Fast part forming using intelligent robotic system with interchangeable tools
A system includes a frame holding a part, a robot arm adjacent to the frame, a tool rack with a plurality of tools that are interchangeable, and a controller. The controller controls the robotic arm to automatically attach a forming tool from the tool rack to the tool holder; controls the robotic arm with the forming tool to form the part in a first geometry into a second geometry; and controls the robotic arm to automatically return the forming tool to the tool rack and detach the forming tool from the tool holder.
1 . A system comprising:
a frame configured to hold a metal sheet;
a robotic arm adjacent to the frame and configured to move through space;
a tool rack;
a plurality of tools in the tool rack, the plurality of tools including a forming tool and a trimming tool, each tool of the plurality of tools interchangeably attachable to a tool holder at a first end of the robotic arm; and
a controller configured to control the robotic arm through execution of program code stored on a non-transitory computer readable storage medium, the program code when executed causes the controller to:
control the robotic arm to automatically attach the forming tool in the tool rack to the tool holder;
control the robotic arm with the forming tool to form the metal sheet in a first geometry into a second geometry different than the first geometry;
control the robotic arm to automatically return the forming tool to the tool rack and detach the forming tool from the tool holder;
control the robotic arm to automatically attach the trimming tool in the tool rack to the tool holder;
control the robotic arm with the trimming tool to trim the metal sheet in the second geometry into a trimmed metal part, wherein to control the robotic arm to trim the metal sheet, the program code, when executed, causes the controller to:
while trimming the metal sheet along a trimming path, use a scanner sensor attached to the robotic arm at the first end to determine a current geometry of a portion of the metal sheet; and
while trimming the metal sheet, revise the trimming path for the trimming tool to trim the portion of the metal sheet based on the determined current geometry of the portion of the metal sheet; and
control the robotic arm to automatically return the trimming tool to the tool rack and detach the trimming tool from the tool holder.
2 . The system of claim 1 , wherein the plurality of tools further includes a hemming tool, and comprising further program code that when executed causes the controller to:
control the robotic arm to automatically attach the hemming tool in the tool rack to the tool holder;
control the robotic arm with the hemming tool to hem the trimmed metal part; and
control the robotic arm to automatically return the hemming tool to the tool rack and detach the hemming tool from the tool holder.
3 . The system of claim 1 , further comprising:
a second robotic arm positioned adjacent to the frame on an opposite side from the robotic arm,
wherein the controller is configured to control the second robotic arm according to a second program code that causes the controller to: control the second robotic arm to interact with the metal sheet concurrently with the robotic arm to form the metal sheet in the first geometry into the second geometry.
4 . The system of claim 1 , wherein the forming tool includes a stylus.
5 . The system of claim 1 , wherein the forming tool includes a roller tool.
6 . The system of claim 5 , wherein the roller tool includes a roller configured to rotate about a first axis.
7 . The system of claim 6 , wherein to control the robotic arm with the forming tool to form the metal sheet in the first geometry into the second geometry, the program code, when executed, further causes the controller to control the robotic arm to:
move the roller tool across a surface of the metal sheet along a direction, and
orient the roller tool so the roller (a) rotates about the first axis and (b) moves along the direction.
8 . The system of claim 6 , wherein the roller is further configured to rotate about a second axis perpendicular to the first axis.
9 . The system of claim 5 , wherein the roller tool includes a ball in a socket.
10 . The system of claim 1 , wherein the robotic arm comprises a six degree-of-freedom actuator system configured to control motion of the robotic arm through three-dimensional space.
11 . A system comprising:
a robotic arm configured to move through space and positioned to interact with a first side of a metal sheet;
a forming tool and a trimming tool, each of which is interchangeably attachable to a tool holder at a first end of the robotic arm; and
a controller configured to:
control the robotic arm to attach the forming tool to the tool holder;
control the robotic arm with the forming tool to form the metal sheet in a first geometry into a second geometry different than the first geometry;
control the robotic arm to detach the forming tool from the tool holder;
control the robotic arm to attach the trimming tool to the tool holder;
control the robotic arm with the trimming tool to trim the metal sheet in the second geometry into a trimmed metal part, wherein to control the robotic arm to trim the metal sheet, the controller is further configured to:
while trimming the metal sheet along a trimming path, use a scanner sensor attached to the robotic arm at the first end to determine a current geometry of a portion of the metal sheet; and
while trimming the metal sheet, revise the trimming path for the trimming tool to trim the portion of the metal sheet based on the determined current geometry of the portion of the metal sheet; and
control the robotic arm to detach the trimming tool from the tool holder.
12 . The system of claim 11 , further comprising a hemming tool, wherein the controller is further configured to:
control the robotic arm to attach the hemming tool to the tool holder;
control the robotic arm with the hemming tool to hem the trimmed metal part; and
control the robotic arm to detach the hemming tool from the tool holder.
13 . The system of claim 11 , further comprising:
a second robotic arm configured to move through space and positioned to interact with a second side of the metal sheet opposite the first side of the metal sheet,
wherein the controller is further configured to control the second robotic arm to interact with the metal sheet concurrently with the robotic arm to form the metal sheet in the first geometry into the second geometry.
14 . The system of claim 11 , wherein the forming tool includes a stylus.
15 . The system of claim 11 , wherein the forming tool includes a roller tool.
16 . The system of claim 15 , wherein the roller tool includes a roller configured to rotate about a first axis.
17 . The system of claim 16 , wherein the roller is further configured to rotate about a second axis perpendicular to the first axis.
18 . The system of claim 16 , wherein to control the robotic arm with the forming tool to form the metal sheet in the first geometry into the second geometry, the controller is further configured to control the robotic arm to:
move the roller tool across a surface of the metal sheet along a direction, and
orient the roller tool so the roller (a) rotates about the first axis and (b) moves along the direction.
19 . The system of claim 11 , wherein to revise the trimming path for the trimming tool to trim the portion of the metal sheet based on the determined current geometry of the portion of the metal sheet, the controller is further configured to provide the current geometry to a trained model.