A wirelessly powered and controlled robotic apparatus enabling performance of tasks within a three-dimensional space includes a rail, a robotic unit, and a tool. The rail comprises negative and second paths to carry an electrical current. The robotic unit comprises a microcontroller having a drive motor and a transceiver engaged thereto and is engaged to and electrically coupled to the rail. A transfer unit is engaged to both the drive motor and the rail and thus can translate rotation of the drive motor to a force to motivate the robotic unit along the rail. The microcontroller selectively actuates the transfer unit to move the robotic unit along the rail to a location. The transceiver receives commands wirelessly from a control unit and transmits data thereto. The tool is engaged to the robotic unit and can perform a task at, or proximate to, the location.

Automated systems and methods of using a smart end-effector tool to prepare (e.g., scuffing, abrading, sanding, polishing, etc.) an object surface are provided. The smart tool can update its working state with a robot arm in real time, which in turn adjusts locomotion parameters to optimize the tool's working state on the object surface.

A welding robot is provided. The welding robot is adapted for operating in the space between an upper and a lower platen of a press and comprises a support frame. A welding tool is movable mounted to the support frame. A grinding tool is movable mounted to the support frame. At least a camera is adapted for capturing a view of a working area. A processor is adapted for executing executable commands stored in a storage medium connected thereto. The processor when executing the commands identifies defects on a surface of one of the upper and the lower platen based on image data received from the at least a camera and controls the welding tool and the grinding tool in dependence on the image data. The processor receives data indicative of the repair area, automatically determines toolpath data for welding and grinding in dependence upon the data indicative of a repair area, and generates and provides control data for controlling the welding tool and the grinding tool in dependence upon the toolpath data.

Described is an apparatus for robot-aided grinding, comprising the following: a manipulator, a linear actuator, and a grinding machine which includes a rotating grinding tool and is connected to the manipulator via the linear actuator. The apparatus further comprises a protective cover that partially surrounds the rotating grinding tool, the rotating grinding tool protruding from the protective cover at least on a first side. An adjusting mechanism is provided which connects the protective cover to the grinding machine and is designed to adjust the position of the protective cover in relation to the grinding machine.

An end effector for a robotic sanding system includes a sanding head including a sander configured to sand a surface of a workpiece. A motor is operatively coupled to the sander. The motor is configured to rotate the sander to sand the surface of the workpiece. The motor includes a first central longitudinal axis. A coupler is configured to removably secure the end effector to an attachment interface of an arm of the robotic sanding system. The coupler includes a second central longitudinal axis. The first central longitudinal axis is offset from the second central longitudinal axis. One or more sensors are coupled to the sanding head. The one or more sensors are configured to detect presence of a metal within the predefined range.

An offline-to-online programming teaching system for robot arm trajectory and a method thereof are disclosed. In the system, a trajectory conversion and control device establishes an offline polishing reference trajectory and performs a polishing operation simulation using the offline polishing reference trajectory. The trajectory conversion and control device converts data flow of the simulation into a polishing reference trajectory. The trajectory conversion and control device calculates a deviation between an end position of the series robot arm and the polishing reference trajectory to generate a guidance force information. A haptic device adjusts the position command based on the guidance force information to achieve the technical effect of integrating offline-to-online programming to provide robot arm trajectory teaching.

An apparatus for automated contact tasks and a related method are described. The apparatus includes a mechanical interface for connecting the apparatus to a manipulator, a holder for receiving a tool and being movable in relation to the mechanical interface, at least one actuator for positioning the holder in relation to the mechanical interface, a sensor unit that senses the actuator force provided by the at least one actuator, and a control unit that sets the actuator force to a desired minimum force to press the holder against a stop, while there is no contact between the tool and a surface, and detects contact when the holder moves in relation to the mechanical interface in opposition to the direction of the desired minimum force. The control unit further regulates the actuator force according to a pre-programmed contact force time-characteristic, when contact between the tool and the surface has been detected.

One variation of a method for autonomously scanning and processing a part includes: collecting a set of images depicting a part positioned within a work zone adjacent a robotic system; assembling the set of images into a part model representing the part. The method includes segmenting areas of the part model—delineated by local radii of curvature, edges, or color boundaries—into target zones for processing by the robotic system and exclusion zones avoided by the robotic system. The method includes: projecting a set of keypoints onto the target zone of part model defining positions, orientations, and target forces of a sanding head applied at locations on the part model; assembling the set of keypoints into a toolpath and projecting the toolpath onto the target zone of the part model; and transmitting the toolpath to a robotic system to execute the toolpath on the part within the work zone.

A method includes: compiling images, captured by an end effector traversing a scan path over a workpiece, into a virtual model of the workpiece; generating a toolpath based on a geometry of the workpiece represented in the virtual model; and assigning a target force to the workpiece. The method also includes, during a processing cycle: navigating a sanding head, arranged on the end effector, across the workpiece according to the toolpath; based on force values output by a force sensor coupled to the sanding head, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece proximal the target force; and tracking a sequence of positions of a reference point on the sanding head, traversing the workpiece, in contact with the workpiece. The method also includes transforming the virtual model into alignment with the sequence of positions of the reference point.

A method includes: accessing a toolpath and processing parameters—including a target force and feed rate—assigned to a region of a workpiece; and accessing a wear model representing abrasive degradation of a sanding pad arranged on a sanding head. The method also includes, during a processing cycle: accessing force values output by a force sensor coupled to the sanding head; navigating the sanding head across the workpiece region according to the toolpath and, based on the force values deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece region proximal the target force; accessing contact characteristics representing contact between the sanding pad and the workpiece; estimating abrasive degradation of the sanding pad based on the wear model and the sequence of contact characteristics; and modifying the set of processing parameters based on the abrasive degradation.