Collaborative robot, method for controlling robot, and system comprising same

Abstract

The present invention relates to a collaborative robot system used in an industrial environment where workers collaborate. The collaborative robot system comprises: a collaborative robot body having a multi-joint structure; a control unit for controlling each joint or auxiliary shaft; one or more sensors for detecting the operational state of the robot in real time; and a status diagnosis and response module for diagnosing the state of the robot on the basis of detected data and controlling the operation of the robot accordingly. Specifically, the system is configured to enable the robot to autonomously perform actions such as deceleration, stopping, and recovery in response to various state changes occurring during work, and to perform self-learning and trajectory optimization on the basis of data accumulated through repetitive tasks. Furthermore, the system includes a graphical user interface (GUI) for intuitive user interaction, which is linked to a digital twin-based virtual simulation environment, enabling presetting and modification of work paths. When multiple collaborative robots are operated together, the system enables task synchronization, path collision avoidance, and sharing of status information among the robots, and may be connected to an external control server or a cloud-based control system to allow integrated management of the entire workflow.

Description

Collaborative robot, robot control method and system including the same

[0001] The present invention relates to a collaborative robot, a control method for the robot, and a system including the same, and more particularly, to an intelligent collaborative robot platform technology that safely works with people in various industrial environments and has precise motion performance, real-time control, an intuitive interface, and inter-process interconnectivity.

[0002] More specifically, the present invention is based on a control structure that integrates functions such as multi-axis joint synchronization, real-time trajectory control, collision and overspeed detection, and temperature and backlash compensation, enabling the collaborative robot to actively respond to the operator's intentions and environmental changes. Furthermore, by incorporating safety zone setting, a user-friendly graphical interface (GUI), digital twin linkage, and automatic recovery procedures, the collaborative robot is designed to perform high-precision, high-safety, and highly flexible tasks.

[0003] In particular, the present invention includes a smart control system that continuously monitors the status of the robot, autonomously controls its operation, and maintains work continuity without user input, even in a complex process environment where a collaborative robot continuously performs multiple tasks such as packaging (incasing), transport, loading, and inspection of a product.

[0004] Meanwhile, some embodiments of the present invention may also incorporate a modular robot configuration that allows for flexible assembly and disassembly, providing a foundation for flexible line layout and expanded robot operation. However, the primary focus of the present invention is on the collaborative robot's control structure, safety features, real-time responsiveness, and user interface integration, ensuring high reliability and productivity even under advanced work conditions that conventional simple-task robots struggle to perform.

[0005] A cooperative robot (or cobot) is a robot designed to share the same workspace with humans and perform collaborative tasks through direct physical interaction. While conventional industrial robots perform high-speed, high-power tasks within a confined space, collaborative robots are characterized by low speed and force control, collision avoidance, and precision control, all designed for safe collaboration with humans. Based on these characteristics, collaborative robots are expanding their applications beyond assembly, packaging, inspection, transport, and loading on manufacturing lines, to diverse fields such as healthcare, logistics, and the service industry.

[0006] As industrial automation becomes more sophisticated, collaborative robots are increasingly required to perform physical collaboration with humans, offering safety, flexibility, and adaptability to diverse work conditions. In particular, in production sites, robots are in dire need of intelligent control structures that enable them to perceive situations in real time, adjust their behavior, and organically connect across processes. This requires not only simple repetitive tasks but also adapt to changes in the position of various objects, environmental fluctuations, and complex work sequences.

[0007] However, existing collaborative robot systems rely on fixed control methods based on fixed trajectories, making it difficult to respond in real time to changes in the target's position or exceptional circumstances. Furthermore, even when operating in multi-axis or controlling additional axes, they face limitations in achieving high precision and synchronization. Detection of abnormal conditions such as collisions, overspeed, and overload is fragmented or limited, and corresponding autonomous recovery and predictive maintenance capabilities are lacking.

[0008] Furthermore, most conventional systems rely on advanced commands or complex setup procedures, making it difficult for field workers to intuitively understand the robot's status, control its operations, or intervene in real-time during the workflow. This results in poor user experience and frequent interruptions in work continuity.

[0009] In processes that utilize multiple collaborative robots or require linkage with various peripheral devices, integrated control is essential, including status synchronization with each piece of equipment, work order coordination, and collision prevention. However, conventional technologies have shown limitations in terms of integration and scalability.

[0010] Accordingly, a system is required that integrates synchronization between multi-joint and auxiliary axes of collaborative robots, real-time detection and response to collision, overspeed, and overload conditions, temperature and backlash error compensation, user-centered intuitive interface and digital twin linkage, and complex control algorithms that can respond to various collaborative scenarios.

[0011] Furthermore, in some work environments, it is desirable to increase space utilization and process adaptability by introducing modular configurations that allow for autonomous combination and separation. Accordingly, it is necessary to develop technologies that can simultaneously realize structural flexibility of the robot system, as well as precise control and safe collaboration functions at the overall system level.

[0012] For collaborative robots to be effectively utilized in real-world industrial settings, they must ensure control precision and stability, enabling them to actively respond to diverse process conditions and changes in the workpiece. In particular, the collaborative robot's complex drive system, including multi-joint structures and auxiliary axes, must enable real-time synchronization and precise trajectory control. These are essential for improving repeatability and productivity in diverse work environments.

[0013] Robots are required to autonomously detect and respond to various abnormal conditions that may occur during operation, such as collisions, overspeed, overload, backlash, and temperature changes. A real-time monitoring and compensation system is also required to automatically recover from these conditions or intuitively notify the user, in conjunction with the workflow. Furthermore, to make the interaction between worker and robot more intuitive and flexible, a graphical user interface (GUI) and a digital twin-based visualization environment must be provided.

[0014] Furthermore, in complex process environments where multiple collaborative robots operate simultaneously, an integrated control system is required, encompassing position synchronization, work order coordination, collision prevention, and status sharing among each robot. This system should enable flexible line configuration and safe collaborative work even in confined spaces, and the system must be structured to easily adapt to changing production conditions.

[0015] The present invention proposes a collaborative robot, a control method for the robot, and a system including the same that can satisfy such technical requirements.

[0016] To address the above-described challenges, the present invention provides a collaborative robot system that operates in an industrial environment where workers collaborate. The collaborative robot system of the present invention comprises a collaborative robot body having a multi-joint structure, a control unit for controlling each joint or auxiliary axis of the collaborative robot, one or more sensors for detecting the operating status of the collaborative robot in real time, and a status diagnosis and response module for diagnosing the status of the collaborative robot based on data received from the sensors and controlling the operation of the collaborative robot based on the diagnosis results.

[0017] According to one embodiment of the present invention, the control unit analyzes the status of the collaborative robot based on at least one of the following information: speed, acceleration, torque, position, and temperature. Based on the analysis results, the control unit decelerates or stops the robot's operation and, if necessary, performs recovery operations. Furthermore, the control unit is configured to synchronize the movements between multi-joint and auxiliary axes in real time and automatically correct the trajectory according to changes in the position of the workpiece. This minimizes errors due to changes in the work environment and enables high-precision trajectory control.

[0018] Another feature of the present invention is that the collaborative robot system includes a task synchronization function that enables the robots to share task sequences, adjust paths to prevent collisions, and exchange status information in real time in environments where multiple collaborative robots operate simultaneously. This collaborative structure ensures task parallelization and safety even in complex process environments.

[0019] The present invention also includes a graphical user interface (GUI) that visually displays at least one of the operation status, trajectory, and alarm information of the collaborative robot and allows a user to input a work command, and the GUI is linked to a virtual space based on a digital twin, so that the user can set or modify a work path in advance based on simulation results.

[0020] Furthermore, the collaborative robot system of the present invention stores at least one of a motion log, a status change history, and a work result record, and includes a function for performing autonomous learning or trajectory optimization of the robot based on this, thereby enhancing precision in long-term operation and increasing maintenance efficiency. If necessary, the collaborative robot is configured with a modular structure that can be combined and separated, allowing for flexible structural modifications according to the task purpose and environment, and automatically updating control criteria when the structure is modified. Furthermore, the robot is controlled to determine whether it has grasped an object and, if grasping fails, to automatically retry or perform an alternative operation, contributing to improved productivity and reduced defect rates.

[0021] Furthermore, the collaborative robot system of the present invention can be configured to integrate with an external control server or cloud-based upper control system to comprehensively manage robot status information and task progress. Through this configuration, the present invention enables the stable and precise operation of collaborative robots in various industrial environments, enabling the implementation of an integrated system capable of flexible task performance and real-time response.

[0022] According to the present invention, precise, real-time, synchronized control of the collaborative robot's multi-joint structure and drive system, including auxiliary axes, enables work to be performed with high precision and stability, even when the workpiece's position changes or process conditions fluctuate. This precise control improves the reliability of repetitive tasks, reduces defect rates, and enables effective response to high-variety, low-volume production environments.

[0023] Furthermore, the present invention can significantly enhance safety in collaborative environments between workers and robots by detecting various abnormal conditions in real time, such as collisions, overspeed, overload, backlash, and temperature changes during robot operation, and providing autonomous recovery algorithms and safety control routines corresponding to each condition. In particular, through detailed joint-level condition detection and condition-specific judgment logic, continuous processing is possible without interruption, minimizing operator intervention while preventing robot failures and improving maintenance efficiency.

[0024] Additionally, a user-centric, intuitive graphical user interface (GUI) allows real-time monitoring of the robot's operating status, work path, and alarm status. Users can easily switch control modes or configure specific work sequences to suit their work environment. In particular, by integrating a digital twin-based visualization environment, the gap between pre-operation simulation and on-site control is narrowed, enabling field workers to predict and intuitively understand robot behavior.

[0025] Furthermore, the present invention enables multiple collaborative robots to operate under a single, integrated control system, enabling complex functions such as automatic inter-process linkage, task division between robots, collision avoidance control, and status sharing. This ensures high efficiency and stability even in complex production environments requiring inter-robot collaboration, while enhancing the flexibility and scalability of the entire line.

[0026] Furthermore, the present invention supports an expandable structure that allows the robot to operate in a modular or composite configuration depending on specific work environments, allowing the system to be easily reconfigured to accommodate diverse space constraints and installation purposes. This allows collaborative robot systems to be applied not only to simple repetitive processes but also to complex processes such as incasing, packaging, transport, sorting, and inspection, dramatically expanding the scope and usability of automation.

[0027] As a result, the present invention provides an integrated solution that can simultaneously satisfy various elements required for collaborative robots in industrial sites, such as precision, safety, intuitiveness, expandability, and maintainability, and can effectively respond to industrial needs such as smart manufacturing, flexible production, and worker-centered automation.

[0028] FIG. 1 is a drawing showing a modular robot system according to one embodiment of the present invention.

[0029] Figure 2 is a drawing showing a modular robot that constitutes the modular robot system of Figure 1.

[0030] Figure 3 is a drawing showing the configuration of the modular robot of Figure 2.

[0031] Figure 4 is a drawing showing the control relationship of a modular robot.

[0032] Figure 5 is a drawing showing the positional relationship of wheels provided to a modular robot.

[0033] FIG. 6 is a drawing showing a modular robot according to another embodiment.

[0034] Fig. 7 is a drawing showing a modular robot system composed of the modular robot of Fig. 6.

[0035] Figure 8 is a flowchart illustrating an incasing method using a collaborative robot according to one embodiment of the present invention.

[0036] FIG. 9 is a diagram schematically illustrating the configuration of an incasing automation system according to one embodiment of the present invention.

[0037] Fig. 10 is a drawing showing the box classification section of Fig. 9.

[0038] Fig. 11 is a drawing showing the first loading section of Fig. 9.

[0039] Figures 12 to 14 are drawings showing the rotation transmission unit of Figure 11.

[0040] FIG. 15 is a diagram schematically illustrating the configuration of an incasing automation system according to another embodiment of the present invention.

[0041] Fig. 16 is a drawing showing the box cleaner of Fig. 15.

[0042] Figure 17 is a drawing showing the horizontal movement slider of Figure 16.

[0043] Figures 18 and 19 are drawings showing the cone-shaped cover of Figure 17.

[0044] Figure 20 is a drawing showing the passage frame of Figure 19.

[0045] Figure 21 is a flowchart explaining the loading steps of Figure 8.

[0046] Figure 22 is a flowchart illustrating the second packaging step of Figure 8.

[0047] Figure 23 is a flowchart illustrating an incasing method using a collaborative robot according to another embodiment of the present invention.

[0048] Fig. 24 is a flowchart illustrating a real-time motion synchronization control method based on multi-axis expansion of a collaborative robot according to an example of the present invention.

[0049] Figure 25 is a flowchart showing a method for synchronizing a joint and an additional axis device according to an example of the present invention.

[0050] Fig. 26 is a block diagram showing the detailed configuration of a real-time motion synchronization control system based on multi-axis expansion of a collaborative robot according to an example of the present invention.

[0051] Fig. 27 is an exemplary diagram showing a collaborative robot according to an example of the present invention.

[0052] Figure 28 is an exemplary diagram showing a system according to an example of the present invention.

[0053] Fig. 29 is a block diagram showing the detailed configuration of a real-time collision and overspeed detection system of a collaborative robot according to an example of the present invention.

[0054] Fig. 30 is an exemplary diagram showing a collaborative robot according to an example of the present invention.

[0055] Fig. 31 is a flowchart illustrating a real-time collision and speed detection method of a collaborative robot according to an example of the present invention.

[0056] Fig. 32 is a flowchart illustrating a method for determining a collision state of a collaborative robot according to an example of the present invention.

[0057] Fig. 33 is a flowchart illustrating a method for determining an overload status of a collaborative robot according to an example of the present invention.

[0058] Fig. 34 is a flowchart illustrating a method for determining an overspeed state of a collaborative robot according to an example of the present invention.

[0059] Fig. 35 is a flowchart illustrating a method for determining a singularity state of a collaborative robot according to an example of the present invention.

[0060] Figure 36 is a flowchart illustrating a method for motion calibration for each joint of a collaborative robot according to an example of the present invention.

[0061] Figure 37 is a block diagram showing the detailed configuration of a temperature compensation calibration system for each joint of a collaborative robot according to an example of the present invention.

[0062] Fig. 38 is an exemplary diagram showing a collaborative robot according to an example of the present invention.

[0063] Fig. 39 is a flowchart illustrating a method for generating backlash compensation parameters according to an example of the present invention.

[0064] Fig. 40 is a flowchart illustrating a method for generating temperature compensation parameters of a collaborative robot according to an example of the present invention.

[0065] Fig. 41 is a flowchart illustrating a temperature compensation parameter correction method of a collaborative robot according to an example of the present invention.

[0066] Fig. 42 is a flowchart illustrating a method for correcting backlash compensation parameters of a collaborative robot according to an example of the present invention.

[0067] Figure 43 is a block diagram showing a detailed configuration of a complex process performing system according to an example of the present invention.

[0068] Figure 44 is an exemplary diagram showing a collaborative robot according to an example of the present invention.

[0069] Figure 45 is an exemplary diagram showing a system according to an example of the present invention.

[0070] Figure 46 is a flowchart showing a method for performing a composite process according to an example of the present invention.

[0071] Figure 47 is a flowchart showing a method for synchronizing a joint and an additional axis device according to an example of the present invention.

[0072] Figure 48 is a flowchart illustrating a real-time collision and overspeed detection method of a collaborative robot according to an example of the present invention.

[0073] Figure 49 is a block diagram showing a detailed configuration of a real-time collision and overspeed detection system of a collaborative robot according to an example of the present invention.

[0074] Figure 50 is an exemplary diagram showing a collaborative robot according to an example of the present invention.

[0075] Figure 51 is a flowchart illustrating a method for determining a collision state of a collaborative robot according to an example of the present invention.

[0076] Figure 52 is a flowchart illustrating a method for determining an overload status of a collaborative robot according to an example of the present invention.

[0077] Figure 53 is a flowchart illustrating a method for determining an overspeed state of a collaborative robot according to an example of the present invention.

[0078] Figure 54 is a flowchart illustrating a method for determining a singularity state of a collaborative robot according to an example of the present invention.

[0079] Figure 55 is a block diagram showing a detailed configuration of a temperature compensation calibration system for each joint of a collaborative robot according to an example of the present invention.

[0080] Fig. 56 is an exemplary diagram showing a collaborative robot according to an example of the present invention.

[0081] Figure 57 is a flowchart illustrating a method for motion calibration for each joint of a collaborative robot according to an example of the present invention.

[0082] Fig. 58 is a flowchart illustrating a method for generating backlash compensation parameters according to an example of the present invention.

[0083] Figure 59 is a flowchart illustrating a method for generating temperature compensation parameters of a collaborative robot according to an example of the present invention.

[0084] Fig. 60 is a flowchart showing a temperature compensation parameter correction method of a collaborative robot according to an example of the present invention.

[0085] Fig. 61 is a flowchart showing a method for correcting backlash compensation parameters of a collaborative robot according to an example of the present invention.

[0086] Figure 62 is a configuration diagram of a safety management system according to one embodiment of the present invention.

[0087] Figure 63 is a logical configuration diagram of a management server according to one embodiment of the present invention.

[0088] Figure 64 is an exemplary diagram showing a route map according to one embodiment of the present invention.

[0089] Figure 65 is an exemplary diagram showing a virtual safety boundary according to one embodiment of the present invention.

[0090] Figure 66 is an exemplary diagram for explaining the function of a detection unit according to one embodiment of the present invention.

[0091] Figures 67 and 68 are exemplary diagrams for explaining a GUI (Graphical User Interface) according to one embodiment of the present invention.

[0092] Figure 69 is a hardware configuration diagram of a management server according to one embodiment of the present invention.

[0093] Figure 70 is a flowchart illustrating a method for setting a virtual boundary of a work area of ​​a user interface-based collaborative robot according to one embodiment of the present invention.

[0094] Figure 71 is a flowchart for explaining a virtual boundary-based collision prevention and work control method using safety signal linkage of a collaborative robot according to one embodiment of the present invention.

[0095] Figure 72 is a flowchart illustrating an intuitive control method of a collaborative robot using a user-centered graphic interface according to one embodiment of the present invention.

[0096] Figure 73 is a configuration diagram of a safety management system according to one embodiment of the present invention.

[0097] Figure 74 is a logical configuration diagram of a management server according to one embodiment of the present invention.

[0098] Figure 75 is an exemplary diagram showing a route map according to one embodiment of the present invention.

[0099] Figure 76 is an exemplary diagram showing a virtual safety boundary according to one embodiment of the present invention.

[0100] Figure 77 is an exemplary diagram for explaining the function of a detection unit according to one embodiment of the present invention.

[0101] Figures 78 and 79 are exemplary diagrams for explaining a GUI (Graphical User Interface) according to one embodiment of the present invention.

[0102] Figure 80 is a hardware configuration diagram of a management server according to one embodiment of the present invention.

[0103] Figure 81 is a flowchart illustrating a method for setting a virtual boundary of a work area of ​​a user interface-based collaborative robot according to one embodiment of the present invention.

[0104] Figure 82 is a flowchart for explaining a virtual boundary-based collision prevention and work control method using safety signal linkage of a collaborative robot according to one embodiment of the present invention.

