Tele-grinding system and method

Abstract

Systems and methods for controlling a material removal process used in a manufacturing environment, comprising installing equipment used for a material removal process in the manufacturing environment; positioning a plurality of sensors within the manufacturing environment wherein the plurality of sensors are configured to gather data from the manufacturing environment; connecting at least one processor to the plurality of sensors, wherein the at least one processor includes software for receiving data from the plurality of sensors and the material removal equipment; and wherein the at least one manual controller receives motion input, wherein the software on the processor mathematically transforms the motion input into corresponding motion commands, wherein the material removal equipment, which is physically remote from the at least one controller, executes the motion commands in real-time during the material removal process.

What is claimed: 
     
         1 . A method for controlling a material removal process used in a manufacturing environment, comprising:
 (a) installing equipment used for or related to a material removal process in a manufacturing environment;   (b) positioning a plurality of sensors within the manufacturing environment in proximity to the material removal equipment, wherein the plurality of sensors are configured to gather data from the manufacturing environment;   (c) connecting at least one processor to the plurality of sensors, wherein the at least one processor includes software for receiving data from the plurality of sensors and the material removal equipment; and   (d) connecting at least one manual controller to the processor, wherein the at least one manual controller receives motion input from a user of the manual controller, wherein the software on the processor mathematically transforms the motion input into corresponding motion commands that are sent to the material removal equipment by the processor, wherein the material removal equipment, which is physically remote from the at least one controller, executes the motion commands in real-time during the material removal process.   
     
     
         2 . The method of  claim 1 , wherein the material removal equipment includes a robot having an end effector for removing an amount material from a weld surface, and wherein the end effector includes a grinder, torch, saw, laser, sander, or a combination thereof. 
     
     
         3 . The method of  claim 2 , using at least one sensor in the plurality of sensors to measure the weld surface before the material removal process. 
     
     
         4 . The method of  claim 2 , further comprising:
 (a) using at least one sensor in the plurality of sensors to measure the amount of material removed from the weld surface during the material removal process;   (b) using at least one sensor in the plurality of sensors to measure a distance between the end effector and the weld surface; and   (c) using at least one sensor in the plurality of sensors to measure a pressure applied between the end effector and the weld surface.   
     
     
         5 . The method of  claim 4 , further comprising:
 (a) disabling the user's control of the material removal equipment if the distance varies from a predetermined operating distance range; and   (b) disabling the user's control of the material removal equipment if the pressure varies from a predetermined operating pressure range.   
     
     
         6 . The method of  claim 5 , further comprising:
 (a) before the material removal process, defining a predetermined maximum amount of material to remove from the weld surface; and   (b) during the material removal process, stopping power to the end effector if the amount of material removed from the weld surface exceeds the predetermined maximum amount of material.   
     
     
         7 . The method of  claim 1 , wherein the at least one manual controller is a hand-held stylus, a computer mouse, or a joystick. 
     
     
         8 . The method of  claim 1 , wherein the software on the processor provides a haptic feedback response to the manual controller based on the data from the plurality of sensors and the material removal equipment. 
     
     
         9 . The method of  claim 1 , further comprising providing a computer network across which the processor communicates with the material removal equipment. 
     
     
         10 . The method of  claim 2 , wherein the robot moves with at least six degrees of freedom. 
     
     
         11 . A method for controlling a material removal process used in a manufacturing environment, comprising:
 (a) installing equipment used for or related to a weld grinding process in a manufacturing environment;   (b) positioning a plurality of sensors within the manufacturing environment in proximity to the weld grinding equipment, wherein the plurality of sensors are configured to gather data from the manufacturing environment;   (c) connecting at least one processor to the plurality of sensors, wherein the at least one processor includes software for receiving data from the plurality of sensors and the weld grinding equipment; and   (d) connecting at least one manual controller to the processor, wherein the at least one manual controller receives motion input from a user of the manual controller, wherein the software on the processor mathematically transforms the motion input into corresponding motion commands that are sent to the weld grinding equipment by the processor, wherein the weld grinding equipment, which is physically remote from the at least one controller, executes the motion commands in real-time during the weld grinding process.   
     
     
         12 . The method of  claim 11 , wherein the weld grinding equipment includes a robot having a grinder for removing an amount material from a weld surface, and wherein the grinder includes a grinding disc, flap disc, or sanding disc. 
     
     
         13 . The method of  claim 12 , further comprising using at least one sensor in the plurality of sensors to measure the weld surface before the weld grinding process. 
     
     
         14 . The method of  claim 12 , further comprising:
 (a) using at least one sensor in the plurality of sensors to measure the amount of material removed from the weld surface during the weld grinding process;   (b) using at least one sensor in the plurality of sensors to measure a distance between the grinder and the weld surface; and   (c) using at least one sensor in the plurality of sensors to measure a pressure applied between the grinder and the weld surface.   
     
     
         15 . The method of  claim 14 , further comprising:
 (a) disabling the user's control of the weld grinding equipment if the distance varies from a predetermined operating distance range; and   (b) disabling the user's control of the weld grinding equipment if the pressure varies from a predetermined operating pressure range.   
     
     
         16 . The method of  claim 15 , further comprising:
 (a) before the material removal process, defining a predetermined maximum amount of material to remove from the weld surface; and   (b) during the material removal process, stopping power to the grinder if the amount of material removed from the weld surface exceeds the predetermined maximum amount of material.   
     
     
         17 . The method of  claim 11 , wherein the at least one manual controller is a hand-held stylus, a computer mouse, or a joystick. 
     
     
         18 . The method of  claim 11 , wherein the software on the processor provides a haptic feedback response to the manual controller based on the data from the plurality of sensors and the weld grinding equipment. 
     
     
         19 . The method of  claim 11 , further comprising providing a computer network across which the processor communicates with the weld grinding equipment. 
     
     
         20 . The method of  claim 12 , wherein the robot moves with at least six degrees of freedom.