Automated Wax Mold Assembly Using Laser Measurement and Force Torque Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual assembly process in lost wax casting is labor-intensive, time-consuming, and prone to variations, leading to quality issues and increased rework due to operator inconsistencies and difficulties in precisely measuring translucent wax and plastic materials.
Innovation Solution
An automated assembly system using multiple inverted 6-axis robots and a visible spectrum laser for precise measurement and adjustment, combined with a force/torque sensor for accurate positioning and processing, to ensure accurate assembly and inspection of wax molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used, then flexibility and adaptability are maintained, but labor intensity increases and assembly precision decreases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated robotic system that uses vision guidance and force/torque sensing to achieve precise assembly of wax mold components, eliminating human labor while maintaining or improving precision
Solution Approach 2:
The automated system performs self-adjustment through force/torque sensing during assembly operations, allowing the robot to automatically compensate for positioning variations and achieve precise assembly without continuous human intervention
2Measurement precision
If manual measurement of translucent wax materials is used, then operator judgment is applied, but measurement precision decreases due to material transparency
Solution Approach 1:
The patent replaces manual visual measurement with an automated vision system using cameras and lasers that can accurately detect the positions and dimensions of translucent wax components, overcoming the limitation of human visual perception through transparent materials
Solution Approach 2:
The patent introduces vision sensors and laser measurement devices as intermediaries between the translucent wax components and the measurement process, enabling accurate detection of material positions and dimensions that would be difficult to measure directly
3Productivity
If automated assembly is implemented, then productivity increases, but system complexity increases
Solution Approach 1:
The patent divides the automated assembly system into modular functional components including vision guidance subsystem, force/torque sensing subsystem, robotic manipulation subsystem, and control subsystem, allowing each to be optimized independently while working together to achieve high productivity
Solution Approach 2:
The patent designs the automated assembly system with multi-functional capabilities, where the robotic system performs multiple operations (positioning, assembly, adjustment) and the control system manages various sensing and actuation functions, reducing overall system complexity through consolidation
4Loss of time
If manual assembly is used, then setup cost is lower, but assembly time increases
Solution Approach 1:
The patent implements preliminary positioning and measurement operations using vision systems and sensors before the actual assembly operation, allowing the robotic system to quickly and accurately prepare components for assembly, reducing overall assembly time despite the automation investment
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 automated system significantly reduces variation, increases efficiency, and improves the quality of the finished product by enabling precise measurement and adjustment of wax mold components, reducing rework and enhancing the accuracy of the assembly process.
Implementation Method 1
a laser measurement and/or displacement system to determine the location of the one or more mold parts
Data Source
AI summary
The present disclosure relates to methods and systems for automating the assembly method for building a wax mold, including a force/torque sensor attached to a robotic arm that provides feedback to a robot controller to determine when to stop motion of the robotic arm, and using a visible spectrum laser to accurately measure translucent wax and plastic parts for orientation, processing, assembly and inspection of assembled products.