[0105] Figure 83 is a flowchart illustrating an intuitive control method of a collaborative robot using a user-centered graphic interface according to one embodiment of the present invention.

[0106] Figure 84 is a configuration diagram of a safety management system according to one embodiment of the present invention.

[0107] Figure 85 is a logical configuration diagram of a management server according to one embodiment of the present invention.

[0108] Figures 86 and 87 are exemplary diagrams for explaining collision of a collaborative robot according to one embodiment of the present invention.

[0109] FIG. 88 and FIG. 89 are exemplary diagrams for explaining a GUI (Graphical User Interface) according to one embodiment of the present invention.

[0110] Figure 90 is a hardware configuration diagram of a management server according to one embodiment of the present invention.

[0111] Figure 91 is a flowchart illustrating a method for automatically detecting and recovering collisions and overloads of a collaborative robot according to one embodiment of the present invention.

[0112] Figure 92 is a flowchart for explaining a method for automatically detecting collisions and resuming work of a collaborative robot using user interface linkage according to one embodiment of the present invention.

[0113] Figure 93 is a flowchart for explaining a method for operating and managing a collaborative robot using a user-customizable graphic interface based on a digital twin according to one embodiment of the present invention.

[0114] Figure 94 is a configuration diagram of a safety management system according to one embodiment of the present invention.

[0115] Figure 95 is a logical configuration diagram of a management server according to one embodiment of the present invention.

[0116] Figures 96 and 97 are exemplary diagrams for explaining collision of a collaborative robot according to one embodiment of the present invention.

[0117] FIG. 98 and FIG. 99 are exemplary diagrams for explaining a GUI (Graphical User Interface) according to one embodiment of the present invention.

[0118] Figure 100 is a hardware configuration diagram of a management server according to one embodiment of the present invention.

[0119] Figure 101 is a flowchart for explaining a method for automatically detecting and recovering collisions and overloads of a collaborative robot according to one embodiment of the present invention.

[0120] Figure 102 is a flowchart for explaining a method for automatically detecting collisions and resuming work of a collaborative robot using user interface linkage according to one embodiment of the present invention.

[0121] Figure 103 is a flowchart for explaining a method for operating and managing a collaborative robot using a user-customizable graphic interface based on a digital twin according to one embodiment of the present invention.

[0122] Figure 104 is a configuration diagram of a safety management system according to one embodiment of the present invention.

[0123] Figure 105 is a logical configuration diagram of a management server according to one embodiment of the present invention.

[0124] Figure 106 is an exemplary diagram showing a route map according to one embodiment of the present invention.

[0125] Figure 107 is an exemplary diagram showing a virtual safety boundary according to one embodiment of the present invention.

[0126] Figure 108 is an exemplary diagram for explaining the function of a detection unit according to one embodiment of the present invention.

[0127] Figures 109 and 110 are exemplary diagrams for explaining a GUI (Graphical User Interface) according to one embodiment of the present invention.

[0128] Figure 111 is a hardware configuration diagram of a management server according to one embodiment of the present invention.

[0129] Figure 112 is a flowchart for explaining a method for setting a virtual boundary of a work area of ​​a user interface-based collaborative robot according to one embodiment of the present invention.

[0130] Figure 113 is a flowchart for explaining a virtual boundary-based collision prevention and work control method using safety signal linkage of a collaborative robot according to one embodiment of the present invention.

[0131] Figure 114 is a flowchart illustrating an intuitive control method of a collaborative robot using a user-centered graphic interface according to one embodiment of the present invention.

[0132] Figure 115 is a configuration diagram of a safety management system according to one embodiment of the present invention.

[0133] Figure 116 is a logical configuration diagram of a management server according to one embodiment of the present invention.

[0134] Figures 117 and 118 are exemplary diagrams for explaining collision of a collaborative robot according to one embodiment of the present invention.

[0135] Figures 119 and 120 are exemplary diagrams for explaining a GUI (Graphical User Interface) according to one embodiment of the present invention.

[0136] Figure 121 is a hardware configuration diagram of a management server according to one embodiment of the present invention.

[0137] Figure 122 is a flowchart for explaining a method for automatically detecting and recovering collisions and overloads of a collaborative robot according to one embodiment of the present invention.

[0138] Figure 123 is a flowchart illustrating a method for automatically detecting collisions and resuming work of a collaborative robot using user interface linkage according to one embodiment of the present invention.

[0139] Figure 124 is a flowchart for explaining a method for operating and managing a collaborative robot using a user-customizable graphic interface based on a digital twin according to one embodiment of the present invention.

[0140] FIG. 125 is a block diagram of a robot calibration system according to an embodiment of the present invention.

[0141] Figure 126 is a flowchart for explaining a robot calibration method according to one embodiment of the present invention.

[0142] FIG. 127 is a drawing for explaining a method for controlling the position of an end effector based on a machine vision sensor in a robot calibration system according to one embodiment of the present invention.

[0143] FIG. 128 is a drawing for explaining a position error and a calibration model in a robot calibration system according to one embodiment of the present invention.

[0144] FIG. 129 is a diagram illustrating a graph of a position error when controlling the position of an end effector based on a first DH parameter in a robot calibration system according to an embodiment of the present invention.

[0145] FIG. 130 is a diagram illustrating a graph of a position error when controlling the position of an end effector based on a second DH parameter in a robot calibration system according to an embodiment of the present invention.

[0146] FIG. 131 is a graph showing the difference between the position error shown in FIG. 129 and the position error shown in FIG. 130 in a robot calibration system according to one embodiment of the present invention.

[0147] FIG. 132 is a diagram illustrating a graph of a reduction in position error when controlling the position of an end effector based on a second DH parameter in a robot calibration system according to an embodiment of the present invention.

[0148] In connection with the description of the drawings, the same or similar reference numerals may be used for identical or similar components.

[0149] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. However, the technical concept of the present invention can be implemented in various forms, and the following description is not intended to limit the technical scope of the present invention. The present invention aims to provide a system in which various components, such as the structure of a collaborative robot, a control algorithm, a sensing system, a user interface, and interoperability control between multiple robots, operate in an integrated manner. These components can be selectively combined and implemented in various industrial settings.

[0150] The collaborative robot utilized in the present invention is generally based on a multi-joint arm structure, and includes a drive motor and reducer for controlling each joint, sensors for real-time feedback of joint positions and speeds, and a central controller for controlling the movements of the entire robot. In addition, it is configured with an end effector for physically contacting or manipulating a workpiece, built-in sensors for detecting conditions such as collisions and overloads, and a communication interface module for transmitting and receiving data with a user or a higher-level control system. Unlike general industrial robots, collaborative robots are characterized by operating at low output and speed, and including a force- or torque-based collision detection function, enabling physical collaboration with workers.

[0151] Based on this structure, the present invention includes various functional elements to enable collaborative robots to operate more safely and precisely in various work environments. The collaborative robot system collects the robot's operating status in real time through one or more sensors, diagnoses the robot's current status based on the collected data, and, if necessary, decelerates or stops the robot's operation or performs recovery operations. These functions are performed by a status diagnosis and response module, which analyzes at least one or more pieces of information, such as speed, torque, acceleration, temperature, and position information, to enable judgment of various operating conditions.

[0152] The collaborative robot system of the present invention includes a real-time trajectory correction function in the control unit to enable stable trajectory control even in an environment where the position or shape of the workpiece changes. In addition, in the case of a robot configuration including a multi-joint and additional axis device, the control routine performs synchronization operations between each axis, thereby enabling precise control without error accumulation. In particular, in processes that handle irregular products or require repeatability, this function plays a crucial role in ensuring consistency in work quality. In addition, the collaborative robot system of the present invention allows the worker to intuitively designate the start and end points of the trajectory, and these settings can be automatically corrected according to a predictive control model based on the robot's learning data.

[0153] This system can be configured to operate not only as a single robot but also as multiple robots within the same process or across adjacent processes. Multiple collaborative robots can share status information and work progress in real time, and can be controlled in conjunction to adjust each robot's work order or adjust paths by predicting potential collisions. This functionality can maximize work efficiency at the overall system level and prevent unexpected process interruptions. When interworking, each robot can be controlled independently while also switching to a master-slave or parallel operation structure, dynamically allocating roles based on factors such as workload, location, and work time.

[0154] In terms of user interaction, the present invention also provides an intuitive and predictable control environment. The robot system visualizes the robot's status, trajectory information, and alarm situations through a graphical user interface (GUI), allowing the user to perceive the robot's current work status in real time and directly input control commands when necessary. The GUI is linked to a digital twin-based virtual interface, allowing users to simulate or set work paths in an environment identical to the actual workspace, providing a user-friendly environment that even non-experts can easily operate. The GUI can include various functions, such as suggesting recommended scenarios based on work conditions, setting safety boundaries, and switching between collaboration modes. It also provides an advance warning function when a potential collision between multiple robots is anticipated.

[0155] The present invention may also include autonomous learning and optimization functions based on log data and status history information collected during robot operation. Error data generated during repetitive work conditions is accumulated and analyzed, and improvements such as trajectory correction, speed compensation, and grip position correction are proposed or automatically applied to identical or similar tasks, thereby gradually improving work precision and stability during long-term operation. This function allows the system to have a continuously evolving structure and offers advantages in terms of maintenance. The system quantifies and reports key precision indicators for each learning cycle and provides learning results in the form of feedback to the user, which can be used as a basis for making decisions regarding inspection and manual intervention.

[0156] Furthermore, in some embodiments, the robot body is implemented with a modular structure, allowing for the assembly and separation of robot units according to workspace constraints or changes in the work process. The connection status between modules is automatically recognized by the control unit, and coordinate standards and control parameters are also automatically adjusted according to structural changes. This allows for flexible response to changes in the work environment and ensures ease of installation and relocation. The control blocks of each module can operate independently, and in the event of a failure, only the relevant unit can be replaced or removed, allowing the entire system to continue operating.

[0157] Thus, the present invention provides a technological foundation for stable and efficient operation of collaborative robots in diverse industrial environments by integrating real-time status diagnosis, autonomous control, trajectory optimization, task integration, user interface provision, and structural flexibility. This enables collaborative robots to handle diverse work scenarios, including not only simple repetitive tasks but also irregular tasks, low-volume, multi-variety production, and safety-critical collaborative work. Furthermore, it can be utilized as a core technology supporting the transition to smart manufacturing and flexible production systems.

[0158] Hereinafter, embodiments of the present invention will be described in more detail with reference to the attached drawings. The embodiments of the present invention may be modified in various ways, and the scope of the present invention should not be construed as being limited to the embodiments described below. These embodiments are provided to more fully explain the present invention to those of ordinary skill in the art. Accordingly, the shapes of elements in the drawings have been exaggerated for clarity.

[0159] FIG. 1 is a drawing showing a modular robot system according to one embodiment of the present invention.

[0160] Referring to Fig. 1, a modular robot system (1) can be formed by connecting at least two modular robots (10) to each other. As an example, Fig. 1 illustrates an example in which a modular robot system (1) is formed by connecting three modular robots (10) to each other. The modular robots (10) can be connected to each other to form a ring-shaped modular robot system (1). As an example, the modular robot system (1) has a circular shape, and a space of a set area can be formed inside the modular robot system (1).

[0161] FIG. 2 is a drawing showing a modular robot that constitutes the modular robot system of FIG. 1, and FIG. 3 is a drawing showing the configuration of the modular robot of FIG. 2.

[0162] Referring to FIGS. 2 and 3, the modular robot (10) includes a housing (100), wheels (110), a driving member (120), a power member (140), a coupling member (151, 152), and a controller (160).

[0163] The housing (100) provides the outer appearance of the modular robot (10). The housing (100) can accommodate or secure the remaining components of the modular robot (10). The housing (100) can have a set length and be provided in a curved rod shape. For example, the housing (100) can be provided in an arc shape with a set radius of curvature. Both ends of the housing (100) can be provided to have a set central angle with respect to the center of the radius of curvature (C of FIG. 5). For example, both ends of the housing (100) can have a central angle of 120° with respect to the center (C) of the radius of curvature. Accordingly, when three modular robots (10) are connected to each other, the modular robot system (1) can have a circular shape. In addition, at least one of the modular robots (10) provided in the modular robot system (1) can have a different length, different radius of curvature, etc. from the others.

[0164] The wheel (110) may be positioned at a point in the longitudinal direction of the housing (100). The housing (100) may include a first housing (101) positioned on one side of the point where the wheel (110) is positioned and a second housing (102) positioned on the other side of the point where the wheel (110) is positioned. The first housing (101) and the second housing (102) may be provided with the same radius of curvature. The first housing (101) and the second housing (102) may have the same or different lengths. FIGS. 2 and 3 illustrate an example in which the first housing (101) is provided longer than the second housing (102).

[0165] Auxiliary wheels (111) may be positioned on the outer circumference of the wheel (110). The auxiliary wheels (111) may be provided in plurality spaced apart from each other on the outer circumference of the wheel (110) and may be provided to be rotatable about the outer circumference of the wheel (110). The auxiliary wheels (111) may be provided to be rotatable about the wheel (110) with the direction of a tangent at one point on the outer circumference of the wheel (110) as the axial direction.

[0166] The driving member (120) is positioned inside the housing (100) and provides power to rotate the wheel (110). For example, the driving member (120) may be positioned inside the first housing (101). The driving member (120) may be provided as a motor. In addition, the driving member (120) may be provided as a servo motor and may be provided to include an encoder. The driving member (120) may be connected to the wheel (110) via a driving shaft (131, 132). The driving shaft (131, 132) may include a first driving shaft (131) and a second driving shaft (132). The first driving shaft (131) is connected to the driving member (120) and may rotate according to the operation of the driving member (120). A bearing is provided on the outer circumference of the first drive shaft (131), so that the first drive shaft (131) can be effectively rotated at a set position inside the housing (100). One end of the second drive shaft (132) is connected to the first drive shaft (131) by a drive shaft connection portion (133), and the other end of the second drive shaft (132) is connected to a wheel (110), so that the rotational state of the first drive shaft (131) is transmitted to the wheel (110). A bearing is provided on the outer circumference of the second drive shaft (132), so that the second drive shaft (132) can be effectively rotated at a set position inside the housing (100). The first drive shaft (131) and the second drive shaft (132) may be provided such that their longitudinal directions are inclined at a set angle. For example, the drive shaft connection portion (133) may be provided as a universal joint. Accordingly, as the driving member (120) is positioned inside the housing (100) provided in a curved shape, the power of the driving member (120) can be effectively transmitted to the wheel (110).

[0167] A rotation control member (121) may be provided at a portion where the driving member (120) and the driving shaft (131, 132) are connected. The rotation control member (121) may allow the power generated by the operation of the driving member (120) to be controlled to a set state and then transmitted to the driving shaft (131, 132). For example, the rotation control member (121) may be provided as a reduction gear.

[0168] The power member (140) is located inside the housing (100) and provides power to operate the driving member (120). The power member (140) may be a battery having a set capacity. For example, the power member (140) may be located in the first housing (101) adjacent to the driving member (120) and may be electrically connected to the driving member (120).

[0169] The coupling members (151, 152) can keep the modular robots (10) coupled to each other. The coupling members (151, 152) can be positioned at the longitudinal ends of the modular robots (10). The coupling members (151, 152) include a first coupling member (151) and a second coupling member (152).

[0170] The first coupling member (151) is positioned at one end in the longitudinal direction of the modular robot (10). The first coupling member (151) may be positioned at one end of the first housing (101) so as to be positioned in a direction opposite to the direction in which the wheel (110) is positioned. The first coupling member (151) may be provided as a magnetic material. For example, the first coupling member (151) may be provided as a metal material, a permanent magnet. In addition, the first coupling member (151) may be provided as an electromagnet and may be electrically connected to the power member (140).

[0171] The second coupling member (152) is positioned at the other end in the longitudinal direction of the modular robot (10). The second coupling member (152) may be positioned at one end of the second housing (102) so as to be positioned in the opposite direction to the direction in which the wheel (110) is positioned. The second coupling member (152) may be provided as a magnetic material that can be coupled to the first coupling member (151) by magnetic force. For example, when the first coupling member (151) is provided as a metal material, the second coupling member (152) may be provided as a magnet. In addition, when the first coupling member (151) is provided as a permanent magnet or an electromagnet, the second coupling member (152) may be provided as a metal material or a magnet. When the first coupling member (151) and the second coupling member (152) are provided as magnets, the directions in which they face each other may have opposite polarities so that an attractive force acts between them.

[0172] Figure 4 is a drawing showing the control relationship of a modular robot.

[0173] Referring to FIG. 4, the controller (160) can control components of the modular robot (10). The controller (160) can control the driving member (120) to rotate the wheel (110). In addition, the controller (160) can control the driving member (120) to control the direction in which the wheel (110) rotates. In addition, the controller (160) can control the driving member (120) to control the speed at which the wheel (110) rotates.

[0174] A modular robot (10) may be provided with a communication unit (170). The communication unit (170) may be provided to be able to receive signals from the outside or transmit signals to the outside through wired or wireless communication.

[0175] When a signal for controlling a modular robot (10) is received through a communication unit (170), the controller (160) can control the driving member (120) in response thereto. In addition, the controller (160) can transmit a signal regarding the operating status of the modular robot (10) to the outside. In addition, the controllers (160) of the modular robots (10) constituting the modular robot system (1) are provided to transmit and receive signals to and from each other through the communication unit (170), so that the controllers (160) of the modular robots (10) constituting the modular robot system (1) can control the driving member (120) in conjunction with each other.

[0176] Additionally, when the first coupling member (151) is provided as an electromagnet, power can be supplied to or cut off from the first coupling member (151). Accordingly, the first coupling member (151) of the modular robot (10) can be connected to or separated from the second coupling member (152) of the adjacent modular robot (10).

[0177] Figure 5 is a drawing showing the positional relationship of wheels provided to a modular robot.

[0178] Referring to FIG. 5, the rotation axis of the wheel (110) provided to the modular robot (10) may be provided at a set angle inclination with respect to the tangential direction of the housing (100). Accordingly, when looking down at the modular robot (10) from above, the direction in which a straight line connecting the outer end and the inner end of the wheel (110) is directed (hereinafter, the direction of the wheel (110)) may be provided at a set angle (θ inclination) with respect to the direction toward the center (C) of the radius of curvature of the modular robot (10).

[0179] Accordingly, the modular robot system (1) can have a high degree of freedom with respect to the direction of movement. For example, all wheels (110) provided on the modular robots (10) constituting the modular robot system (1) can be controlled to rotate in the same direction, for example, in a direction in which all move inward of the modular robot system (1) (hereinafter, “inward direction”) or in a direction in which all move outward of the modular robot system (1) (hereinafter, “outward direction”). In this case, since the direction of the wheels (110) is provided to be inclined with respect to the center (C) of the radius of curvature, the modular robot system (1) can move. For example, when the wheels (110) of each modular robot (10) rotate at the same speed, the modular robot system (1) can perform a rotational movement.

[0180] In addition, the wheels (110) of the modular robots (10) constituting the modular robot system (1) can be controlled to rotate in the same direction, while at least one of them rotates at a different speed from the others. Accordingly, the modular robot system (1) can be moved to different locations.

