Abstract
This paper presents a robotic assembly methodology for the manufacturing of large segmented composite structures. The approach addresses three key steps in the assembly process: panel localization and pick-up, panel transport, and panel placement. Multiple stationary and robot-mounted cameras provide information for localization and alignment. A robot wrist-mounted force/torque sensor enables gentle but secure panel pick-up and placement. Human-assisted path planning ensures reliable collision-free motion of the robot with a large load in a tight space. A finite state machine governs the process flow and user interface. It allows process interruption and return to the previous known state in case of error condition or when secondary operations are needed. For performance verification, a high resolution motion capture system provides the ground truth reference. An experimental testbed integrating an industrial robot, vision and force sensors, and representative laminated composite panels demonstrates the feasibility of the proposed assembly process. Experimental results show sub-millimeter placement accuracy with shorter cycle times, lower contact force, and reduced panel oscillation than manual operations. This work demonstrates the versatility of sensor guided robotic assembly operation in a complex end-to-end tasks using the open source Robot Operating System (ROS) software framework.
Highlights
Composite wind turbine blades more than 50 meters in length are routinely used for wind power generation
Our goal is to demonstrate the ability of a sensor-based industrial robot, without the benefit of any mechanical alignment fixturing, to efficiently and accurately locate and pick up flexible laminate panels from a loosely defined pick-up point, transport each panel to the assembly nest quickly, align the panel precisely through the vision system with the nest and with other panels, and place it softly and accurately into the nest using force feedback
This paper presents an industrial robotic system for large composite assembly using force and vision guidance, demonstrated in both simulation and experiments
Summary
Composite wind turbine blades more than 50 meters in length are routinely used for wind power generation. Industrial robots offer the potential of assisting with the manipulation and assembly of these large, curved, and flexible panels under human supervision Such an approach would reduce the drudgery of manual labor and could decrease cycle time, improve precision, enhance consistency, and offer versatility to adapt to different part geometries and manufacturing processes. This work contributes to the development and demonstration of the architecture and methodology for using a sensor-driven industrial robot to perform a complete multi-step manufacturing process efficiently and precisely. This capability is beyond how robots are used in manufacturing processes today, which still largely depends on teach-andrepeat operations with dedicated fixtures for alignment and support.
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