Analysis of end effector operations by a robot

• US 10,118,297 B2
• Filed: 06/29/2016
• Issued: 11/06/2018
• Est. Priority Date: 06/29/2016
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Greer, Christopher A
• Primary Examiner(s): Bendidi, Rachid
• Application Number:
  US15/196,510
• Publication Number:
  US 20180001477A1
• Time in Patent Office: 860 Days
• CPC Class Codes: B25J 9/1692 Calibration of manipulator
• CPC Class Codes: B25J 9/1697 Vision controlled systems
• CPC Class Codes: G05B 19/128 the workpiece itself serves as a record carrier, e.g. by its form, by marks or codes on it
• CPC Class Codes: G05B 19/401 characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes G05B19/19 takes precedence
• CPC Class Codes: G05B 19/425 Teaching successive positions by numerical control, i.e. commands being entered to control the positioning servo of the tool head or end effector
• CPC Class Codes: G05B 2219/32025 Automatic marking of article
• CPC Class Codes: G05B 2219/37097 Marker on workpiece to detect reference position
• CPC Class Codes: G05B 2219/39024 Calibration of manipulator
• CPC Class Codes: G05B 2219/45134 Marking
• CPC Class Codes: G05B 2219/49327 Combine punch and marker, engraving for workpiece

Abstract

Systems and methods are provided for placing non-destructive marks onto a part via an end effector of a robot. One embodiment is a system comprising an end effector of a robot. The end effector includes an extendable punch that places targets onto a part, and supports that hold a strip of reflective adhesive tape between the punch and the part. Extending the punch cuts out a target from the strip and applies an adhesive side of the target to the part, and retracting the punch leaves a reflective side of the target visible on the part.

Claims

1. A system comprising:

an end effector of a robot, the end effector comprising;

an extendable punch that places targets onto a part;

supports that hold a strip of reflective adhesive tape between the extendable punch and the part, the tape having a reflective side and an adhesive side wherein extension of the punch cuts out a target from the strip and applies force that moves an adhesive side of the target to the part, and retraction of the extendable punch leaves the reflective side of the target visible on the part;

a memory storing a Numerical Control (NC) program directing the robot; and

a controller that directs actuators of the robot to reposition the end effector based on the NC program, wherein the NC program includes instructions for placing a target at each location where the part will be permanently altered.

2. The system of claim 1 wherein:

the controller revises the NC program based on actual locations of the targets.

3. The system of claim 1 wherein:

each target corresponds with a location on the part that will be drilled by the robot.

4. The system of claim 1 wherein:

the end effector takes the place of another end effector that will perform work on the part.

5. The system of claim 1 wherein:

the adhesive tape is removable from the part without damaging the part.

6. A method for controlling a robot via a controller, the method comprising:

identifying, via the controller, locations indicated by a Numerical Control (NC) program that includes instructions for placing a target at each location where a part will be permanently altered;

directing actuators of the robot to reposition an end effector based on the NC program;

placing, via the end effector of the robot, non-destructive marks onto the part at each of the locations indicated by the NC program, wherein placing the non-destructive marks comprises operations selected from the group consisting of;

extending a punch that applies removable tape to the part, extending an ink dispenser into contact with the part, and projecting a laser onto the part;

determining actual locations of the marks at the part, based on input from a sensing element;

comparing, via the controller, the actual locations of the marks to desired locations for permanently altering the part; and

determining an accuracy of the NC program based on the comparing prior to permanently altering the part.

7. The method of claim 6 wherein:

the non-destructive marks comprise reflective targets.

8. The method of claim 6 further comprising:

iteratively marking the part at the locations indicated by the NC program.

9. The method of claim 6 wherein:

the non-destructive marks are applied as reflective targets, ink spots, or laser spots.

10. The method of claim 6 further comprising:

directing an actuator to reposition a rigid body of the robot in order to adjust a location of the end effector mechanically coupled with the rigid body to a desired position.

11. The method of claim 6 further comprising:

adjusting the NC program based on the determining; and

applying a new mark at a location indicated by the adjusted NC program.

12. The method of claim 6, wherein:

placing the non-destructive marks onto the target comprises;

drawing a strip of reflective adhesive tape from a supply;

applying tension to the strip;

extending a punch to penetrate through the strip and cut out a target from the strip;

applying an adhesive side of the target to a part while the punch is extended;

retracting the punch behind the strip after applying the target, leaving a reflective side of the target visible on the part; and

drawing additional tape from the supply in response to the punch retracting, enabling the punch to cut out an additional target from the strip.

13. The method of claim 12 further comprising:

removing the target from the part without damaging the part.

14. A non-transitory computer readable medium embodying programmed instructions which, when executed by a processor, are operable for performing a method of operating an end effector of a robot, the method comprising:

identifying, via the controller, locations indicated by a Numerical Control (NC) program that includes instructions for placing a target at each location where the part will be permanently altered;

directing actuators of the robot to reposition the end effector based on the NC program;

placing, via the end effector of the robot, non-destructive marks onto the part at each of the locations indicated by the NC program, wherein placing the non-destructive marks comprises operations selected from the group consisting of;

extending a punch that applies removable tape to the part, extending an ink dispenser into contact with the part, and projecting a laser onto the part;

determining actual locations of the marks at the part, based on input from a sensing element;

comparing, via the controller, the actual locations of the marks to desired locations for permanently altering the part; and

determining an accuracy of the NC program based on the comparing prior to permanently altering the part.

15. The medium of claim 14, wherein the method further comprises:

iteratively marking the part at locations indicated by the NC program and determining accuracy of the NC program.

16. The medium of claim 14 wherein:

each target corresponds with a location on the part that will be drilled by the robot.

17. The medium of claim 14 wherein the method further comprises:

replacing the end effector with another end effector that will perform work on the part.

18. The medium of claim 14 wherein the method further comprises:

removing the target from the part without damaging the part.

19. A system comprising:

a robot comprising;

a marking element that applies non-destructive marks to a part, wherein the marking element performs operations selected from the group consisting of;

extending a punch that applies removable tape to the part, extending an ink dispenser into contact with the part, and projecting a laser onto the part; and

a controller that directs actuators of the robot to reposition the end effector based on a Numerical Control (NC) program that indicates that permanent alterations will be made on the part, directs the marking element to apply the non-destructive marks at each location where the NC program indicates that permanent alterations will be made on the part, that determines actual locations of the marks at the part, that compares the actual locations of the marks to desired locations for permanently altering the part, and that determines an accuracy of the NC program based on the comparing, prior to permanently altering the part.

20. The system of claim 19 wherein:

the robot further comprises a mark sensing element that detects the locations of the marks on the part.

21. The system of claim 20 wherein:

the controller compares the detected locations with desired locations, and revises the NC program based on the comparison.

22. The system of claim 19 wherein:

the marks are selected from the group comprising;

reflective targets, ink spots, and laser spots.

23. The system of claim 19 wherein:

the NC program indicates that each location will be drilled by the robot.