[0181] In addition, at least one of the modular robots (10) constituting the modular robot system (1) may have wheels (110) that rotate in a different direction from the rest. For example, at least one of the modular robots (10) may have wheels (110) that rotate inward, and the rest may have wheels (110) that rotate outward. In addition, the rotational speeds of the respective wheels (110) may be adjusted to be the same or different.

[0182] In addition, at least one of the modular robots (10) constituting the modular robot system (1) can be controlled so that its wheels (110) rotate, and the rest can be controlled so that its wheels (110) do not drive. For example, one or two modular robots (10) can be controlled so that its wheels (110) do drive, and the rest of the modular robots (10) can be controlled so that its wheels (110) do not drive. When the wheels (110) of the two modular robots (10) are driven, their rotational directions can be the same or different. In addition, their rotational speeds can be adjusted so that they are the same or different.

[0183] The modular robot system (1) configured by connecting modular robots (10) according to this invention can have a variety of movement directions depending on the combination of driving states of the wheels (110) as described above. In addition, the modular robot system (1) can easily change its movement direction to a different direction while moving in one direction.

[0184] At this time, auxiliary wheels (111) are provided on the outer circumference of the wheel (110), so that the modular robot (10) can effectively move in a direction inclined with respect to the direction of movement of the wheel (110).

[0185] FIG. 6 is a drawing showing a modular robot according to another embodiment.

[0186] Referring to FIG. 6, the modular robot (11) includes a housing (100a), a wheel (110a), a driving member (120a), a power member (140a), a coupling member (151a, 152a), and a controller (160a).

[0187] The connecting member (151a, 152a) includes a first connecting member (151a) and a second connecting member (152a).

[0188] The first coupling member (151a) is positioned at one end in the longitudinal direction of the modular robot (11). The first coupling member (151a) may be positioned at one end of the first housing (101a) so as to be positioned in the opposite direction to the direction in which the wheel (110a) is positioned. The first coupling member (151a) may be connected to an auxiliary driving member (155). The auxiliary driving member (155) is provided so as to rotate the first coupling member (151a) around an axis that passes through the central region of the housing (100a) in a tangential direction with respect to the longitudinal direction of the housing (100a). For example, the auxiliary driving member (155) may be provided as a motor and may be electrically connected to a power source member (140a). In addition, the controller (160a) may control the auxiliary driving member (155) to control the rotational state of the first coupling member (151a).

[0189] In addition to the fact that the first connecting member (151a) is provided to be rotatable, the configuration and operation of the housing (100a), the wheel (110a) that may be provided with auxiliary wheels on the outer periphery, the driving member (120a), the driving shaft (131a, 132a), the rotation control member (121a), the power member (140a), and the control of the driving member (120a) by the controller (160a) are the same or similar to those of the modular robot (10) of FIG. 3, so repeated descriptions are omitted.

[0190] Fig. 7 is a drawing showing a modular robot system composed of the modular robot of Fig. 6.

[0191] Referring to Fig. 7, when adjacent modular robots (11) are connected through first connecting members (151a) and second connecting members (152a), respectively, the first connecting member (151a) of one of the modular robots (11) can be controlled to rotate. Accordingly, the modular robot (11) connected through the second connecting member (152a) rotates, and the shape of the modular robot system (1a) can be changed. In a similar manner, the modular robot (11) located on the other side can also rotate. Accordingly, the shape of the modular robot system (1a) can be changed into a circle or a curved shape having at least one inflection point. In addition, in a state where the shape is changed, the rotation direction and speed of the wheel (110a) are controlled in a manner similar to the above-described manner, so that the movement direction of the modular robot system (1a) can have a high degree of freedom.

[0192] Additionally, the modular robot system may be configured in a mixed form of a modular robot (10) according to the embodiment of FIG. 2 and FIG. 3 and a modular robot (11) according to the embodiment of FIG. 6.

[0193] Figure 8 is a flowchart illustrating an incasing method using a collaborative robot according to one embodiment of the present invention.

[0194] Referring to FIG. 8, an incasing method using a collaborative robot according to one embodiment of the present invention uses an incasing automation system (10) described below in FIG. 9, and first, a packaged product is placed in a packaging box (1) and packaged (S110).

[0195] The packaging box (1) packaged by the first packaging step (S110) is continuously supplied to the box sorting unit (200) in an upside-down state using a transfer conveyor (100) (S120).

[0196] Here, the packaging box (1) can store fresh food such as plastic-wrapped natto.

[0197] In the box sorting unit (200), the packaging boxes (1) supplied by the box transfer step (S120) are alternately sorted and moved in the left and right directions where the first loading unit (300) and the second loading unit (400) are installed (S130).

[0198] In one embodiment, the box sorting step (S130) may include a first sorting movement step of sorting and moving the packaging boxes (1) supplied from the transport conveyor (100) by the box sorting unit (200) to the first loading unit (300), and a second sorting movement step of sorting and moving the packaging boxes (1) supplied from the transport conveyor (100) by the box sorting unit (200) to the second loading unit (320).

[0199] In one embodiment, the box sorting step (S130) may move the packaging boxes (1) supplied by the box transfer step (S120) in an alternating left-right direction, or may move them in a sorting manner to the first loading unit (300) or the second loading unit (400) in response to a preset sorting criterion (e.g., the size of the box or the weight of the box).

[0200] In the box sorting step (S130), the upside-down packaging boxes (1) moved from the box sorting unit (200) are rotated so that the upside-down direction becomes the correct direction in the first loading unit (300) and the second loading unit (400), and then sequentially loaded in the horizontal direction (S140).

[0201] The packaging box (1) loaded by the first collaborative robot (500) and the second collaborative robot (600) in the loading step (S140) is stored in another packaging box (i.e., the first loading box (B1) and the second loading box (B2)) and packaged (S150).

[0202] The encasing method using a collaborative robot according to one embodiment of the present invention having the steps described above may further include a buffer step (not shown in the drawing for convenience of explanation) of temporarily loading the packaging box (1) into the buffer box (B3) instead of the loading box in which the loading is completed when either the first loading box (B1) or the second loading box (B2) completes storing the packaging box (1) first.

[0203] In one embodiment, the first collaborative robot (500) and the second collaborative robot (600) described below in FIG. 9 can move the packaging box (1) temporarily loaded in the buffer box (B3) by the buffer step to the empty loading box and load it when the loading box, which has been completed after the buffer step, is replaced with an empty loading box.

[0204] In addition, the encasing method using a collaborative robot according to one embodiment of the present invention having the steps described above can perform continuous packaging without interruption of packaging by using a buffer box when a packaging box that has been stored first is generated during the storage of packaging boxes.

[0205] The encasing method using a collaborative robot according to one embodiment of the present invention having the steps described above is a method of packaging a packaging box containing a packaged product by placing it in another packaging box using the encasing automation system (10) described below in FIG. 9, and the encasing automation system (10) will be described first below.

[0206] FIG. 9 is a diagram schematically illustrating the configuration of an incasing automation system according to one embodiment of the present invention.

[0207] Referring to FIG. 9, an incasing automation system (10) according to one embodiment of the present invention includes a transfer conveyor (100), a box sorting unit (200), a first loading unit (300), a second loading unit (400), a first collaborative robot (500), a second collaborative robot (600), a first loading box (B1), and a second loading box (B2).

[0208] The transport conveyor (100) continuously supplies packaging boxes (1) containing packaged products to the box sorting section (200) in an upside-down state.

[0209] The box sorting unit (200) receives packaging boxes (1) supplied from the transfer conveyor (100) in an upside-down state and then sorts and moves them alternately in the left and right directions toward the first loading unit (300) or the second loading unit (400), and a first collaborative robot (500) and a second collaborative robot (600) are installed at the top.

[0210] The first loading unit (300) is installed on the left side of the box sorting unit (200) and rotates the packaging boxes (1) delivered from the box sorting unit (200) so that the vertical direction is in the correct direction and then sequentially loads them in the horizontal direction.

[0211] The second loading unit (400) is installed on the right side of the box sorting unit (200) and rotates the packaging boxes (1) delivered from the box sorting unit (200) so that the vertical direction is in the correct direction and then sequentially loads them in the horizontal direction.

[0212] The first collaborative robot (500) is a multi-joint robot installed on the upper left side of the box sorting section (200) and simultaneously moves the packaging boxes (1) loaded on the first loading section (300) using vacuum suction.

[0213] The second collaborative robot (600) is a multi-joint robot installed on the upper right side of the box sorting section (200) and simultaneously moves the packaging boxes (1) loaded on the second loading section (400) using vacuum suction.

[0214] In one embodiment, the first collaborative robot (500) and the second collaborative robot (600) may be equipped with independent small air tanks (2) used solely for their vacuum suction.

[0215] In one embodiment, the first collaborative robot (500) and the second collaborative robot (600) may each be equipped with a vacuum suction device (510, 610) to enable suction-fastening of a packaging box (1).

[0216] The first loading box (B1) is installed on the left side of the rear side of the box sorting unit (200) and stores a packaging box (1) moved by the first collaborative robot (500).

[0217] The second loading box (B2) is installed on the right side of the rear side of the box sorting unit (200) and stores the packaging box (1) moved by the second collaborative robot (600).

[0218] An incasing automation system according to one embodiment of the present invention having the configuration described above may further include a buffer box (B3).

[0219] The buffer box (B3) temporarily loads the packaging box (1) in place of the loading box on which the first collaborative robot (500) or the second collaborative robot (600) has completed loading when either the first loading box (B1) or the second loading box (B2) has completed loading the packaging box (1).

[0220] An incasing automation system according to one embodiment of the present invention having the configuration described above may further include a safety fence (3).

[0221] A safety fence (3) is installed in front of the box sorting section (200) while forming an opening for placing a transfer conveyor (100) to prevent entry of workers.

[0222] An incasing automation system according to one embodiment of the present invention having the configuration described above can improve packaging efficiency by sequentially placing primary packaging boxes containing packaged products into secondary packaging boxes using two collaborative robots.

[0223] Fig. 10 is a drawing showing the box classification section of Fig. 9.

[0224] Referring to FIG. 10, the box sorting unit (200) includes a sorting unit casing (210), a sorting conveyor (220), a sorting cylinder (230), and a sorting plate (240).

[0225] The sorting unit casing (210) is installed in front of the transfer conveyor (100) between the first loading unit (300) and the second loading unit (400), and the first collaborative robot (500) and the second collaborative robot (600) are installed on the upper left and right sides, and forms an internal space for settling a packaging box (1) delivered from the transfer conveyor (100), and components such as a sorting conveyor (220), a sorting cylinder (230), and a sorting plate (240) are installed.

[0226] The sorting conveyor (220) is installed in close contact with the front end of the transport conveyor (100) and is arranged inside the sorting unit casing (210), and moves the packaging box (1) delivered from the transport conveyor (100) to the inside of the sorting unit casing (210).

[0227] The classification cylinder (230) is installed so as to be able to expand or contract horizontally in the left and right directions on the upper side of the internal space of the classification unit casing (210) and moves the classification plate (240) back and forth in the left and right directions in response to the transport speed of the packaging box (1).

[0228] The sorting plate (240) is installed upright on the sorting cylinder (230), and moves back and forth in the horizontal direction left and right as the sorting cylinder (230) is driven to expand or contract in the left and right direction, and alternately sorts and moves the packaging boxes (1) entering the internal space of the sorting unit casing (210) by the sorting conveyor (220) toward the first loading unit (300) and the second loading unit (400).

[0229] The box sorting unit (200) having the configuration described above not only provides a foundation for installing the first collaborative robot (500) and the second collaborative robot (600), but also enables stable and efficient sorting by sequentially moving the packaging boxes (1) supplied continuously by the transfer conveyor (100) toward the first loading unit (300) or the second loading unit (400).

[0230] Fig. 11 is a drawing showing the first loading section of Fig. 9.

[0231] Referring to FIG. 11, the first loading unit (300) includes a loading body unit (310), a loading unit (320), a rotation transfer unit (330), and a plurality of loading conveyors (340).

[0232] Here, the second loading unit (400) has the same configuration as the first loading unit (300) described below, and the loading body unit (310), loading unit (320), rotating transmission unit (330), and multiple loading conveyors (340) of the first loading unit (300) can be applied in the same manner. Therefore, the description thereof will be omitted to avoid duplication of explanation.

[0233] The loading body (310) is installed on the left side of the classification unit casing (210), and is configured with a loading unit (320), a rotation transmission unit (330), and a plurality of loading conveyors (340).

[0234] The loading section (320) is formed on the upper side of the loading body section (310) with the lower side being open except for the mounting protrusions for mounting the front and rear ends of the packaging box (1).

[0235] In one embodiment, the first collaborative robot (500) can simultaneously fasten a plurality of packaging boxes (1) using vacuum suction when a preset number (e.g., 4 to 10, etc.) of packaging boxes (1) are sequentially placed from the end of the loading unit (320) and then move them to the first loading box (B1).

[0236] The rotation transfer unit (330) is installed so as to be capable of rotational driving on one side of the loading body unit (310) facing the sorting unit casing (210) at the same height as the sorting conveyor (220), and when the packaging box (1) is transferred by the sorting plate (240), the rotation unit (330) rotates the packaging box (1) while reversing its up-down direction and simultaneously places it on the loading unit (320).

[0237] At this time, the packaging box (1) can be moved after being placed on the upper side of a plurality of loading conveyors (340) by the rotating transmission unit (330).

[0238] A plurality of loading conveyors (340) are installed at regular intervals in the front-back direction along the lower opening of the loading section (320), and when a packaging box (1) delivered by the rotating transfer section (330) is placed, the conveyors are driven to rotate to sequentially move the packaging box (1) to the end of the loading section (320).

[0239] In one embodiment, the loading conveyor (340) is installed by bolting to the loading body (310), and can be separated from the loading body (310) by separating the bolt.

[0240] The first loading unit (300) having the configuration described above can receive a packaging box (1) in an upside-down state, rotate the packaging box (1) in a forward direction while upside-down, and then load it in sequence to ensure stable transport by the first collaborative robot (500).

[0241] Figures 12 to 14 are drawings showing the rotation transmission unit of Figure 11.

[0242] Referring to FIGS. 12 to 14, the rotation transmission unit (330) includes a mounting box (331), a rotation drive motor (332), a plurality of first belt mounting units (333), and a plurality of second belt mounting units (334).

[0243] The mounting box (331) is installed so as to be rotatable by 180º on the upper side of one side of the loading body (310) facing the sorting unit casing (210) at the same height as the sorting conveyor (220), but one side facing the sorting unit casing (210) is formed open so that the packaging box (1) can enter the internal space by the sorting plate (240).

[0244] In one embodiment, the mounting box (331) may be formed by bending so that the upper end (331a) and the lower end (331b) of one side, where the inlet for the packaging box (1) to enter the internal space is formed, are symmetrically inclined.

[0245] The rotation drive motor (332) is installed in the loading body (310) and repeatedly drives the loading box (331) to rotate in the forward or reverse direction.

[0246] A plurality of first belt mounting portions (333) are formed by cutting along the upper side of the mounting box (331) corresponding to the position of the loading conveyor (340) so that the loading conveyor (340) can be mounted when the mounting box (331) is driven to rotate in the forward direction and mounted on the loading portion (320).

[0247] A plurality of second belt mounting portions (334) are cut and formed along the lower side of the mounting box (331) while facing the plurality of first belt mounting portions (333).

[0248] FIG. 15 is a diagram schematically illustrating the configuration of an incasing automation system according to another embodiment of the present invention.

[0249] Referring to FIG. 15, an incasing automation system (20) according to another embodiment of the present invention includes a transfer conveyor (100), a box sorting unit (200), a first loading unit (300), a second loading unit (400), a first collaborative robot (500), a second collaborative robot (600), a first loading box (B1), a second loading box (B2), and a box cleaning unit (700).

[0250] Here, the transfer conveyor (100), box sorting unit (200), first loading unit (300), second loading unit (400), first collaborative robot (500), second collaborative robot (600), first loading box (B1), and second loading box (B2) are the same as the components of Fig. 9, so their descriptions will be omitted to avoid duplication of explanation.

[0251] The box cleaner (700) is installed to cover the upper side of the transport conveyor (100) and cleans and removes foreign substances such as dust attached to both sides and the upper side of the bottom surface of the packaging box (1) being transported along the transport conveyor (100).

[0252] An incasing automation system (20) according to another embodiment of the present invention having a configuration as described above can improve the packaging quality of a product by removing foreign substances such as dust attached to the packaging box (1) during the transport stage before the packaging of the packaging box (1) is completed.

[0253] Fig. 16 is a drawing showing the box cleaner of Fig. 15.

[0254] Referring to FIG. 16, the box cleaner (700) includes a box moving tunnel (710), an entry detection sensor (720), a horizontal moving rail home (730), a horizontal moving rail (740), a horizontal moving slider (750), two vertical moving rail homes (760), two vertical moving rails (770), and two vertical moving sliders (780).

[0255] The box moving tunnel (710) is formed by bending both sides in a downward perpendicular direction, and is installed to cover the upper side of the transport conveyor (100) so that the packaging box (1) can move along the inner side.

[0256] The entry detection sensor (720) detects that a packaging box (1) enters the inside of the box movement tunnel (710).

[0257] The horizontal movement rail home (730) is formed to extend horizontally left and right along the inner upper part (711) of the box movement tunnel (710).

[0258] The horizontal movement rail (740) is formed to extend along the inner side of the horizontal movement rail home (730).

[0259] The horizontal movement slider (750) is installed so as to be interlocked and connected to the horizontal movement rail (740) so as to be able to slide, and is placed on the inside of the horizontal movement rail home (730). When a packaging box (1) enters the inside of the box movement tunnel (710), it moves back and forth along the horizontal movement rail (740) and sprays compressed air toward the bottom of the packaging box (1) to remove foreign substances attached to the bottom of the packaging box (1).

[0260] Two vertical moving rail homes (760) are formed to extend vertically in the up-and-down direction along one inner side (713) and the other inner side (714) of the box moving tunnel (710).

[0261] Two vertical movement rails (770) are formed to extend along the inner side of the vertical movement rail home (760).

[0262] Two vertical movement sliders (780) are interlocked and connected to enable sliding movement on a vertical movement rail (770) and are placed inside a vertical movement rail home (760). When a packaging box (1) enters the inside of a box movement tunnel (710), the two vertical movement sliders (780) move back and forth along the vertical movement rail (770) and spray compressed air toward one side and the other side of the packaging box (1) to remove foreign substances attached to one side and the other side of the packaging box (1).

[0263] A box cleaner (700) having a configuration as described above can effectively separate and remove foreign substances such as dust attached to the packaging box (1) by spraying compressed air onto the bottom and both sides of the packaging box (1).

[0264] Figure 17 is a drawing showing the horizontal movement slider of Figure 16.

[0265] Referring to FIG. 17, the horizontal movement slider (750) includes a slider (751), a cover rotation motor (752), a cone-shaped cover (800), a first spray nozzle (753), and a second spray nozzle (754).

[0266] The slider (751) is installed in a manner that allows sliding movement on the horizontal movement rail (740).

[0267] The cover rotation motor (752) is installed on the lower side of the slider (751) and drives the cone-shaped cover (800) to rotate.

