US 12,304,080 B2Granted

Method for autonomously repairing surface defects in a workpiece through surface modifications

AssigneeGrayMatter Robotics Inc.

InventorsAvadhoot Ahire, YiWei Chen, Rishav Guha, Satyandra K. Gupta, Ariyan M. Kabir, Ashish Kulkarni, Ceasar Navarro, Sagar Panchal, Brual C. Shah

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Abstract

A method includes: compiling lower-resolution images, captured during a global scan cycle executed over a workpiece, into a virtual model; defining a nominal toolpath and a nominal target force for the workpiece based on a the virtual model; detecting a defect indicator on the workpiece based on the lower-resolution images; accessing a higher-resolution image captured during a local scan cycle over the defect indicator; characterizing the defect indicator as a defect reparable via material removal based on the higher-resolution image; defining a repair toolpath for the defect based on the virtual model; navigating a sanding head over the workpiece according to the repair toolpath to repair the defect; and, during a processing cycle: navigating the sanding head across the workpiece according to the nominal toolpath and deviating the sanding head from the nominal toolpath to maintain forces of the sanding head on the workpiece proximal the nominal target force.

Claims20

Dependent claims

A method comprising:

accessing a virtual model of a workpiece;
accessing a nominal toolpath for the workpiece;
accessing a nominal target force assigned to the nominal toolpath;
accessing a first set of images depicting the workpiece;
based on the first set of images, detecting a first defect in a first workpiece region of the workpiece;
in response to characterizing the first defect as repairable via material removal from the workpiece, generating a repair toolpath for the first workpiece region based on a first geometry of the first workpiece region represented in the virtual model;
during a repair cycle, via a set of actuators coupled to a sanding head, navigating the sanding head across the first workpiece region according to the repair toolpath;
and
during a processing cycle:
accessing a first sequence of force values output by a force sensor coupled to the sanding head;
and
via the set of actuators:
navigating the sanding head across the workpiece according to the nominal toolpath;
and
based on the first sequence of force values, deviating the sanding head from the nominal toolpath to maintain forces, applied by the sanding head to the workpiece, proximal the nominal target force.

12 more elements

A method comprising:

accessing a virtual model of a workpiece;
accessing a first image depicting a first workpiece region of the workpiece;
based on the first image, detecting a first defect in the first workpiece region of the workpiece;
in response to characterizing the first defect as repairable via material removal from the workpiece, generating a first toolpath for the first workpiece region based on a first geometry of the first workpiece region represented in the virtual model;
accessing a second toolpath for a second workpiece region of the workpiece;
accessing a nominal target force assigned to the workpiece;
during a repair cycle, via a set of actuators coupled to a sanding head, navigating the sanding head across the first workpiece region according to the first toolpath;
and
during a processing cycle:
accessing a sequence of force values output by a force sensor coupled to the sanding head;
and
via the set of actuators:
navigating the sanding head across the second workpiece region of the workpiece according to the second toolpath;
and
based on the sequence of force values, deviating the sanding head from the second toolpath to maintain forces, applied by the sanding head to the second workpiece region of the workpiece, proximal the nominal target force.

12 more elements

A method comprising:

accessing a virtual model of a workpiece;
accessing a first image depicting a first workpiece region of the workpiece;
based on the first image, detecting a first defect in the first workpiece region of the workpiece;
in response to characterizing the first defect as repairable via material removal from the workpiece:
generating a first toolpath for the first workpiece region based on a first geometry of the first workpiece region represented in the virtual model;
and
assigning a target repair force to the first toolpath;
accessing a second toolpath for a second workpiece region of the workpiece;
and
during a processing cycle:
accessing a sequence of force values output by a force sensor coupled to a sanding head;
and
via a set of actuators coupled to the sanding head:
navigating the sanding head across the first workpiece region of the workpiece according to the first toolpath;
and
based on the sequence of force values, deviating the sanding head from the first toolpath to maintain forces, applied by the sanding head to the first workpiece region of the workpiece, proximal the target repair force;
and
via the set of actuators, navigating the sanding head across the second workpiece region according to the second toolpath.

15 more elements

Dependencies are inferred from the claim text.

Facts

Application: 18/379,130Filed 11 Oct 2023 · continuation
Priority: 31 Jul 2020
Published: US 2024/0033915 A11 Feb 2024
Granted: 20 May 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification23 codes

B25J 9/1653
Characterised by the control loop: parameters identification, estimation, stiffness, accuracy, error analysis
B24B 51/00
Arrangements for automatic control of a series of individual steps in grinding
B25J 5/005
Manipulators mounted on wheels or on carriages: mounted on endless tracks or belts
B25J 9/162
Characterised by special kind of manipulator, e.g. planar, scara, gantry, cantilever, space, closed chain, passive/active joints and tendon…

Family

Application63/059,932Us provisional application · filed 31 Jul 2020
Application17/390,885Parent of this continuation-in-part · filed 31 Jul 2021
Application17/826,840Parent of this continuation · filed 27 May 2022
Application17/829,193Parent of this continuation · filed 31 May 2022
Application18/111,470Parent of this continuation-in-part · filed 17 Feb 2023
US 11,613,014 B2Parent of this continuation · filed 28 Mar 2023
Application18/142,480Parent of this continuation · filed 2 May 2023
US 2024/0033915 A1Pre-grant publication · published 1 Feb 2024
US 11,938,632 B2Parent of this continuation
US 12,049,009 B2Parent of this continuation-in-part
Application18/142,480Parent of this continuation-in-part
Application18/111,470Parent of this continuation
Application17/826,840Parent of this continuation-in-part
US 12,370,681 B2Related patent
US 2022/0032461 A1Published application
US 2022/0347843 A1Published application
US 2022/0388115 A1Published application
US 2023/0278207 A1Published application
US 2023/0302641 A1Published application
US 12,304,080 B2This patent

From the US filing history. Foreign family members aren’t listed.

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