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Novel optical instrumentation for robotic manufacturing

用于机器人制造的新型光学仪器

基本信息

批准号：
EP/M020401/1
负责人：
Ralph Tatam
金额：
$ 82.43万
依托单位：
CRANFIELD UNIVERSITY
依托单位国家：
英国
项目类别：
Research Grant
财政年份：
2015
资助国家：
英国
起止时间：
2015 至无数据
项目状态：
已结题

来源：
https://gtr.ukri.org/projects?ref=EP%2FM020401%2F1
关键词：
Novel optical instrumentation robotic manufacturing

项目摘要

The aim of this proposal is to undertake research into novel optical instrumentation to support future manufacturing aims for more agile and flexible manufacturing systems as well as to improve precision of traditional robot-based manufacturing operations. New optical instrumentation will be developed combining two complimentary optical measurements techniques, range-resolved interferometry and laser speckle pattern correlation. These will be capable of remote, high quality and high-bandwidth measurements of the relative motion and orientation between a robotic end-effector mounted sensor and the workpiece, cumulating in a combined multi-parameter sensor.The applications of these sensors are common to many areas of manufacturing and can be grouped into three main areas:i) The stabilisation and control of the end-effector relative to the workpiece.ii) Motion tracking to lock the robot to a moving assembly line.iii) Relative positioning operations. In these application areas there is a need for new effective, low cost instrumentation to provide real-time feedback about their relative motion and orientations, which this proposal will attempt to address.In the first application area, the stabilisation and control of a tool's motion, positioning and orientation is required in the presence of end-effector and/or workpiece vibrations. For example contact tasks such as polishing, drilling, and riveting are often challenging tasks due to the comparatively low mechanical stiffness of typical industrial robots. This can result in excessive tool-tip deflection, vibration, and resulting poor quality of the finished part. Other methods of monitoring the motion suffer from limitations; vision systems can have limited update rates, whilst laser scanning/tracking systems are expensive and inflexible in that the scanning system needs to be mounted externally to the robot and maintain a line-of-sight.The motion tracking of robotic manipulators to follow moving assembly lines is an important application in many manufacturing operations. Currently vision-systems can provide a flexible sensor capable of determining the relative position and orientation of objects to good precision, but their slow update rate and latency make them unsuitable for many feedback loops for real-time motion control. In addition, these visual systems sometimes require visual markers or beacons for operation and unless the cameras are mounted directly on the end-effector, the field-of-view can sometimes be obscured towards the end of the manoeuvring operation, at the point where control is most critical.Finally, in the area of relative positioning many applications require high accuracy relative to a reference and this makes the adoption of standard robots difficult. For example, in airframe manufacturing the high accuracies of between 0.2 mm and 0.02 mm relative to a local reference a few meters away are required for drilling, fettling and component location operations and in remote laser cutting there is a requirement for high precision in the positioning of the cutting beam between scans, with any misalignment leading to multiple grooves and failure to cut the workpiece. Here laser speckle correlation may offer a solution with the proposed sensors capable of precise relative positioning between the end-effector and workpiece (potentially down to <1 micron in mm's and <50 micron in m's) while relying on other means, such as the robot encoders or vision systems, to reference to an absolute position.

该提案的目的是对新型光学仪器进行研究，以支持未来制造目标，实现更敏捷和灵活的制造系统，并提高传统机器人制造操作的精度。新的光学仪器将结合两个互补的光学测量技术，距离分辨干涉测量和激光散斑相关。这些传感器将能够远程、高质量和高带宽地测量机器人末端执行器安装的传感器和工件之间的相对运动和方向，累积在组合的多参数传感器中。这些传感器的应用在许多制造领域都很常见，可以分为三个主要领域：i）末端执行器相对于工件的稳定和控制。ii）将机器人锁定到移动装配线的运动跟踪。iii）相对定位操作。在这些应用领域中，需要新的有效的、低成本的仪器来提供关于它们的相对运动和取向的实时反馈，本建议将试图解决这一问题。在第一个应用领域中，在存在末端执行器和/或工件振动的情况下，需要稳定和控制工具的运动、定位和取向。例如，由于典型工业机器人的机械刚度相对较低，抛光、钻孔和铆接等接触任务通常是具有挑战性的任务。这可能导致过度的刀尖偏转、振动，并导致成品零件的质量差。其他监控运动的方法有其局限性;视觉系统的更新速率有限，而激光扫描/跟踪系统昂贵且不灵活，因为扫描系统需要安装在机器人外部并保持视线。机器人操纵器跟踪移动装配线的运动跟踪在许多制造操作中是一个重要的应用。目前的视觉系统可以提供一种灵活的传感器，能够确定物体的相对位置和方向，以良好的精度，但他们的更新速度慢和延迟使他们不适合许多反馈回路的实时运动控制。此外，这些视觉系统有时需要用于操作的视觉标记或信标，并且除非摄像机直接安装在末端执行器上，否则视场有时会在操纵操作的末端、在控制最关键的点处变得模糊。在相对定位领域，许多应用要求相对于基准的高精度，这使得采用标准机器人难例如，在机身制造中，钻孔、修整和部件定位操作需要相对于几米远的局部基准在0.2mm和0.02mm之间的高精度，并且在远程激光切割中，在扫描之间的切割光束的定位中需要高精度，任何未对准都会导致多个凹槽和切割工件的失败。这里，激光散斑相关可以提供一种解决方案，其中所提出的传感器能够在末端执行器和工件之间进行精确的相对定位（可能低至以mm计<1微米和以m计<50微米），同时依赖于其他装置（例如机器人编码器或视觉系统）来参考绝对位置。