[0268] The cone-shaped cover (800) is formed in a cone shape, and the upper part, which forms an outer diameter smaller than the lower outer diameter, is installed by shaft coupling to the drive shaft of the cover rotation motor (752), and is rotationally driven by the cover rotation motor (752).

[0269] The first injection nozzle (753) is installed on the upper side of the inner space of the cone-shaped cover (800) and injects compressed air.

[0270] The second injection nozzle (754) is installed on the upper side of the inner space of the cone-shaped cover (800) and is spaced apart from the first injection nozzle (753) to inject compressed air.

[0271] The horizontal movement slider (750) having the configuration described above injects compressed air through the first injection nozzle (753) and the second injection nozzle (754) installed on the inside of the rotating cone-shaped cover (800), thereby inducing diffusion of the compressed air and enabling more effective removal of foreign substances through the compressed air injected from two separated locations.

[0272] Figures 18 and 19 are drawings showing the cone-shaped cover of Figure 17.

[0273] Referring to FIGS. 18 and 19, the cone-shaped cover (800) includes a cone body (810), a frame mounting groove (820), a cover mounting groove (830), a plurality of passage frames (840), a gap cover (850), and a frame driving gear (860).

[0274] The cone body (810) is formed in a cone shape, and the upper part, which forms an outer diameter smaller than the outer diameter of the lower part, is installed by means of an axial coupling to the drive shaft of the cover rotation motor (752), and is rotationally driven by the cover rotation motor (752), and is provided with components such as a frame mounting groove (820), a cover mounting groove (830), a plurality of passage frames (840), a gap cover (850), and a frame driving gear (860).

[0275] The frame mounting grooves (820) are formed in multiple recesses spaced at regular intervals along the inward surface of the cone body (810).

[0276] The cover mounting groove (830) is formed in communication between a plurality of frame mounting grooves (820).

[0277] A plurality of passage frames (840) are inserted and installed into the frame mounting groove (820).

[0278] The gap cover (850) is made of a flexible thin film that can expand or contract and is installed between a plurality of passage frames (840) and placed in the cover mounting groove (830). As the passage frame (840) is exposed from the frame mounting groove (820), it is also exposed from the cover mounting groove (830) to form an exhaust passage for compressed air sprayed from the first spray nozzle (753) and the second spray nozzle (754).

[0279] The frame drive gear (860) is installed so as to be rotatably driven on one side of the frame mounting groove (820), and is connected by gear engagement to a gear tooth formed along the passage frame (840), and is driven to rotate in the forward or reverse direction to insert or expose the passage frame (840) into the frame mounting groove (820).

[0280] The cone-shaped cover (800) having the configuration described above can be selectively used in response to the compressed air spray area by spraying compressed air through an air discharge passage formed by the inner surface (S1) of the cone body (810) when spraying compressed air over a wide area is required, and by spraying air using an air discharge passage formed by the inner surface (S2) of the gap cover (850) when spraying compressed air over a narrow area is required.

[0281] Figure 20 is a drawing showing the passage frame of Figure 19.

[0282] Referring to FIG. 20, the passage frame (840) includes a frame body (841), an auxiliary frame (842), a first magnetic body (843), a second magnetic body (844), and a catch (845).

[0283] The frame body (841) is inserted and installed into the frame mounting groove (820), a gear mountain (G) is formed along the outward surface, and a gap cover (850) is installed and covers the outward surface except for the gear mountain.

[0284] The auxiliary frame (842) is installed so as to be rotatably connected to the lower end of the frame body (841), and has an inward surface formed as an inclined surface to be seated on the lower inward surface of the frame body (841) so as to be engaged with the lower inward surface of the frame body (841) formed as an inclined surface, and when deployed from the frame body (841), it covers the frame body (841) along the outwardly facing surface and is installed so as to be covered by the lower end of the remaining gap cover (850).

[0285] The first magnetic body (843) is a magnetic body that forms magnetism and is installed on the lower inward surface of the frame body (841).

[0286] The second magnetic body (844) is installed on the inward surface of the auxiliary frame (842), and is attached to the first magnetic body (843) by forming an opposite polarity to the first magnetic body (843) or separated from the first magnetic body (843) by forming the same polarity as the first magnetic body (843) depending on the switching of the supplied power.

[0287] The catch (845) is installed on the upper outward surface of the auxiliary frame (842), and as the auxiliary frame (842) is deployed from the frame body (841), it is seated on the lower outward surface of the frame body (841) to stop the rotation of the auxiliary frame (842).

[0288] The passage frame (840) having the configuration described above can extend the air exhaust passage formed by the gap cover (850) by separating the auxiliary frame (842) from the frame body (841).

[0289] Figure 21 is a flowchart explaining the loading steps of Figure 8.

[0290] Referring to FIG. 21, in the loading step (S140), the packaging boxes (1) delivered by the first classification movement step in the first loading unit (300) are rotated so that the vertical direction is in the normal direction and then sequentially loaded in the horizontal direction (S141), and at the same time, the packaging boxes (1) delivered by the second classification movement step in the second loading unit (400) are rotated so that the vertical direction is in the normal direction and then sequentially loaded in the horizontal direction (S142).

[0291] Here, the first rotation loading step (S141) may include a box transfer step of receiving an upside-down packaging box (1) transferred by the first classification movement step, a box rotation step of rotating the packaging box (1) transferred by the box transfer step so that the upside-down direction becomes the normal direction, and a horizontal alignment step of sequentially loading the packaging boxes (1) arranged in the upside-down direction by the box rotation step in a horizontal direction.

[0292] Figure 22 is a flowchart illustrating the second packaging step of Figure 8.

[0293] Referring to FIG. 22, the second packaging step (S150) is performed simultaneously with the first storage packaging step (S151) in which the packaging box (1) loaded on the first loading section (300) by the first collaborative robot (500) is simultaneously moved to the first loading box (B1) and then stored therein, and the second storage packaging step (S152) in which the packaging box (1) loaded on the second loading section (400) by the second collaborative robot (600) is simultaneously moved to the second loading box (B2) and then stored therein.

[0294] Here, in the first storage packaging step (S151), when a preset number of packaging boxes (1) are sequentially placed from the end of the first loading section (300), the first collaborative robot (500) can simultaneously fasten a plurality of packaging boxes (1) loaded on the first loading section (300) using vacuum suction and then move them to the first loading box (B1).

[0295] And, in the second storage packaging step (S152), when a preset number of packaging boxes (1) are sequentially placed from the end of the second loading unit (400), the second collaborative robot (600) can simultaneously fasten a plurality of packaging boxes (1) loaded on the second loading unit (400) using vacuum suction and then move them to the second loading box (B2).

[0296] Figure 23 is a flowchart illustrating an incasing method using a collaborative robot according to another embodiment of the present invention.

[0297] Referring to FIG. 23, an encasing method using a collaborative robot according to another embodiment of the present invention further includes a box cleaning step (S110-1) of cleaning and removing foreign substances attached to both sides and the bottom surface facing upward of a packaging box (1) being transported along a transport conveyor (100) using a box cleaning unit (700) described above in FIGS. 15 to 13 before the first packaging step (S110).

[0298] The encasing method using a collaborative robot according to another embodiment of the present invention having the steps described above can improve the packaging quality of a product by removing foreign substances such as dust attached to the packaging box (1) during the transport stage before the packaging of the packaging box (1) is completed.

[0299] In one embodiment, in operation 23, the control device (200) can transmit a control command based on a control parameter to the collaborative robot (100) and the additional axis device (300). For example, the control device (200) can generate and transmit a control command suitable for each joint part (110) and the components of the additional axis device (300) based on the calculated control parameter.

[0300] The control device (200) can transmit command data regarding position information, speed, acceleration, and torque to each joint (110) through an integrated network or a dedicated communication bus, and at the same time, can transmit control commands to the lift (310), rail (320), positioner (330), etc. belonging to the additional axis device (300) according to the same principle.

[0301] At this time, the control command includes correction values ​​to minimize the difference between the operation target value of each axis and the current state, thereby enabling the driving unit (180) composed of a servo motor and a reducer to be precisely driven within a minute error range. The control device (200) can immediately apply correction commands to minute errors or disturbances occurring in real time by repeatedly transmitting commands while maintaining a short control cycle of 1 millisecond or less, thereby allowing the synchronization state of the entire system to always be maintained at an optimal state.

[0302] In one embodiment, in operation 24, the collaborative robot (100) and the auxiliary axis device (300) can be driven in real time in synchronization. For example, the collaborative robot (100) and the auxiliary axis device (300) can be driven simultaneously in real time according to a synchronization control command received from the control device (200).

[0303] Each joint part (110) of the collaborative robot (100) moves precisely according to the path and control parameters set by the control device (200), and the gripper (140) can approach the workpiece (1) through the robot arm (120) and perform necessary operations. At the same time, the lift (310) belonging to the auxiliary axis device (300) can adjust the vertical position of the collaborative robot (100) to support the robot to work stably even in a high or low position, and the rail (320) can move the collaborative robot (100) left and right or forward and backward to maximize work efficiency in a wide work area.

[0304] In addition, the positioner (330) can change the posture of the workpiece (1) by rotating or tilting it, thereby providing an optimal working environment in complex assembly, inspection, and processing processes. The control device (200) can detect and correct in real time any unexpected errors or disturbances that may occur during the work by precisely adjusting the operation timing of each component in this way, thereby enabling the collaborative robot (100) and the auxiliary axis device (300) to stably perform high-speed, high-precision work in a perfectly synchronized state. This synchronization control can be particularly usefully applied in complex processes where the relative position between the robot arm (120) and the workpiece (1) is maintained constant during the process, or work is performed simultaneously at multiple work points, and can greatly improve the productivity and safety of the entire system.

[0305] The main configuration of the present invention is described below with reference to FIGS. 26 to 28.

[0306] Referring to FIGS. 26 to 28, a real-time motion synchronization control system (10) according to the present disclosure performs a complex process using multi-axis real-time motion synchronization control of a collaborative robot (100), and may include a collaborative robot (100), a control device (200), and an additional axis device (300).

[0307] In one embodiment, as illustrated in FIGS. 26 and 27, the collaborative robot (100) may include a plurality of joints (110), a robot arm (120), a base (130), a gripper (140), an encoder (150), a current sensor (160), a temperature sensor (170), and a driving unit (180).

[0308] For example, a collaborative robot (100) may be configured to have multiple joints (110) to form multiple axes of rotation, and each joint (110) may be mechanically and firmly connected to a robot arm (120) so that the robot arm (120) may move freely along multiple axes of rotation. This configuration may enable the robot arm (120) to secure a high degree of freedom in various work environments, and may support precise access to and manipulation of a workpiece (1) when performing a complex process. For example, a collaborative robot (100) may be applied to an automobile parts assembly process in a production line, and each joint (110) may receive position and angle information in real time through a sensor such as a high-resolution encoder (150), so that the robot arm (120) may implement finely tuned movements.

[0309] In addition, the robot arm (120) can perform linear or rotational motion in a complex manner depending on the kinematic structure combined with the joint part (110), thereby enabling the path for approaching the workpiece (1) to be optimized in various angles. For example, the robot arm (120) can be simultaneously extended or contracted in the horizontal and vertical directions, thereby enabling it to operate effectively even in a narrow space to stably pick up or place the workpiece (1). This function can serve as a core technology that allows the robot arm (120) to be utilized in various fields, such as automated assembly lines, logistics warehouses, or surgical support systems in the medical field.

[0310] Furthermore, the collaborative robot (100) can apply an advanced control algorithm and an integrated sensor network to minimize motion errors that may occur in multiple rotation axes based on the continuous and flexible movement of the robot arm (120) installed between each joint part (110). The control device (200) can collect such sensor data in real time to correct the movement of the robot arm (120) and generate precise control commands to maintain a constant relative positional relationship with the workpiece (1). For example, even in a situation where the collaborative robot (100) moves at high speed, the movements of each joint part (110) and the robot arm (120) are consistently maintained, so that access to the workpiece (1) can be stably achieved, and this can greatly improve the efficiency and safety of the entire process.

[0311] In addition, the collaborative robot (100) of the present invention is designed to be applicable to various work environments, so that it can flexibly respond even in dynamic situations where the workpiece (1) moves or its position changes, and can immediately respond to minute changes in position or angle of the workpiece (1) through the multi-axis movement of the robot arm (120). For example, the collaborative robot (100) can be applied to the task of precisely picking up and placing very small-sized parts at a specific position in an electronic component assembly process, and at this time, the rotation and extension movements of the robot arm (120) can be finely adjusted to minimize gaps or errors between parts.

[0312] In one embodiment, the base (130) positioned at the lowest end of the collaborative robot (100) can be designed to firmly fix the entire robot structure, thereby ensuring the stability of the entire robot from vibrations or external impacts that may occur within the work environment. The base (130) can be made of a strong material, such as a high-strength metal or composite material, and can perform a support function so that the robot can precisely maintain its position without micro-vibrations or shaking caused by external impacts even when handling heavy loads or moving at high speeds. For example, in an automobile assembly line or an aerospace parts production process, the base (130) can ensure stable posture control even under conditions of heavy materials and high-speed movement, thereby improving the reliability of the production process.

[0313] In one embodiment, the robot arm (120) may be configured to be positioned between a plurality of joints (110) and expand or contract by effectively receiving the rotational motion of each joint (110), thereby playing an important role in precisely adjusting the distance to the workpiece (1) and enabling manipulation at various angles and positions within the workspace. The robot arm (120) may be designed to have a built-in precision gear mechanism and a high-resolution sensor to enable fine position adjustment and speed control, and may significantly improve work efficiency and quality by optimizing the path and angle of approach to the workpiece (1) in applications such as electronic component assembly, medical surgical assistance, or precision welding. In addition, the robot arm (120) supports various operation modes through its connection structure with the joints (110), and may stably handle the workpiece (1) by maintaining precise linkage between the joints even while moving along a complex path.

[0314] In one embodiment, the gripper (140) may be installed at the end of the robot arm (120) and configured to directly grasp or place a workpiece (1), and may adopt a multi-functional gripper structure to efficiently handle objects of various shapes and sizes. The gripper (140) may apply various drive methods such as pneumatic, electric, and hydraulic, and each drive method may be designed to simultaneously satisfy the clamping force applied to the workpiece (1) and precise control. For example, an electric gripper can be finely adjusted through electronic control, a hydraulic gripper can provide strong pressure to be suitable for handling large parts, and a pneumatic gripper can advantageously operate in high-speed operations of a production line due to its fast response speed. In addition, the gripper (140) may be equipped with a replaceable tip or extension module to apply various clamping methods according to the characteristics of the workpiece (1), which may greatly improve the flexibility and efficiency of the production process.

[0315] In this way, the base (130), robot arm (120), and gripper (140) of the collaborative robot (100) can perform complementary roles to support the entire system to accurately and safely handle complex work objects (1), and each component can be applied with optimized materials, mechanical design, and sensor technology to ensure stable operation even in high-speed and high-precision work environments. This integrated system can be applied in various industrial fields such as manufacturing, logistics, medical, and others, to significantly improve work quality and productivity when performing complex processes, and to ensure the stability and reliability of the entire process.

[0316] In one embodiment, the encoder (150) may be configured as a key element that precisely measures the rotational angle or position of each joint part (110) and detects the movement state of the collaborative robot (100) in real time and transmits it to the control device (200). For example, the encoder (150) may convert the rotational movement of each joint part (110) into a digital signal, thereby enabling the control device (200) to precisely determine the angle and position of the robot arm (120). Such measurement data may be utilized as essential input values ​​for setting a work path, synchronization control, PID control, and real-time compensation algorithms, thereby maximizing the precision and reliability of the entire system.

[0317] In addition, the encoder (150) is designed to have high resolution, so that even minute position changes or angle differences can be accurately detected, and thus even minute errors between each joint (110) of the collaborative robot (100) can be detected and corrected in real time. For example, even minute angle changes that occur when the robot arm (120) rotates at a high speed or approaches a workpiece (1) can be detected through precise measurement by the encoder (150), so that the control device (200) can immediately output a correction command. In this way, the encoder (150) can be implemented in an incremental or absolute manner, and each manner can be selectively applied depending on a specific application or work environment.

[0318] Furthermore, the encoder (150) can provide a real-time data stream through communication with the robot arm (120) and each joint (110), thereby enabling the control device (200) to accurately grasp the motion state of the entire system and derive optimal control commands accordingly. For example, the real-time trajectory of the collaborative robot (100) can be predicted based on data generated from the sensor, and a correction value for synchronization with the additional axis device (300) can be calculated, thereby preventing the accumulation of minute errors that may occur during operation.

[0319] In addition, the encoder (150) can be installed in combination with a high-precision gear mechanism, and this structure can be designed to minimize measurement errors caused by external shocks or vibrations, and to provide stable position data through a continuous correction process. For example, even when the collaborative robot (100) moves at high speed, the encoder (150) can transmit accurate position information of each joint (110) in real time, thereby supporting the stable and precise operation of the entire system.

[0320] As a result, the encoder (150) plays a key role within a control system integrated with a collaborative robot (100) and an additional axis device (300), and by providing real-time position and angle information, it can improve the precision of work path setting, synchronization control, and compensation algorithms, thereby significantly increasing the stability and reliability of the entire system.

[0321] In one embodiment, the current sensor (160) may be designed to monitor in real time the current consumed when the driving unit (180) drives each joint unit (110), thereby optimizing the energy efficiency of the system. The current sensor (160) precisely detects changes in the electrical load of the servo motor and reducer connected to each joint unit (110), thereby providing real-time data to the control device (200), thereby enabling analysis of the power consumption pattern of the entire system.

[0322] For example, when a collaborative robot (100) moves at high speed, the current sensor (160) can detect a sudden increase in current and transmit the point where an overload occurs to the control device (200) in real time, thereby enabling an immediate safety control command to be issued. In addition, the current sensor (160) can apply high-sensitivity sensor technology to detect even a minute change in the electrical load, and through this, the operating status of the driving unit (180) can be determined in detail, which can be utilized as data for optimizing power consumption and improving energy efficiency. The current sensor (160) can quickly detect, for example, a short circuit or overload situation when an abnormal current occurs during the operation of the driving unit (180), and transmit an immediate safety control signal to the control device (200), thereby ensuring that the entire system can quickly respond to an emergency situation.

[0323] In this way, the current sensor (160) can be configured to determine whether the driving unit (180) is operating normally through electrical load detection, analyze energy consumption patterns according to the external environment or working conditions, reduce unnecessary energy loss during the process, and control optimal operating conditions in real time in terms of power management. Consequently, the current sensor (160) can serve as a key technology that can increase the operational reliability of the collaborative robot (100) and the additional axis device (300) and simultaneously maximize the safe operation and energy efficiency of the system.

[0324] In one embodiment, the temperature sensor (170) can precisely detect the heating state of the driving unit (180) or each joint unit (110), measure the temperature data in real time, and transmit it to the control device (200), thereby ensuring the safe operation of the system and the reliability of the equipment. The temperature sensor (170) can apply high-sensitivity sensor technology to detect even a slight temperature increase that occurs during operation of major components such as the servo motor or reducer of the driving unit (180), thereby detecting unexpected overheating situations or abnormal signs of components at an early stage, and can perform safety control functions such as generating a warning signal to the control device (200) or automatically stopping operation.

