robot positioning and orientation in real-time by scanning the work surface and applying mechanical locking, allowing for precise machining operations like drilling and riveting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If anthropomorphic robots are used for machining tasks, then versatility and cost-effectiveness are improved, but manufacturing precision deteriorates due to lack of stiffness and accuracy
Solution Approach 1:
The patent replaces mechanical precision systems with vision-based measurement and correction systems. Instead of using high-precision mechanical equipment or modifying the robot's mechanical structure, the invention uses 3D vision equipment to detect workpiece geometry and robot position, then corrects positioning errors through software calculations and real-time control adjustments.
Solution Approach 2:
The patent introduces vision equipment as an intermediary between the robot and the workpiece. The 3D cameras and laser projector capture workpiece geometry and robot position information, which is then processed by a computer to calculate correction values. This intermediary system enables precision correction without modifying the robot's mechanical structure.
2Manufacturing precision
If high-precision equipment or parallel kinematic machines are used, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex high-precision mechanical equipment with a vision-based measurement and correction system. The solution uses 3D cameras, laser projector, and computer processing to achieve precision correction, avoiding the need for expensive parallel kinematic machines or heavily modified robot systems.
Solution Approach 2:
The patent creates a digital copy of the workpiece geometry and robot position through vision measurement. The 3D vision system captures the workpiece shape and robot location, then uses this digital information to calculate and apply correction values, eliminating the need for physical measurement devices or complex mechanical correction mechanisms.
3Manufacturing precision
If external measuring systems like laser trackers are used, then manufacturing precision is improved, but reliability deteriorates due to requirement for clear line-of-sight
Solution Approach 1:
The patent nests the vision equipment within the robot end effector or pressure foot structure. The 3D cameras and laser projector are integrated into the machining head, allowing measurements to be taken from the exact position where machining occurs. This eliminates the need for external laser trackers that require clear line-of-sight from a distance.
Solution Approach 2:
The patent uses vision equipment as an intermediary positioned at the robot end effector to directly measure workpiece geometry and robot position at the machining location. This eliminates the need for external measuring systems that require clear line-of-sight paths, as the vision system operates from within the machining head where obstructions are minimal.
4Manufacturing precision
If standard robots are modified with high-accuracy encoders and CNC controllers, then manufacturing precision is improved, but ease of repair and maintenance deteriorate
Solution Approach 1:
The patent replaces mechanical precision modifications (encoders, CNC controllers) with a vision-based correction system. Instead of modifying the robot's mechanical components, the invention uses 3D vision equipment and software to detect and correct positioning errors, maintaining standard robot hardware that is easier to maintain and repair.
Solution Approach 2:
The patent creates a digital model of the workpiece and robot position through vision measurement, then uses this information to calculate correction values. This approach avoids physical modifications to the robot's mechanical systems, preserving the original hardware that can be easily maintained and repaired according to manufacturer specifications.
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 significantly enhances the accuracy of anthropomorphic robots to match that of high-precision machines, enabling precise positioning and orientation corrections in real-time, reducing errors, and allowing for higher preload forces without mechanical slippage, thus improving machining processes like drilling and riveting.
Implementation Method 1
which includes several video cameras and, optionally, a laser projector
Data Source
AI summary
An automated machining head with vision and procedure includes a pressure foot provided with side windows with the capacity to open and close, encasing the machining tool, associated with a vertical movement device provided with mechanical locking, vision equipment connected to a computer and a communications module. The main advantage is endowing an anthropomorphic robot, originally designed for the car industry and with relatively low accuracy, with a notably higher machining accuracy, equivalent to equipment of a much greater accuracy or to parallel kinematic-type robots, also compensating, in real-time and in a continuous manner, for off-centring and loss of perpendicularity by the pressure foot, which are common in conventional heads and are a source of errors and inaccuracy.