Design and simulation of a multisensory-multi-process end-effector for application to various kinematics

Abstract

In the manufacturing industry, there is a growing need for flexible and interchangeable production systems. These systems must be capable of adapting to various processes and components. One of the central challenges is the development of versatile end-effectors. This paper focuses on designing and simulating a multi-process and multi-sensorial end-effector applicable to various kinematic systems, including machine tools (MT) and industrial robots (IR). The end-effector features a changeable process module suitable for additive, subtractive, and assembly processes. Its housing is fabricated using a combination of additive and subtractive manufacturing methods and employs a variety of materials. Emphasis is placed on lightweight construction, achieved through topology-optimized structures. The design is optimized to distribute force effectively throughout the operational process. A servo motor drives the end-effector’s spindle via a toothed belt, allowing for the automated insertion of different process modules into a hollow shaft. Moreover, the paper provides an initial outlook on integrating sensor technology to monitor the end-effector’s performance. For instance, strain gauges and accelerometers are utilized for data collection. These sensors are integrated within the end-effector structure. Furthermore, the concept of HSKi is discussed, enabling energy transfer from the spindle through the tool holder to the TCP.