[0325] For example, when the temperature of the driving unit (180) exceeds a preset reference value due to heat generation during high-load work or high-speed movement of the collaborative robot (100), the temperature sensor (170) detects this in real time and transmits abnormal temperature information to the control device (200), so that the system can be switched to emergency stop mode or the operating speed can be automatically reduced to prevent damage to the equipment.

[0326] In addition, the temperature sensor (170) monitors the heat generation status of each joint part (110), thereby preventing mechanical deformation or performance degradation due to overheating of the drive mechanism or gear part built into the joint part (110) in advance, thereby supporting the maintenance of the overall precision and work quality of the collaborative robot (100). In addition, the temperature sensor (170) records the measured temperature data, thereby analyzing changes in the thermal pattern and operating environment over a long period of time, which can be utilized to optimize the maintenance cycle and predict the timing of component replacement.

[0327] For example, when a temperature sensor (170) detects a repetitive high temperature state, the control device (200) can analyze this to identify the aging trend of the component and issue a warning in advance or establish an automatic maintenance plan, thereby extending the life of the equipment and preventing unexpected failures. In addition, the temperature sensor (170) is sensitive to temperature changes due to changes in the external environment or working conditions, so that it can provide stable data even when the working environment changes rapidly, and such information can play an important role in energy efficiency management and safe operation of the entire system. Consequently, the temperature sensor (170) can quickly detect temperature abnormalities that occur during the operation of the collaborative robot (100) and the auxiliary axis device (300), and based on this, support the control device (200) to take appropriate safety measures, thereby acting as a key component that can significantly improve the overall safety and reliability of the system.

[0328] In one embodiment, the driving unit (180) may be configured with a servo motor and a reducer to precisely drive each joint (110) of the collaborative robot (100), and this configuration may serve to provide the necessary power so that each joint (110) can move stably and precisely along a required motion path. The driving unit (180) may be designed by integrating the latest electronic control technology and a high-performance motor driver so that the position and angle of the joint (110) can be finely controlled even during high-speed operation, and as a result, the manipulation accuracy for the workpiece (1) and the productivity of the work process can be greatly improved.

[0329] For example, the driving unit (180) can process minute electrical signals generated when each servo motor operates individually at high speed and control them in real time in conjunction with a reducer, thereby enabling smooth acceleration and deceleration even during high-speed movement. In addition, the driving unit (180) can be designed to minimize performance degradation due to mechanical wear or heat generation even during long-term continuous operation or under heavy loads by adopting a high-precision gear mechanism and highly durable materials, thereby ensuring the reliability and safety of the entire system.

[0330] In addition, the driving unit (180) can be configured to continuously monitor the operating status of each joint unit (110) through real-time communication with the control device (200) and perform immediate correction when necessary, which can effectively offset external disturbances or internal errors that may occur during the work process, thereby supporting the collaborative robot (100) to move accurately along the predicted path. In addition, the driving unit (180) can be applied with a control algorithm that optimizes the rotation speed and torque of the servo motor, the gear ratio and efficiency of the reducer, so that the entire system can maintain stable and smooth movement performance even in a high-speed operation environment, and such performance improvement can play an important role in complex palletizing work or precise assembly processes.

[0331] As a result, the driving unit (180) can accurately implement the motion path required by each joint (110) of the collaborative robot (100) through a combination of the latest electronic control technology, high-performance motor drivers, and highly durable mechanical components, and can serve as a key element that can significantly improve the efficiency and safety of the entire process by enabling stable and precise position control even under high-speed and high-load conditions.

[0332] In addition, each component linked to the collaborative robot (100) can operate complementarily to each other, thereby helping to efficiently handle the workpiece (1) and significantly improving the overall productivity and stability of the real-time motion synchronization control system. For example, the precise position information provided by the encoder (150) can be combined with the status information monitored by the current sensor (160) and the temperature sensor (170), thereby contributing to the stable driving of each joint (110) by the driving unit (180), which can play a crucial role in the synchronization and precise control of the entire system.

[0333] In one embodiment, as illustrated in FIG. 28, an additional axis device (300) is coupled to the collaborative robot (100) and may provide an additional axis different from a plurality of axes corresponding to the plurality of joints (110), and the additional axis device (300) may include a lift (310) for vertically moving the collaborative robot (100), a rail (320) for horizontally moving the collaborative robot (100), and a positioner (330) for moving a workpiece (1) of the collaborative robot (100). The additional axis device (300) may increase the flexibility of the entire system, thereby supporting maximizing accessibility to the workpiece (1) and work precision when performing a complex process.

[0334] In one embodiment, the lift (310) may serve to vertically move the collaborative robot (100) within the auxiliary axis device (300). The lift (310) may be designed to adjust the height of the collaborative robot (100) to enable the robot to perform work at a high or low position, and to effectively overcome the height difference between the position where the workpiece (1) is placed and the working range of the robot. For example, the lift (310) may precisely adjust the vertical position of the collaborative robot (100) using an electric or hydraulic actuator, thereby assisting the robot to work stably in high loads or complex assembly processes. The lift (310) may also communicate with the control device (200) to receive real-time feedback and perform fine position corrections according to synchronized control commands, thereby ensuring that the vertical movement motion of the entire system is maintained within a certain error range.

[0335] In one embodiment, the rail (320) may perform a function of moving the collaborative robot (100) horizontally within the auxiliary axis device (300). The rail (320) is installed on a fixed structure such as a factory floor or ceiling, and supports the collaborative robot (100) to be smoothly moved left and right or forward and backward, and may enable the robot to move efficiently even when the workpiece (1) is distributed in multiple locations. The rail (320) is manufactured with a structure including a linear guide and a precision bearing, so as to minimize vibration or unnecessary shaking that may occur during movement, and increase the position control accuracy of the collaborative robot (100). In addition, the rail (320) exchanges data with the control device (200) in real time, and can enable smooth and stable position changes of the robot during the work process through a synchronization command that adjusts the movement speed and acceleration.

[0336] In one embodiment, the positioner (330) can perform the function of rotating or tilting the workpiece (1) of the collaborative robot (100) within the additional axis device (300). The positioner (330) can provide an optimal working environment in a complex assembly, inspection, or processing process by changing the posture of the workpiece (1), and can maximize work efficiency by exposing a specific surface or angle of the workpiece. The positioner (330) includes a multi-axis rotation mechanism, and can rotate or tilt the workpiece (1) at various angles. In this process, the control device (200) can adjust control parameters such as the rotation angle, speed, and acceleration in real time to support the workpiece (1) to accurately maintain the desired posture. The positioner (330) can also be designed to respond to workpieces (1) of various shapes by applying a correction factor that can be set differently depending on the weight, size, shape, etc. of the workpiece.

[0337] The auxiliary axis device (300) configured in this way can be combined with the collaborative robot (100) to enable additional operations such as vertical and horizontal movement and rotation or tilting of the workpiece (1) that the collaborative robot (100) has difficulty performing alone, and can greatly expand the working range of the entire system when performing a complex process. The auxiliary axis device (300) receives in real time the operating status of the collaborative robot (100) and the positional information of the workpiece (1) through communication with the control device (200), and based on this, receives control commands so that each auxiliary component, such as the lift (310), the rail (320), and the positioner (330), can operate in precise synchronization, so that the entire system can operate organically as a single integrated operating system.

[0338] In addition, the additional axis device (300) can be designed to have a structure that can expand the range of motion of the collaborative robot (100), enable the workpiece (1) to be handled at various angles and positions, and significantly improve the flexibility and productivity of process execution. The additional axis device (300) can overcome the limitations of the operation of the existing collaborative robot (100) alone by having each of the lift (310), the rail (320), and the positioner (330) operate through individually optimized control modules, and can support efficient performance of high-speed, high-precision tasks required in various industrial fields such as complex assembly, inspection, processing, and palletizing processes.

[0339] The additional axis device (300) of the present invention can apply various types of additional axes in addition to the lift (310), rail (320), and positioner (330), and these can be flexibly changed according to the characteristics of the work process and on-site requirements. For example, the additional axis device (300) can include a telescopic arm to expand the work range of the collaborative robot (100) horizontally and vertically, while further improving accessibility to the work object. In addition, by applying a rotary module, the work object can be additionally rotated to precisely adjust the angle, thereby enabling the response to complex assembly processes or precise inspection tasks.

[0340] In addition, the additional axis device (300) can include modular additional axes such as an interchangeable gripper or a multi-tool attachment, so that various work tools can be quickly replaced and multiple processes can be performed within a single system. In addition, by integrating a vision sensor module or a LiDAR sensor into the additional axis device (300), a function can be added to recognize the surrounding environment in real time, more precisely determine the position or shape of the workpiece, and reflect it in synchronization control.

[0341] Additionally, additional axes specialized for specific processes, such as an automatic tool changer (ATC) or a spraying device, can be introduced, thereby further increasing the efficiency of process automation. In this way, the additional axes device (300) includes various additional axes in addition to the lift (310), rail (320), and positioner (330), thereby expanding the scope of application of the real-time motion synchronization control system and providing an optimal working environment tailored to the requirements of each process.

[0342] In one embodiment, the control device (200) can control each axis so that the plurality of axes and the auxiliary axes are synchronized in real time. For example, the control device (200) is a core component for integrating and controlling the collaborative robot (100) and the auxiliary axes device (300) into a single system, and can control each axis so that the plurality of joints (110) and auxiliary axes (lift (310), rail (320), positioner (330), etc.) can perform tasks in real time by synchronizing. The control device (200) can include a high-speed processor so that it can continuously update the control commands of each axis in short cycles of 1 ms or less, thereby commanding all axes to form synchronized paths simultaneously. This control method can be configured to detect the difference between the current operation state and the target operation state of each axis in real time, and immediately transmit a correction command when such a difference occurs, thereby drastically reducing the synchronization error of the entire system.

[0343] In addition, the control device (200) can precisely collect trajectory information generated from multiple joints (110) of the collaborative robot (100), and simultaneously analyze the operating status of the lift (310), rail (320), and positioner (330) of the additional axis device (300) in real time. Through this, the control device (200) can plan the work sequence of the entire process in advance, calculate control parameters such as target position, speed, acceleration, and deceleration for each axis, and distribute control commands so that all axes can move organically in cooperation. In this process, an integrated control algorithm that considers not only the individual operation of each axis but also the interconnectivity of the entire system is applied, so that it can quickly respond to unexpected errors or disturbances that may occur during the process.

[0344] The control device (200) can also continuously monitor and correct the synchronization status based on the sensor data transmitted from each joint unit (110) and the additional axis device (300) through a real-time feedback loop. For example, the control device (200) can comprehensively analyze position data obtained from the encoder (150) and various sensor information such as the current sensor (160) and the temperature sensor (170) to minimize the difference between the command transmitted from the driving unit (180) and the actual operation by applying various control techniques such as PID control. In this way, the control device (200) can efficiently manage control commands for multiple axes in real time and maintain the entire system to operate stably and precisely, which can provide the effect of significantly improving work efficiency and quality when performing a complex process.

[0345] The collaborative robot (100) illustrated in Fig. 27 has a plurality of joint parts (110) and a robot arm (120) axially connected to cover various work spaces, and the base part (130) can be coupled to the ground or a fixed device to support the robot arm (120) so that it can move without shaking. The gripper (140) performs the function of holding and placing a work object (1), and the encoder (150), current sensor (160), and temperature sensor (170) can measure the operating status of the collaborative robot (100) and transmit it to the control device (200). The driving part (180) is composed of a servo motor and a reducer, and can support each joint part (110) to accurately implement the required motion.

[0346] The auxiliary axis device (300) illustrated in FIG. 28 includes a lift (310), a rail (320), a positioner (330), etc., and each can actively change the installation position of the collaborative robot (100) or the posture of the workpiece (1). The lift (310) can adjust the height of the collaborative robot (100), thereby helping the multiple joints (110) to perform work even in difficult-to-access locations, and the rail (320) can move the collaborative robot (100) left and right to cover a wide work area, thereby enabling automated work to be performed at multiple locations within the factory. The positioner (330) can rotate or tilt the workpiece (1) at a certain angle, thereby facilitating processes such as welding, coating, and inspection.

[0347] Ultimately, the control device (200) can accurately and quickly perform a complex process on the workpiece (1) by synchronously controlling all axes of the collaborative robot (100) and the auxiliary axis device (300). In particular, even if multiple joints (110) rotate at different angles and the lift (310), rail (320), and positioner (330) operate simultaneously, the control device (200) can compensate to minimize errors based on the target position of each axis and real-time feedback. Such synchronous control can provide great advantages in shortening the process time, improving work precision, and ensuring the stability of the entire system.

[0348] The detailed operation of the present invention is described as follows according to Fig. 25.

[0349] Referring to FIG. 25, in one embodiment, in operation 31, the control device (200) can set the target position of the additional axis according to Equation 1 below.

[0350] [Formula 1]

[0351]

[0352] Here, Qad(t) is the target position of the additional axis, Qi(t) is the actual position of the six axes of the collaborative robot, a is a scaling constant for the average motion of the basic six axes, and b is the position compensation value (offset) of the additional axis.

[0353] For example, the control device (200) can set the target position Qad(t) so that the additional axis (e.g., lift, rail, positioner, etc.) operates in harmony with the main motion trajectory of the collaborative robot (100). To this end, the control device (200) can collect the positions Qi(t) measured from each of the six joints (110) of the robot in real time with reference to Equation 1, and calculate the target position of the additional axis by applying a scaling constant a and a position compensation value (offset) b to the result of averaging these position values.

[0354] For example, the control device (200) can continuously monitor the motion trajectory of the joint part (110) to derive an average value for Qi(t), multiply the average value by a, and then add an offset b to determine Qad(t). At this time, a is a coefficient indicating the ratio at which the additional axis should operate compared to the average motion range of the robot, and b can be applied when fine adjustment is required depending on the field environment or process characteristics. This setting can prevent problems such as collisions or overshoots from occurring during the complex process by preventing unnecessary gaps from occurring between the motion path of the collaborative robot (100) and the motion path of the additional axis device (300).

[0355] In addition, the control device (200) can control the additional axis to respond in real time to the movement of the collaborative robot (100) by periodically recalculating Qad(t) by reflecting the position information of the robot joint part (110) that is updated every moment.

[0356] For example, even if the robot joint part (110) moves at a faster speed than expected or a positional deviation occurs due to external factors, the control device (200) can immediately recognize the error between the Qad(t) calculated through Equation 1 and the actual position Qa(t) of the auxiliary axis, and issue a correction command through various algorithms such as PID control. Through this, the auxiliary axis can maintain synchronized movement within a certain error range without excessively leading or lagging behind the main trajectory of the robot, and ultimately, an accurate and stable work environment can be implemented even in complex processes. Furthermore, since the scaling constant a and the offset b can be set differently depending on the shape or weight of the workpiece (1), process characteristics, etc., the control device (200) can flexibly respond to various industrial sites by defining the corresponding values ​​in advance or adjusting them in real time.

[0357] Ultimately, the process of setting the target position of the additional axis by using Equation 1 by the control device (200) in operation 31 can play an important role in reducing the risk of collision between multiple axes and maximizing process efficiency by precisely controlling the additional axis based on the average motion of the six joints (110) of the collaborative robot (100).

[0358] In one embodiment, in operation 32, the control device (200) can calculate the control input function U(t) of the additional axis according to Equation 2 below based on the PID (proportional integral derivative) control method.

[0359] [Formula 2]

[0360] ,

[0361] Here, E(t) is the control error, Qad(t) is the target position of the additional axis, Qa(t) is the actual position of the additional axis, Kp is the proportionality constant, Ki is the integration constant, and Kd is the differentiation constant.

[0362] For example, the control device (200) can use the PID (proportional integral derivative) control technique to calculate a control input function U(t) to correct the operation error of an additional axis (such as a lift, rail, or positioner) in real time. At this time, the control device (200) can refer to Equation 2 to define the difference between the target position Qad(t) and the actual position Qa(t) of the additional axis as E(t), and then calculate the optimal control command by combining the three elements of proportionality, integration, and differentiation. First, the proportional component Kp × E(t) determines the control signal in proportion to the size of the error occurring at the current point in time, thereby compensating so that the system immediately matches the target position. For example, the larger the error, the greater the proportional component acts to perform a quick correction, and the smaller the error, the more finely the proportional component acts to induce stable control.

[0363] The integral component Ki × ∫ττ is a term that offsets errors that accumulate over time, and can gradually compensate for a constant deviation when the auxiliary axis continues to show a certain deviation. For example, if the auxiliary axis continues to slightly lag behind the target position, the integral component can prevent long-term errors from accumulating by gradually increasing the compensation command to reflect the accumulated error. This can help the system ultimately converge to the target position even when external interference or load changes occur in the process environment, and can contribute to improving process stability.

[0364] The differential component Kd × dE(t) / dt can perform predictive compensation to prepare for rapid motion changes based on the error change rate. For example, when the auxiliary axis moves at a high speed or the joint part (110) suddenly changes direction, the differential component can alleviate the phenomenon of the system shaking excessively or overshooting by applying a compensation signal just before the error changes rapidly. This can be advantageous in ensuring stable operation by reducing unnecessary vibration or risk of collision when the robot and the auxiliary axis move in combination during the process.

[0365] The PID control configured in this way operates as a real-time algorithm within the control device (200), and recalculates the difference E(t) between Qad(t) and Qa(t) for each cycle, and recalculates the proportional, integral, and differential components based on the value to update U(t). Through this, the control device (200) can transmit an appropriate control command to the driving unit (180) composed of a servo motor and a reducer, and maintain the additional axis in a state of being precisely synchronized with the main trajectory of the collaborative robot (100). For example, in a process where the robot arm (120) moves at a high speed, when the additional axis must precisely adjust its position according to the movement, the PID control can correct the control signal before the error becomes excessively large, and reduce the deviation that accumulates in the long term, so that ultimately stable operation can be supported.

[0366] Ultimately, the PID control performed in operation 32 can provide the advantage of enabling the auxiliary axis to quickly reach the target position Qad(t) while enabling immediate response to errors or disturbances that may occur during the process. By implementing an immediate response with the proportional component, eliminating accumulated errors with the integral component, and performing a predictive response to rapid changes with the differential component, synchronization between the auxiliary axis and the collaborative robot (100) can be precisely maintained. This improves the stability and work efficiency of the overall real-time motion synchronization control system, and can lay the foundation for implementing robot automation processes with greater precision and safety in various industrial environments.

[0367] In one embodiment, in operation 33, the control device (200) can adjust the synchronization error value expressed by Equation 3 to within 0.1 mm so that the plurality of axes and the additional axes are synchronized in real time.

[0368] [Formula 3]

[0369]

[0370] Here, Qa(t) is the actual position of the additional axis, Qi(t) is the actual position of the six axes of the collaborative robot, a is a scaling constant for the average motion of the basic six axes, and b is the position compensation value (offset) of the additional axis.

[0371] For example, Equation 3 represents the difference between the actual position Qa(t) of the additional axis (lift (310), rail (320), positioner (330), etc.) and the target position Qad(t) calculated by Equation 1 as an absolute value, and the control device (200) can monitor and correct the error at each control cycle so that the difference becomes 0.1 mm or less.

[0372] To this end, the control device (200) first calculates the target position Qad(t) of the additional axis based on the position data measured at each joint (110), and then defines the difference from the actual position Qa(t) of the additional axis as the synchronization error. If the synchronization error exceeds 0.1 mm, the control device (200) can immediately reduce the error by readjusting the PID control parameters (Kp, Ki, Kd) or slightly changing the values ​​of the scaling constant a and the offset b. For example, when the moving speed of the lift (310) or the rail (320) is too fast, the acceleration or speed can be limited so that the additional axis does not excessively lead the main motion trajectory of the robot. Conversely, when the additional axis moves slowly and cannot keep up with the motion of the robot, the motion speed or acceleration can be increased to compensate for recovering the relative position.

[0373] This real-time compensation process is particularly useful in complex palletizing tasks or multi-position processes, and can be very effective when the additional axis must be precisely linked to the movement of the collaborative robot (100). For example, in a situation where the positioner (330) must rotate or tilt the workpiece (1), if the robot arm (120) moves quickly along the movement path, the positioner (330) may cause a deterioration in product quality or a risk of collision due to a slight timing difference. The control device (200) periodically measures the synchronization error at this time and adjusts the PID control parameters in real time so that the error does not exceed 0.1 mm, thereby stably maintaining the relative position between the robot and the additional axis.

[0374] Furthermore, the control device (200) can comprehensively analyze feedback signals collected from sensors (e.g., encoders, current sensors, temperature sensors, etc.) distributed in the joints (110) and auxiliary axes (300) of the collaborative robot (100) for each axis, and perform motion correction considering load conditions or external interference. For example, in a situation where the auxiliary axes are to transport a heavy workpiece or the collaborative robot (100) has to move in a narrow space, the acceleration and deceleration can be finely adjusted so that the motion timing of the robot and the auxiliary axes are evenly aligned. This not only improves work quality and process safety, but also prevents situations where errors accumulate and large-scale corrections have to be repeated.

[0375] As a result, by adjusting the control device (200) in operation 33 to maintain the synchronization error to 0.1 mm or less based on equation 3, it is possible to minimize minute errors or inconsistencies that may occur when the collaborative robot (100) and the auxiliary axis device (300) perform a complex process. This contributes to improving not only process efficiency but also work safety and product quality, and can support the stable operation of an automation system that links a robot and an auxiliary axis in various industrial sites.

[0376] In one embodiment, in operation 34, the control device (200) can transmit a control command to the collaborative robot (100) and the auxiliary axis device (300). For example, the control device (200) can generate a command including specific control data such as the final target position, target speed, acceleration, and torque value of each axis, and transmit the command to the driving unit (180) including a servo motor or a reducer, so that the robot arm (120) and the auxiliary axis (lift (310), rail (320), positioner (330), etc.) can be precisely driven.

[0377] The control device (200) can be designed to repeat this control command transmission process in very short cycles, and receive the current operating status of each axis in real time from a sensor (e.g., encoder, current sensor, temperature sensor, etc.) for each control cycle, and correct the command based on this. In this process, if each axis deviates from the target position due to unexpected external interference or internal error, the control device (200) can immediately detect the error and recalculate and transmit a correction command, thereby preventing the accumulation of errors.

[0378] In addition, the control device (200) can transmit control commands for all axes simultaneously by utilizing an integrated network or a dedicated communication bus, thereby supporting high-speed and synchronized operations of the collaborative robot (100) and the auxiliary axis device (300). For example, the control device (200) can command the robot arm (120) to approach the workpiece, while simultaneously commanding the lift (310) to perform a vertical position, the rail (320) to perform a horizontal position, and the positioner (330) to perform rotation or tilting of the workpiece. Since these operations are performed with all axes precisely synchronized, the work quality and safety of the entire system can be greatly improved.

[0379] Furthermore, the control device (200) sets the update cycle of the control command transmitted to each axis to 1 millisecond or less, thereby enabling quick error correction based on real-time feedback, thereby minimizing the relative position error between the collaborative robot (100) and the additional axis device (300). Such a repetitive control and correction process can immediately respond to minute disturbances or mechanical errors that may occur during the process, so that the synchronization state of the axes is constantly maintained even during long-term work, and as a result, the stability and reliability of the entire system can be greatly improved.

[0380] In addition, the control device (200) can precisely adjust the driving characteristics of the servo motor and reducer based on control parameters such as target position, speed, acceleration, and torque for each axis, thereby ensuring that the operation of each axis matches the predicted trajectory. This control command transmission and correction process allows all axes within the system to communicate with each other in real time and continuously correct based on sensor feedback, thereby preventing errors occurring during the process from accumulating and maintaining stable operation even in high-speed and high-precision work.

[0381] As a result, the process in which the control device (200) transmits the control command to the collaborative robot (100) and the auxiliary axis device (300) in operation 34 can provide the effect of maximizing process safety and product quality by continuously maintaining the entire system in a state of synchronization with the predicted work path and correcting synchronization problems that may occur due to external interference or internal errors in real time.

[0382] By summarizing the processes from operation 21 to operation 34 described in the above embodiment, the present invention can provide an innovative control system that enables the basic 6-axis operation of the collaborative robot (100) and the lift (310), rail (320), positioner (330) of the additional axis device (300) to be synchronized in real time to perform a complex process stably and precisely.

[0383] The control device (200) dynamically updates the target position Qad(t) of the additional axis calculated by averaging the position information of each joint part (110) based on real-time feedback data collected from sensors (encoder (150), current sensor (160), temperature sensor (170), etc.), and applies a scaling constant a and a position compensation value b for this purpose. In addition, the control device (200) utilizes the PID control technique to analyze the error E(t) between the actual position Qa(t) of the additional axis and the target position Qad(t) into three components: proportional, integral, and differential, and calculates a control input function U(t) that corrects this, thereby ensuring a precise synchronization state in real time so that the error is maintained at 0.1 mm or less.

[0384] Meanwhile, the control device (200) transmits control commands for each axis (final target position, target speed, acceleration, torque value, etc.) to the collaborative robot (100) and the auxiliary axis device (300) with a short control cycle of 1 ms or less, thereby enabling immediate correction of accumulated errors due to unexpected disturbances or internal errors even during high-speed motion. This integrated control system can provide a technical effect that can significantly improve work quality, productivity, and process safety in various industrial processes such as complex palletizing work or multi-position processes, while ensuring the stability and reliability of the entire system.

[0385] Figure 29 is a block diagram illustrating a detailed configuration of a real-time collision and overspeed detection system for a collaborative robot according to an example of the present invention. Figure 30 is an exemplary diagram illustrating a collaborative robot according to an example of the present invention.

[0386] Referring to FIGS. 29 to 2, the real-time collision and overspeed detection system (10) of a collaborative robot according to the present disclosure monitors an abnormal state of a collaborative robot (100) and may include a collaborative robot (100) and a control unit (200).

[0387] In one embodiment, the collaborative robot (100) may include a plurality of joints (110), a robot arm (120), a base (130), a gripper (140), an encoder (150), a current sensor (160), a temperature sensor (170), and a driving unit (180), and each of these components may be interconnected with and operate with a control unit (200).

[0388] In one embodiment, the collaborative robot (100) may be designed to collaborate with humans in various work environments such as industrial sites, research environments, and service fields. In particular, each of the plurality of joints (110) has an independent rotation axis, and each joint (110) may be equipped with a motor. The motor may be implemented as a servo motor, a brushless DC motor, or a stepper motor, and the rotation angle of the joint (110) may be precisely controlled. Since the joints (110) may be formed as a multi-joint structure, the collaborative robot (100) may secure multiple degrees of freedom and move in various directions. For example, some of the joints (110) may form a horizontal rotation axis, and others may form a vertical rotation axis, thereby enabling flexible movement of the robot arm (120).

[0389] In one embodiment, the robot arm (120) is a structure that connects a plurality of joint parts (110) to each other, and may generally include a tube or alloy frame made of a metal material. The robot arm (120) may have wires or cables routed inside to supply power required for the motor of the joint part (110) or transmit signals obtained from an encoder (150), a current sensor (160), a temperature sensor (170), etc. to the control unit (200). Since the robot arm (120) must satisfy both light weight and rigidity, it may utilize aluminum alloy or carbon fiber materials, and it may maintain durability even against external impacts or vibrations in the working environment.

[0390] In one embodiment, the base (130) is the lowest structure that supports the collaborative robot (100) and can be installed on a fixed floor or workbench. The base (130) can have sufficient weight and fixing force to stably support the movements of the joints (110) and the robot arm (120) that occur while the collaborative robot (100) is operating. In addition, the base (130) can manage the power and control signals required for the operation of the entire robot by incorporating a power supply device or various electronic circuits inside the housing. In addition to the function of fixing the collaborative robot (100) so that it operates in a specific location, the base (130) can be equipped with casters to enable movement when necessary, or can provide an interface for coupling with other equipment.

[0391] In one embodiment, the gripper (140) may include a device that can grip or manipulate objects of various shapes as an end effector of the collaborative robot (100). For example, the shape of the gripper (140) may vary depending on the task, such as a two-finger gripper, a three-finger gripper, a vacuum suction gripper, etc. The gripper (140) may move to a desired position along with the rotational motion of the joint (110), and may pick up or place an object by performing detailed motions such as opening and closing or rotation according to a command from the control unit (200). The gripper (140) may be additionally equipped with a sensor to have a function of detecting the presence or absence of a gripped object or the weight of the object.

[0392] In one embodiment, the encoder (150) is a sensor that acquires rotation data of each joint part (110), and may be implemented in an optical, magnetic, or other manner. The encoder (150) is connected to each joint part (110) and can transmit pulses or codes generated whenever the joint part (110) rotates to the control part (200). Through this, the control part (200) can accurately calculate the current angle, rotation speed, acceleration, etc. of the joint part (110), and, if necessary, estimate the position of the distal end of the robot arm (120) through an inverse kinematics algorithm, etc. The rotation data acquired from the encoder (150) can be an important basis for determining an abnormal state (collision, overspeed, overload, singularity, etc.) which is the core of the present invention.

[0393] In one embodiment, the current sensor (160) is a sensor that can obtain current data supplied to the motor in real time, and can be attached to the motor driver circuit of each joint part (110) or a separate sensing unit. The current sensor (160) can be implemented in various ways, such as a shunt resistor or a Hall sensor, and can transmit the current value required by the motor to the control part (200). Since the current value measured by the current sensor (160) is directly related to the motor torque, the current value may increase sharply momentarily when the robot receives an unexpected load or a collision occurs. In the present invention, by analyzing such current fluctuation data, a collision or overload state can be quickly detected, and by monitoring at a short cycle of 5 ms or less, safe robot operation can be ensured.

[0394] In one embodiment, the temperature sensor (170) is a sensor that can measure the temperature of components that are prone to generating heat, such as a motor or a driving unit (180), and can monitor the heat generation status during long-term operation of the collaborative robot (100) to prevent overheating. For example, the temperature sensor (170) can be attached to the inside of the motor housing or installed adjacent to the driving unit (180) to transmit the surface temperature or internal temperature of the corresponding component to the control unit (200). When the temperature value transmitted from the temperature sensor (170) exceeds the allowable range, the control unit (200) can temporarily stop the motor operation or operate the cooling fan to prevent damage to the robot and safety accidents.

[0395] In one embodiment, the driving unit (180) may refer to a component that integrates mechanical elements that actually rotate the joint unit (110), such as a motor, a reducer, a bearing, and a gear. The driving unit (180) is directly connected to the rotational axis of the joint unit (110) and operates, and may execute driving commands (speed, position, torque control, etc.) received from the control unit (200) through the motor. The driving unit (180) may have a built-in high-precision reducer to stably control the movement of the robot arm (120), and may be designed to maintain mechanical rigidity even under external impact. In addition, the driving unit (180) may internally arrange the wiring of sensors, such as the encoder (150) and the current sensor (160), to prevent cable tangling or breakage.

[0396] In one embodiment, the control unit (200) can detect an abnormal state of the collaborative robot (100) based on current data and the rotation data. For example, the control unit (200) performs the core control logic of the collaborative robot (100) and can detect an abnormal state in real time based on data collected from the current sensor (160) and the encoder (150). The control unit (200) can be implemented in various forms such as a microprocessor (MCU), a DSP, an FPGA, or an industrial PC, and can perform data processing at a fast cycle of 5 ms or less by mounting a real-time operating system (RTOS). The control unit (200) can comprehensively analyze the current value measured from the current sensor (160) and the rotation angle, speed, acceleration, etc. calculated from the encoder (150) to determine the status of a collision (current surge), overload (high current maintained for a long time), overspeed (speed limit exceeded), and singularity (Jacobian minimum singular value decrease). In addition, the control unit (200) can check the temperature data transmitted from the temperature sensor (170) and control the operation of the robot or generate a warning when an overheating condition occurs.

[0397] When an abnormal condition is detected, the control unit (200) can transmit a command to each drive unit (180) to temporarily stop the robot operation or limit the speed, thereby ensuring the safety and protecting the parts of the collaborative robot (100). For example, when the current sensor (160) detects a current exceeding a threshold value due to a collision, the control unit (200) can immediately send a 'Safe Torque Off' command to the drive unit (180) of the corresponding joint unit (110) to block the motor torque or switch to a low-speed mode to prevent further damage. In addition, when an overspeed condition is detected and it is determined that the actual speed calculated by the encoder (150) is out of the allowable range, the control unit (200) can control the movement of the robot arm (120) by sending a speed limit command to the drive unit (180).

[0398] Meanwhile, in order to detect a singularity state, the control unit (200) can calculate a Jacobian matrix based on the position data of each joint unit (110) transmitted from the encoder (150). If the minimum singular value of the Jacobian matrix falls below a certain threshold, it means that the robot arm (120) has entered a singularity section, and therefore, the control unit (200) can issue a speed reduction command to the drive unit (180) or control it to detour the path. This can prevent the problem of the robot unstably accelerating rapidly or causing a control error near the singularity.

[0399] As an example, a plurality of joint parts (110) can be configured with 6 or 7 or more axes to implement a range of motion similar to a human arm, and the base part (130) can be fixed to a factory floor or workbench by a bolt-fastening method. The robot arm (120) is made of an aluminum alloy frame, and a servo motor and a high-precision reducer built into each joint part (110) are combined to handle a variety of small to medium-sized workpieces. The gripper (140) can be exemplified as a 2-finger gripper, and a separate sensor can be installed to transmit whether an object is gripped to the control part (200). At this time, the encoder (150) optically measures the rotational position of each joint part (110) with high resolution, and the current sensor (160) can detect changes in motor current with low noise using a Hall sensor. The temperature sensor (170) can be attached to the motor housing and can be linked with the control part (200) to operate a cooling fan when the overheating state becomes severe.

[0400] The collaborative robot (100) configured as described above can monitor various abnormal conditions such as external collisions, overloads, overspeeds, and singularities with a fast response speed (5 ms or less) through a real-time collision and overspeed detection system (10), and when an abnormal condition occurs, the robot operation can be immediately switched to a safe mode or stopped, thereby greatly improving safety in an environment where people and robots work together. In addition, since each component is modularized, the length of the robot arm (120) or the shape of the gripper (140) can be easily replaced according to user requirements, and the specifications of the temperature sensor (170), current sensor (160), etc. can also be changed according to the purpose.

[0401] Figure 31 is a flowchart illustrating a real-time collision and speed detection method of a collaborative robot according to an example of the present invention.

[0402] Referring to FIG. 31, in one embodiment, in operation 21, the current sensor (160) can obtain current data supplied to the motor. To this end, the current sensor (160) can be linked to the motor driver circuit to measure in real time the instantaneous value, average value, and spike-like sudden increase phenomenon of the current applied to the motor. The current sensor (160) can use a shunt resistor method, a Hall sensor method, or other precision sensing technique, and can detect even minute current changes that occur while the collaborative robot (100) is operating by collecting data at short cycles of 5 ms or less. In addition, the current sensor (160) can apply a correction coefficient in collaboration with a temperature sensor (170), if necessary, to correct errors due to the internal temperature of the motor or surrounding environmental conditions. Through this, the current sensor (160) can distinguish between one-time noise and an actual load increase, and can quickly identify signs when a collision or overload condition occurs. For example, if a motor connected to a joint (110) encounters unexpected resistance and the current increases rapidly, the current sensor (160) can detect this change in units of several milliseconds and transmit the necessary data so that the control unit (200) can respond quickly.

[0403] In one embodiment, in operation 22, the encoder (150) can obtain rotation data of multiple joint parts (110). For example, the encoder (150) can be implemented in an optical or magnetic manner, and can precisely measure the angle and speed at which each joint part (110) moves and transmit the measured data to the control unit (200). For example, the encoder (150) can convert a pulse signal generated whenever the joint part (110) rotates into a digital value, thereby estimating the current posture and movement speed of the robot arm (120). Such rotation data of the encoder (150) can play a key role in feedback control for the robot motion path, and can be essential for determining the precise position of the robot and implementing smooth movement. In addition, the encoder (150) can measure an error between a target position or speed set by the motor and the actual motion of the joint part (110), thereby assisting the control unit (200) in performing real-time correction (feedback control). For example, if the joint part (110) receives an unexpected force and a position error accumulates, the encoder (150) immediately detects the fact and reports it to the control part (200), thereby safely maintaining the movement of the robot.

[0404] In one embodiment, in operation 23, the control unit (200) can detect an abnormal state of the collaborative robot (100). For example, the control unit (200) can detect an abnormal state of the collaborative robot (100). The control unit (200) can comprehensively analyze current data transmitted from the current sensor (160) and rotation data acquired from the encoder (150) to determine abnormal states such as collision, overload, overspeed, and singularity. A collision situation generally shows a pattern in which the motor current suddenly increases, and an overload state can be identified as a pattern in which a high current continues for a certain period of time or longer. In addition, the control unit (200) can recognize a situation in which the robot moves unnecessarily quickly by checking whether the speed calculated from the encoder (150) exceeds an overspeed threshold value. In addition, a singularity state can be defined as a point in time when the angles of multiple joints (110) satisfy a specific condition and the minimum singular value of the Jacobian matrix is ​​significantly reduced, and at this time, the control unit (200) can automatically control the movement of the robot arm (120) so that it does not become unstable. If the above abnormal state is confirmed, the control unit (200) can immediately switch to a safe mode or issue a speed reduction command to control the robot operation. For example, if the current data exceeds the threshold value and a sudden position error is detected in the encoder (150), the control unit (200) can determine that the possibility of collision is very high and immediately cut off the motor torque of the joints (110).

[0405] In one embodiment, in operation 24, the control unit (200) may stop the operation of the collaborative robot (100) or decelerate the speed of the collaborative robot (100) below a predetermined speed. For example, this may be a protective measure after an abnormal condition is determined in operation 23, to immediately control the operation of the robot so that it does not lead to further damage or a safety accident. The operation stop may be implemented in a complete stop (Safe Torque Off) manner, and the torque may be cut off to the motor drive unit (180) so that the joint unit (110) does not move any further. On the other hand, if a speed limit is more appropriate than a complete stop due to the nature of the task, the control unit (200) may reduce the speed of the robot to a predetermined low-speed range to prevent the abnormal condition from spreading seriously. For example, when a minor collision occurs, the robot may be designed to switch to a low-speed mode and recheck the surrounding situation rather than stopping immediately. This can provide the effect of ensuring safety while minimizing unnecessary interruptions in an environment where a collaborative robot (100) must continuously work on a production line.

[0406] In one embodiment, the control unit (200) may perform a process of restoring robot operation after confirming that the abnormal condition has been resolved. Specifically, the control unit (200) may re-analyze data collected from the current sensor (160) and the encoder (150) to determine whether indicators such as collision, overload, and overspeed have returned to a normal range. For example, if the current temporarily surged when a collision occurred but has now stabilized and the current value has returned to a normal range, the control unit (200) may switch the robot back to the original operation mode. At this time, the control unit (200) may issue a return command when the joint unit (110) is completely stopped, or may gradually resume operation in a low-speed mode to increase safety. In addition, the load weight or the status of the driving components of the joint unit (110) that was in an overload state may be checked, and preventive measures may be taken to prevent the problem from recurring. The control unit (200) can set up this return procedure in detail to ensure both the safety of the robot parts and the safety of the user while minimizing unnecessary downtime, taking into account the efficiency of the work site.

[0407] In one embodiment, the control unit (200) can store data acquired during the robot operation process (current value of the current sensor (160), rotation angle of the encoder (150), time of occurrence of abnormal condition, collision intensity, etc.) in the form of a log, and can process it so that it can be analyzed or output in the form of a report. The control unit (200) can transmit the log data recorded in the internal memory to an external server or cloud system when necessary, and can utilize it to monitor the robot operation status in the long term and establish a maintenance strategy. For example, if a collision occurs repeatedly in a specific joint part (110), the drive part (180) or motor alignment status of the joint part (110), or the work space layout can be re-examined to devise an improvement plan. In addition, if an overload condition occurs frequently, it can be checked whether the collaborative robot (100) is working beyond the load that it can actually handle, or whether there is a structural problem with the robot arm (120) or component wear. Through this, the control unit (200) can identify the robot maintenance time in advance and operate in a way that minimizes unexpected downtime in the production line.

[0408] The series of procedures from the above-described operation 21 to operation 24 can be repeatedly performed while the collaborative robot (100) is operating, and some steps may be omitted or the order may be changed depending on the operating conditions or working environment of the robot. For example, in a simple task that does not require singularity detection logic, the singularity determination step in operation 23 may be skipped, and in a low-speed task where an overspeed condition does not occur at all, the process of comparing the overspeed threshold value may be omitted. In addition, when the control unit (200) detects a condition more than once and stops the robot, the measurement accuracy may be improved by performing a re-initialization process from the time of restarting by re-setting the reference value of the current sensor (160) or the reference position of the encoder (150).

[0409] In this way, through the operations according to the present invention, the collaborative robot (100) can check the current and rotation data supplied across multiple joints (110) in real time, and can immediately respond when an abnormal condition occurs to implement a safe working environment. In particular, unlike the existing method that depends on external sensors or vision systems, it can achieve high-precision abnormality detection while reducing the cost and complexity of installing additional equipment by directly analyzing the internal motor current and joint rotation data. In addition, after the robot stops or switches to low-speed mode, it can continuously track whether the abnormal condition is resolved and quickly return to the original working mode, thereby minimizing productivity loss. This series of operations is particularly important in industrial environments where the collaborative robot (100) must work in close proximity with people, and can contribute to improving both safety and efficiency.

[0410] Figure 32 is a flowchart illustrating a method for determining a collision state of a collaborative robot according to an example of the present invention.

[0411] Referring to FIG. 32, in one embodiment, in operation 31, the control unit (200) may calculate a current sample value based on current data. For example, the current sample value may refer to a result value obtained by collecting current data supplied to a motor equipped in a joint unit (110) of a collaborative robot at a predetermined sampling cycle and processing the collected current data according to a specific algorithm. The control unit (200) stores measurement data transmitted from a current sensor (160) at predetermined time intervals (dt), and calculates the difference between the expected current value (Iexpj) according to the motor operation and the actual measured current value (Ij), thereby providing basic information for determining whether the robot is operating normally. This current sample value may increase momentarily when the robot encounters unexpected resistance or when a collision occurs during operation and the motor receives a sudden load. Accordingly, the control unit (200) can mathematically process the amount of current change over a short time interval (H samples) to quantify how much force (torque) the motor is actually producing.

[0412] For example, the control unit (200) can obtain a current sample value (Ck) for determining a collision according to Equation 1 below. As shown in Equation 1,

[0413] [Formula 1]

[0414]

[0415] Here, k is a natural number, Ij is the current measured at the current point in time, Iexpj is the expected current at the current point in time, H is the number of sampling intervals, and Ck is the current sample value.

[0416] The control unit (200) can define the average of the difference in absolute values ​​of Ij and Iexpj at the kth point in time, which is calculated by dividing the difference by H samples, as the current sample value (Ck). At this time, the higher the absolute value of Ij-Iexpj, the more the actual current deviates from the expected current, and thus the greater the possibility that a collision, overload, or other abnormal condition has occurred in the robot joint (110).

[0417] In one embodiment, in operations 32 and 33, the control unit (200) may compare the current sample value with a collision threshold value. For example, the collision threshold value here is a numerical value indicating a current deviation range that the robot can tolerate during normal operation, and may vary depending on the work environment and the specifications of the robot. For example, assuming that the average current required when the motor mounted on the robot joint (110) operates at a constant speed is 0.8 A, the collision threshold value may be set to a level slightly higher than that, such as 1.2 A to 1.5 A. However, in an actual implementation, more precise collision detection may be enabled by setting detailed threshold values ​​according to not only the simple absolute value but also the joint speed, the posture of the robot arm (120), whether or not an object is grasped, etc.

[0418] The control unit (200) checks whether the current sample value (Ck) calculated at the kth time point exceeds the collision threshold value, and thereby can assess the abnormal state of the robot. If Ck is lower than the collision threshold value, it means that the robot joint part (110) is moving with a current within the expected range, and thus, there is a high possibility that no additional safety measures are required. However, if Ck exceeds the collision threshold value, it indicates that the robot is receiving a much greater load than expected, and therefore, the control unit (200) can determine that this is a situation that may lead to a collision occurrence. This comparison operation can be performed sequentially in operations 32 and 33. For example, in operation 32, it is first checked whether Ck has reached the vicinity of the collision threshold value, and in operation 33, a finely tuned criterion or additional conditions (e.g., number of samplings, whether continuous occurrence occurs, etc.) can be further checked to make a final collision determination.

[0419] In one embodiment, in operation 34, if the current sample value exceeds the collision threshold as a result of the comparison, the control unit (200) may determine that the collaborative robot is in a collision state. At this time, the “collision state” may actually refer to a situation in which the robot joint part (110) comes into contact with an external object or a worker and the physical resistance suddenly increases, and may exhibit characteristics that are distinct from other abnormal states such as overload or overspeed. If the control unit (200) determines that a collision state exists, the control unit (200) may immediately transmit a command to the drive unit (180) to limit or stop the robot operation. For example, the torque of the motor may be cut off or the rotation speed of the joint part (110) may be lowered to a safe mode to minimize the collision damage. In addition, the control unit (200) may record the current sensor (160) log and encoder (150) data at the time of collision occurrence, and may utilize them to analyze the cause of the collision or prevent recurrence thereafter.

[0420] The method of determining a collision state by having the control unit (200) calculate the current sample value according to the following equation 1 may have the advantage of directly reflecting the amount of current change over a short period of time. That is, if the current values ​​measured by the current sensor (160) in units of ms are grouped into H groups and averaged, the pattern of rapid increase due to an actual collision can be identified with greater reliability than temporary noise or single-shot spikes. In addition, in order to distinguish whether the reason for the increase in motor load is an increase in mechanical friction or a collision with the outside of the robot, the control unit (200) may refer to information about the motor rotation speed or acceleration. If the current increases rapidly even though the motor has received a command to maintain speed, it can be assumed that there is a high possibility of a collision due to external resistance (obstacles, human bodies, etc.).

[0421] In one embodiment, in operation 35, if the current sample value is lower than the collision threshold as a result of the comparison, the control unit (200) may transmit the next control command to the drive unit (180). For example, in this case, since it is determined that the collaborative robot is not in a collision state, the normal operation mode may be maintained or the planned work procedure may be continued. For example, if the robot is performing an operation of moving an object, the control unit (200) may send a command to the drive unit (180) to “move to the next step,” and the robot arm (120) may continue to operate along a preset path. In addition, if the current sample value continues to be sufficiently lower than the threshold value, the control unit (200) may issue an additional command to optimize the robot operation for higher speed or efficiency. For example, in a section where it is determined that “there is no risk of collision,” the motor acceleration may be increased to improve the operation speed, or the movement path of the robot arm (120) may be shortened to maximize productivity.

[0422] Furthermore, in operation 35, the control unit (200) may not only rely on the result of being below the collision threshold, but may also simultaneously check for other abnormal factors such as overspeed, overload, and singularity states. For example, even if the current sample value is within the normal range, since the speed reported by the encoder (150) may exceed the overspeed threshold, the control unit (200) may determine overspeed through a different algorithm in this case. Accordingly, the "next control command" transmitted to the driving unit (180) in operation 35 may not simply mean normal operation, but may be a result value that takes into account all other abnormal states of the robot (e.g., overspeed, approaching a singularity). This may be because the collision detection system proposed by the present invention is not limited to a single sensor, but rather integrates and analyzes data from the current sensor (160) and the encoder (150) to implement safer and more flexible robot control.

[0423] The sequence of operations 31, 32, 33, 34, and 35 described in this embodiment can be repeatedly performed during the real-time motion control process of the collaborative robot (100), and the control unit (200) can skip some steps or insert additional verification steps depending on the situation. For example, if the current sample value (Ck) is very close to the collision threshold but has not yet exceeded it, the control unit (200) can temporarily reduce the robot speed to switch to a “safety reserve mode” and then check the re-measured current data. This can prevent potential collisions in advance or respond to a situation where the volume or weight of the workpiece (work target) suddenly changes. In addition, by setting the collision threshold value itself to dynamically change according to the posture or load weight of the robot joint (110) rather than being a fixed value, it is possible to implement a collision detection algorithm that is more optimized for a specific work situation.

[0424] As described above, in operation 31, the control unit (200) calculates a current sample value based on the current data, and in operations 32 and 33, compares the current sample value with the collision threshold value to predict the possibility of collision of the robot, and in operation 34, if the result exceeds the threshold value, a collision state is declared and appropriate safety measures can be taken. Meanwhile, in operation 35, if it is determined to be below the threshold value, the next operation command can be sent to the driving unit (180) to continue the robot in a normal operation state. This series of processes is the core of the motor current-based collision detection technique, and can provide the advantage of determining whether there is a collision using only the robot's internal sensors without using existing external sensors or complex image analysis systems. As a result, the installation cost and maintenance burden of the robot system can be reduced, and the response speed can be shortened, thereby improving the safety of collaboration between the operator and the robot.

[0425] Figure 33 is a flowchart illustrating a method for determining an overload status of a collaborative robot according to an example of the present invention.

[0426] Referring to FIG. 33, in one embodiment, in operation 41, the control unit (200) can calculate a current section value based on current data. For example, at this time, the control unit (200) can measure the current supplied to the motor at regular intervals and analyze the accumulated current to produce an index capable of diagnosing an overload condition. Specifically, the current value (Ij) per point in time transmitted from the current sensor (160) is aggregated in units of L samples, so that it can be evaluated how much current the robot is maintaining for a certain period of time. This current section value (Ok) can be calculated according to the following Equation 2, where L represents the length of a preset measurement section.

[0427] [Formula 2]

[0428]

[0429] Here, k is a natural number, Ij is the current measured at the current point in time, L is a preset measurement interval, and Ok is the current interval value.

[0430] The control unit (200) can determine the current level over a certain period of time, rather than a simple instantaneous current spike, by calculating the average of the previous L current values ​​at the kth point in time. This takes into account that an overload condition is usually not a short-term sudden increase, but a phenomenon in which a high current is maintained for a certain period of time. For example, if the collaborative robot (100) is holding a heavy object for a long period of time, or if an unexpectedly high resistance continues to act on the joint (110), the current value measured by the current sensor (160) may remain high for a certain period of time or longer.

[0431] In one embodiment, in operations 42 and 43, the control unit (200) may compare the current section value with the overload threshold value. For example, the overload threshold value is a limit set so as not to exceed a current range in which the robot can safely operate, and may vary depending on the mechanical structure of the robot, motor rating, cooling performance, etc. For example, if L is 20 samples, Ok, which is an average of current values ​​of about 100 ms (assuming a sampling cycle of 5 ms), may be obtained and compared with the overload threshold value. If Ok is much lower than the overload threshold value, it can be considered that the robot is operating within a normal load range. Conversely, if Ok exceeds the overload threshold value, it can be determined that the robot joint part (110) is receiving a load exceeding the design range.

[0432] The control unit (200) can first check whether Ok is close to the overload threshold value in operation 42, and then comprehensively review additional conditions (number of samplings, whether it occurs continuously within a specific section, etc.) in operation 43 to finally determine whether there is an overload. This is to prevent false detection, and a multi-step verification process can be performed so that a momentary current increase during robot operation is not mistakenly recognized as an overload. For example, it can be designed so that an “actual overload state” is determined only when Ok is measured several times in a row near the overload threshold value. In addition, the control unit (200) can additionally utilize temperature information of the motor or drive unit (180) measured by the temperature sensor (170) to analyze whether the thermal burden increases when a high current state continues for a long time.

[0433] In one embodiment, in operation 44, if the current section value exceeds the overload threshold as a result of the comparison, the control unit (200) may determine that the collaborative robot is in an overload state. An overload state may mean that the robot is subjected to a load exceeding the normal operating range, and thus the motor, reducer, bearing, etc. are subjected to excessive stress. If this continues for a long time, it may cause wear and tear on the robot parts, overheating, energy loss, etc., which may reduce work efficiency and stability. Therefore, as soon as the control unit (200) determines that an overload state has occurred, it may issue a command to reduce the load by limiting the output of the motor or changing the movement path of the robot arm (120). For example, if it is estimated that the object being lifted by the joint unit (110) is heavier than expected, the control unit (200) may issue a speed reduction command to distribute the load or stop the work process to instruct a re-examination of the work environment.

[0434] An overload condition can be distinguished from a collision or overspeed in that "high current is maintained for a long period of time." A collision mainly observes a momentary surge, and overspeed checks whether the speed measured by the encoder (150) exceeds a threshold value. On the other hand, an overload can determine in real time whether the robot is exceeding its workload by utilizing an indicator based on Equation 2 that "the average current of L samples exceeds the overload threshold value." The control unit (200) can detect risks that may arise from a task in which the robot joint (110) lifts a certain weight or more for a long period of time and take safety measures before fatal damage occurs to the motor or drive unit (180).

[0435] In one embodiment, in operation 45, if the current section value is lower than or equal to the overload threshold as a result of the comparison, the control unit (200) may transmit the next control command to the drive unit (180). For example, since this means that the robot is under a load within a normal range, the control unit (200) may continue the current working state or allow the operation of the robot arm (120) to proceed to the next step. For example, when performing a task of moving an object, if Ok is lower than the overload threshold, the robot may be determined to be able to lift the object without difficulty, and may be instructed to move to the next location according to the path plan. In addition, when it is confirmed that there is no overload state, the control unit (200) may issue a command to slightly increase the motor output or movement speed for efficient productivity. This may be a way to maximize work efficiency while maintaining a safe range.

[0436] Additionally, operation 45 may include a procedure for returning the robot to its original operating mode after a prolonged overload condition has been resolved. For example, if a joint (110) that was previously judged to be in an overload condition and temporarily stopped or decelerated, and now has a current section value (Ok) that has fallen below a threshold value, the control unit (200) may gradually accelerate the robot operation to restore it to a normal level. At this time, the control unit (200) may also check the motor temperature information transmitted from the temperature sensor (170) and delay the speed recovery if the overheating condition has not yet been resolved. This can ensure the durability of robot components and prevent unnecessary failures.

[0437] The flow from operation 41 to operation 45 described in this embodiment can be repeatedly performed when the collaborative robot (100) is actually working, and can quickly determine an overload condition by comprehensively analyzing data obtained from various sensors such as a current sensor (160), a temperature sensor (170), and an encoder (150). In particular, by utilizing the current section value (Ok) defined in Equation 2, it is possible to clearly distinguish whether the robot consumes a high current momentarily at a specific point in time or requires a high current steadily for a certain period of time. Unlike momentary collision detection, this can be a method of more effectively identifying a situation in which a long-term load increase occurs.

[0438] For example, if L is set to 50 and the sampling period is assumed to be 2 ms, Ok is calculated by averaging the current values ​​for approximately 100 ms. If the weight of the object unexpectedly increases while the robot is lifting an object, or if additional friction is generated at the joint (110) and the motor continues to consume high current, Ok may gradually exceed the overload threshold. The control unit (200) that detects this may immediately limit the movement of the joint (110) to prevent long-term damage to the motor, or may stop the operation and display a warning message for the user to inspect the robot. On the other hand, if Ok is stably maintained below the threshold, the robot can perform the operation within the normal range without overload, so that the user can secure both high productivity and safety.

[0439] In addition, the control unit (200) can accumulate log data on the frequency of overload conditions to diagnose whether a specific joint (110) frequently causes problems or whether excessive load is applied during a specific work step. Through this, the user can secure long-term stability by redesigning the path plan of the robot arm (120) or upwardly adjusting the specifications of the drive unit (180). In addition, the overload threshold value can be dynamically adjusted so that the threshold value can flexibly change depending on the type of work or the status of the robot components. For example, if the robot has been continuously operating for a long time and the motor temperature is already high, the threshold value can be lowered to prevent damage to the components.

[0440] In conclusion, the process in which the control unit (200) calculates the current section value in operation 41, compares it with the overload threshold value in operations 42 and 43, determines an overload state in operation 44 and then takes necessary safety measures, or confirms that it is below the threshold value in operation 45 and proceeds to normal operation, can play a key role in real-time overload detection and response of the collaborative robot (100). Through this series of procedures, the robot can efficiently monitor not only collisions and overspeeding, but also situations in which load increases accumulate relatively slowly, thereby ensuring both the safety of the worker and the durability of the equipment.

[0441] Figure 34 is a flowchart illustrating a method for determining an overspeed state of a collaborative robot according to an example of the present invention.

[0442] Referring to FIG. 34, in one embodiment, at operation 51, the control unit (200) can calculate the velocity values ​​of the plurality of joints based on the rotation data. For example, the rotation data at this time refers to the angle change amount or pulse number of the joints (110) obtained from the encoder (150), and the control unit (200) can calculate the joint velocity by dividing it according to the time interval. For example, if the encoder (150) measures and transmits the angle at a regular cycle, the control unit (200) can obtain the joint rotation velocity from the angle change amount. In addition, the control unit (200) can precisely determine the actual movement of the robot arm (120) by calculating the acceleration or the position error of the joint. This joint velocity information can be an important basis for determining whether the collaborative robot (100) is out of the target velocity range or moving faster than expected. For example, it can also be determined through this joint velocity calculation process whether the robot is at high risk of overspeeding due to a sudden increase in acceleration only during a specific work step.

[0443] In one embodiment, in operations 52 and 53, the control unit (200) may compare the speed value with an overspeed threshold value. For example, the overspeed threshold value is a value that defines the maximum speed at which the collaborative robot (100) can safely move, and may be set by comprehensively considering the structure of the robot, motor performance, work environment, etc. For example, if it is determined that there is a possibility of causing a danger to surrounding workers or equipment when the speed exceeds 300° / s per joint, this may be set as the overspeed threshold value. In operation 52, the control unit (200) primarily checks whether the current speed value is close to the overspeed threshold value, and in operation 53, checks additional conditions (e.g., how many times the speed is measured continuously near the threshold value, whether the angular range of the joint (110) corresponds to a singular point, etc.) to finally make an overspeed determination. Through this, the control unit (200) can implement logic that recognizes actual speeding only when a speed above a certain level is sustained, without unnecessarily making an overspeed judgment due to a single temporary speed peak.

[0444] In one embodiment, in operation 54, if the speed value exceeds the overspeed threshold as a result of the comparison, the control unit (200) may determine that the collaborative robot is in an overspeed state. For example, an overspeed state is a situation where the joint part (110) of the collaborative robot (100) exceeds the maximum speed specified in the safety guidelines, which increases the risk of collision with the surrounding environment or the work target and is highly likely to cause mechanical damage to the robot parts. As soon as the control unit (200) detects an overspeed state, it may issue a speed limit command to the drive unit (180) to suppress the movement of the robot or switch to a low-speed mode to ensure work safety. For example, if the robot is moving at a slightly high speed for smooth work, but it is determined to be dangerous considering the distance from the surrounding worker or the load condition, the control unit (200) may immediately lower the driving speed of the joint part (110) to comply with human safety standards. Additionally, the control unit (200) can store the encoder (150) log at the time when an overspeed condition occurs, and use it to improve the work process design or adjust the robot speed control parameters through subsequent analysis.

[0445] Overspeeding can be determined simply by momentarily recording the speed exceeding a set threshold. However, for the efficiency of robot operation, it is also possible to consider whether the speed exceeding a certain standard continues for a certain period of time. For example, if a peak exceeding the threshold occurs for only 1 to 2 ms, the control unit (200) may not regard this as overspeeding but rather as noise or temporary acceleration. On the other hand, if the overspeed threshold is continuously exceeded for tens of ms or more, it may be desirable to control the robot's operation as it is clearly a dangerous condition. This overspeed judgment logic can operate in an integrated manner with the collision and overload judgment logic to enhance the overall safety of the robot.

[0446] In one embodiment, in operation 55, if the speed value is determined to be below the overspeed threshold as a result of the comparison, the control unit (200) may transmit the following control command to the drive unit (180). For example, if it is determined that the robot joint unit (110) is operating within the target speed range, the control unit (200) may continue the work, or may instruct a faster speed or an optimized path as needed. For example, if the work situation is determined to be safe, a strategy may be adopted to slightly increase the moving speed of the robot arm (120) to improve productivity. In addition, if the robot was limiting its speed in a certain section but is now determined to be maintained below the threshold, the control unit (200) may return to the originally planned speed to maximize work efficiency. This may contribute to striking a balance between safety and productivity by allowing the collaborative robot (100) to flexibly perform speed control in an actual work site rather than simply staying in a safe mode.

[0447] Meanwhile, in operation 55, the control unit (200) can monitor whether the robot maintains a speed within a safe range for a certain period of time by checking for a state in which an overspeed judgment has not been made over several sampling cycles. Through this, the control unit (200) can transmit a signal indicating “safe operation” to another upper system (e.g., a process management server) or instruct the robot arm (120) to change its path and move to the next work process. In addition, by comprehensively analyzing the encoder (150) data and the current sensor (160) data, it can be checked whether the current fluctuation also remains in a low range while the speed is maintained stably. If the speed is at an appropriate level but the current is measured to be high, the possibility that another abnormality (e.g., an overload) has occurred cannot be ruled out, and therefore, whether an overload has occurred can be re-examined using a separate algorithm.

[0448] In this way, the control unit (200) calculates the speed value of the joint unit (110) through the encoder (150) in operation 51, compares it with the overspeed threshold value in operations 52 and 53, and immediately takes safety measures such as limiting the speed if it is determined to be overspeed in operation 54, and continues normal operation if it is below the overspeed threshold value in operation 55. This series of processes can be a very important safety control procedure in an environment where robots collaborate with people. In particular, since the risk of colliding with a worker may increase when the robot moves with high inertia or acceleration, quickly determining and responding to an overspeed state plays a key role in the safe operation of the collaborative robot (100). Furthermore, this overspeed determination logic can be linked to whether a singularity is approached or a collision occurs, so that a comprehensive robot operation safety system can be built.

[0449] For example, if the joint part (110) is likely to approach a singular point in a specific posture and the speed changes rapidly, the control unit (200) can recognize this fact in advance and lower the overspeed threshold value to conservatively set the safety limit. Conversely, in the case of a robot that operates automatically in a closed space without a worker, there may not be a major problem even if the overspeed threshold value is set somewhat high. In this way, the control unit (200) can dynamically change the overspeed threshold value according to the work environment and robot status, and the process from operation 51 to operation 55 can realize robot motion control that satisfies both safety and efficiency by evaluating the robot speed with the changed threshold value at that time.

[0450] Additionally, the control unit (200) can determine through log data whether there are joints (110) or work steps where overspeed judgments frequently occur. Based on this, the path design of the robot arm (120) can be re-examined or the speed profile can be reset to reduce the frequency of overspeed judgments and optimize the work flow. Furthermore, if the robot frequently receives overspeed judgments, it may be necessary to check whether the weight of the workpiece mounted on the gripper (140) has changed or whether the drive unit (180) of the joint (110) has worn out and changed its rotational characteristics. The control unit (200) can use this feedback information to predict maintenance times or establish a parts replacement plan, thereby contributing to increasing equipment operating rates and preventing unexpected downtime.

[0451] As a result, the cyclic process of operations 51, 52, 53, 54, and 55 proposed in the present invention can specifically represent the overspeed detection and control procedure essential for the safe operation of the collaborative robot (100). The control unit (200) periodically checks the joint speed value calculated through the encoder (150) and compares it with the overspeed threshold value to determine whether it has been exceeded, thereby preventing dangerous high-speed movements in advance even in a work space where a person and a robot are in close proximity. In addition, if it is determined that the speed is maintained within the normal range, the control unit (200) can transmit an additional command to the drive unit (180) to maximize work efficiency. In this way, the present invention can operate the collaborative robot more effectively by suggesting an overspeed control method that takes both safety and productivity into consideration.

[0452] Figure 35 is a flowchart illustrating a method for determining a singularity state of a collaborative robot according to an example of the present invention.

[0453] Referring to FIG. 35, in one embodiment, in operation 61, the control unit (200) can obtain singular point index values ​​of the plurality of joints based on the angle values ​​of the plurality of joints included in the rotation data. To this end, the control unit (200) can first collect real-time information on each axis (angle) of the joints (110) from the encoder (150), and calculate a Jacobian matrix based on the collected angle values. The Jacobian matrix is ​​a key element representing the kinematic characteristics of the robot manipulator, and can mathematically express how a subtle change in the joints (110) affects the position and posture of the end of the robot arm (120). The control unit (200) can obtain the Jacobian matrix according to the robot joint structure (link length, rotation axis configuration, etc.), and then perform a singular value decomposition (SVD) or similar algorithm on the matrix to extract the minimum singular value (SMink). At this time, the smaller the minimum singular value, the closer the robot joint is to the singularity.

[0454] For example, the control unit (200) can analyze the angle value to calculate the Jacobian matrix at the current point in time, extract the minimum singular value among the Jacobian matrix values, and calculate the singular point index value according to Equation 3 below.

[0455] [Formula 3]

[0456]

[0457] Here, Mk is the singularity index value, and Smink is the minimum singular value.

[0458] As SMink approaches 0, it means that the robot joint (110) is in a posture very similar to the singular point state, and its inverse, Mk, increases. In other words, as Mk increases, it is possible to numerically and intuitively determine that the robot is near the singular point. The control unit (200) can perform this calculation process in operation 61 to calculate the Mk value reflecting the angle data of the joint (110) at each point in time.

[0459] In one embodiment, in operations 62 and 63, the control unit (200) may compare the singularity index value with the singularity threshold value. For example, the singularity threshold value is a reference value set to maintain a safe operating range of the robot, and when Mk exceeds this threshold value, it may be determined that there is a high possibility that the robot will cause excessive acceleration or unstable operation near the singularity. For example, it may be set that the sensitivity of the robot control increases significantly from the point where Mk exceeds 10, and at this time, there may be a high risk that the robot joint (110) may move rapidly at the distal end with even a small movement or that the control error may be amplified. In operation 62, the control unit (200) may primarily compare Mk with the singularity threshold value to determine whether it is close to the threshold value, and in operation 63, additional conditions (e.g., whether Mk continuously exceeds the threshold value over multiple samples, whether a specific joint (110) falls within a specific angular range, etc.) may be reflected to make a final singularity status determination.

[0460] In one embodiment, in operation 64, the control unit (200) may determine that the collaborative robot is in a singularity state if the singularity index value exceeds the singularity threshold value. For example, the singularity state may refer to a situation in which the joint unit (110) forms a specific angular arrangement in a serialized section, causing the Jacobian matrix to have a rank deficiency or the minimum singular value to approach 0. In this state, the robot control may become unstable, the speed may change rapidly, and there is a high possibility that unpredictable movements may occur. Therefore, if the control unit (200) determines that the singularity state exists, it may immediately transmit a control command to the driving unit (180) to decelerate the operation of the robot joint unit (110) or change the path. For example, if the control unit (200) detects that the robot arm (120) is entering the vicinity of the singularity, the control unit (200) may design the robot's movement path to slightly detour to avoid the singularity or switch the operation of the joint unit (110) to a low-speed mode to safely pass through it.

[0461] If the robot moves rapidly in a singularity state, control errors can be significantly amplified, and the collaborative robot (100) may move in an unexpected direction, increasing the risk of collision with surrounding equipment or human bodies. Therefore, the control unit (200) can immediately detect the moment when Mk exceeds a threshold value and adjust the robot's movements to prevent accidents in advance. Unlike other abnormal conditions (e.g., collisions, overloads, overspeeding), this can be an important safety device for resolving control difficulties caused by the robot's internal kinematic structure.

[0462] In one embodiment, at operation 65, the control unit (200) may: For example, if the robot has switched to low-speed mode or has performed a path detour after a singularity condition has been detected, the control unit (200) may continuously monitor whether the singularity index value (Mk) has fallen below the singularity threshold value again. If Mk remains at a sufficiently low value, the control unit (200) may control the robot arm (120) to return to the original speed or path. In addition, the control unit (200) may analyze the encoder (150) and current sensor (160) data at the time when the singularity condition has been resolved, and record the load or speed change applied to the joint (110) while the robot passes through the singularity section. Through this, the operation near the singularity can be further optimized in similar tasks in the future, or the automatic path planning algorithm can be improved when approaching the singularity.

[0463] Meanwhile, in operation 65, specific scenarios can be determined for how the entire robot system will manage and resolve a singularity state. For example, if a robot is performing a welding task, the welding trajectory may become unstable during a singularity state, which could degrade quality. Therefore, the task can be temporarily suspended, the singularity can be bypassed, and welding can be resumed. On the other hand, if the task is a simple transport task, the control unit (200) can maintain work efficiency by passing the relevant section in low-speed mode and then returning to the original speed upon entering the safe zone. Furthermore, the control unit (200) can repeatedly perform these procedures and accumulate robot operation logs during singularity states, which can be utilized for future system maintenance or work process improvement.

[0464] Through a series of operations 61, 62, 63, 64, and 65, the present invention calculates a singularity index (Mk) reflecting the kinematic characteristics of the robot manipulator, and determines in real time whether the singularity threshold value is exceeded based on this, thereby controlling the collaborative robot (100) to operate safely. Unlike an external collision or overload, the singularity state is an unstable section created by the joint arrangement of the robot itself. Therefore, if the control unit (200) does not quickly detect this, the predictability of the robot operation may significantly decrease. However, in the present invention, the control unit (200) measures the joint angle through the encoder (150), obtains the minimum singular value (SMink) of the Jacobian matrix, and then calculates Mk to determine whether a specific threshold value is exceeded, thereby quickly identifying the singularity approach point.

[0465] In addition, the present invention can additionally utilize other indices (e.g., condition number, determinant value, etc.) that reflect the actual movement of the robot joint (110) in addition to the singularity index (Mk). However, the method of using Mk may have the advantage of being easy to numerically interpret by simplifying the fact that the difficulty of robot control increases exponentially as the Jacobian minimum singular value approaches 0. For example, when Mk increases to 20 or more, it can be seen that the robot arm (120) has entered a considerably unstable section, and the control unit (200) can take various safety measures such as route detour, speed limit, and work stoppage from this point on.

[0466] Ultimately, through the entire process in which the control unit (200) calculates the singularity index (Mk) based on the angle value in operation 61, compares it with the singularity threshold value in operations 62 and 63, determines the singularity state in operation 64, and then performs subsequent control in operation 65, the collaborative robot (100) can detect and prevent unstable operation near the singularity in advance. This can serve as a safety factor that must be considered when operating the robot, along with other abnormal conditions such as collisions, overloads, and overspeeds. Therefore, the present invention can achieve a high level of safety and work efficiency at the same time even in an environment in which a person and a robot collaborate in the same space by including a singularity detection function.

[0467] Figure 36 is a flowchart illustrating a method for motion calibration for each joint of a collaborative robot according to an example of the present invention. Figure 37 is a block diagram illustrating a detailed configuration of a precision motion calibration system according to an example of the present invention. Figure 38 is an exemplary diagram illustrating a collaborative robot according to an example of the present invention.

[0468] Before explaining the main components of the present invention, the representative operation of the present invention will be explained.

[0469] Referring to FIG. 36, in one embodiment, in operation 21, the temperature sensor (160) can measure the temperature of a plurality of joint parts (110). For example, the temperature sensor (160) is installed adjacent to a plurality of joint parts (110) and configured to measure the internal temperature and the ambient temperature of each joint part in real time. At this time, the temperature sensor (160) may use a high-precision sensor such as an optical, thermocouple, or resistance temperature detector (RTD), and is placed at an optimal position considering the physical location and mechanical structure of each joint part (110). The temperature sensor (160) transmits temperature data to the control device (200) or the control system through a dedicated data bus, and this data can be utilized in a temperature compensation algorithm. For example, the temperature sensor (160) can individually measure the temperature around the motor of each joint part (110) and inside the gearbox, so as to accurately detect the temperature deviation according to the extreme temperature change of the external environment (from -10℃ to 50℃), and through this, temperature-related phenomena such as mechanical expansion and contraction of the joint part and viscosity change of lubricating oil can be precisely analyzed. The real-time temperature data provided by the temperature sensor (160) can be used as basic data in the calibration process of the entire system, so that the temperature data measured in operation 21 can play an essential role in calculating correction parameters and motion compensation in subsequent operations.

[0470] In one embodiment, in operation 22, the encoder (140) can obtain position data of a plurality of joints. For example, the encoder (140) performs the role of precisely obtaining position data of each joint (110). The encoder (140) can generally use an optical, magnetic, or inductive sensor, and can be directly connected to each joint (110) to measure the actual rotation angle or linear movement distance in real time. At this time, the encoder (140) provides high-resolution data, so that it can detect a minute position change of the robot arm (120), and the measured data is converted into a digital signal and transmitted to the control device (200). The data of the encoder (140) can reflect the operation status such as the current position, speed, and acceleration of each joint, and is used to derive correction parameters in the backlash compensation algorithm and the temperature compensation algorithm based on the data. The encoder (140) acts as a key element for reducing minute errors that occur especially during repetitive movements, and the position data acquired in operation 22 can be configured to be analyzed by a calibration algorithm within the control device (200) to precisely calculate the difference between the actual position of the joint and the target position.

[0471] In one embodiment, in operation 23, the control device (100) can perform motion calibration of the collaborative robot (100) based on the temperature and position data. For example, the control device (200) performs motion calibration of the collaborative robot (100) based on the temperature and position data received from the temperature sensor (160) and the encoder (140). The control device (200) analyzes the received data in real time to calculate static and dynamic backlash compensation parameters and temperature compensation parameters, and drives a control algorithm to correct errors of each joint (110) using the same. For example, the control device (200) can calculate correction parameters Hi(t) using the difference between temperature data Ti(t) of each joint and the reference temperature Tref according to the temperature compensation algorithm, and can calculate static and dynamic correction parameters Bi(t) based on the position data obtained from the encoder (140) according to the backlash compensation algorithm. These correction parameters are applied to minimize the actual motion error of the joint (110) during the real-time calibration process, and the control device (200) integrates them to generate a final motion calibration command. The control device (200) utilizes a number of algorithm modules and correction tables to offset complex error factors such as temperature changes and mechanical backlash phenomena occurring during operation, and thereby can generate a control command so that the collaborative robot (100) can accurately achieve the set target position and speed.

[0472] In one embodiment, in operation 24, the control device (100) can drive the drive unit (170) to drive the plurality of joint units (110). For example, the control device (200) transmits the final calibration command calculated to the drive unit (170), so that the drive unit (170) actually drives the plurality of joint units (110). The drive unit (170) is composed of a servo motor, a reducer, a gearbox, and a connecting link, and is driven to precisely move each joint unit (110) according to the command received from the control device (200). For example, the drive unit (170) can finely correct the rotation angle or linear movement distance of the joint unit (110) by adjusting the voltage, current, or PWM signal transmitted to the motor by reflecting the correction parameter calculated by the control device (200). The driving unit (170) receives such control commands and compensates for mechanical errors that may occur during actual operation or physical fluctuations due to temperature changes, thereby optimizing the overall motion calibration of the collaborative robot (100). The driving unit (170) may also be configured to continuously receive feedback on the response speed and driving status according to commands through real-time communication with the control device (200), and to readjust the correction commands as needed.

[0473] In this way, in operation 21, the temperature sensor (160) precisely measures the temperature of each joint part (110), in operation 22, the encoder (140) obtains the position data of each joint part (110) in real time, in operation 23, the control device (200) calculates static and dynamic backlash compensation parameters and temperature compensation parameters based on these sensor data to perform motion calibration, and in operation 24, the correction command calculated by the control device (200) is transmitted to the driving unit (170) to drive each joint part (110), thereby enabling the overall system operation to maintain the operation accuracy and repeatability of the collaborative robot (100) even in an extreme temperature environment. The system can be configured so that each operation step is organically connected to each other, and errors that may occur during operation are minimized through accurate collection of sensor data, real-time analysis, and rapid transmission of control commands, thereby ensuring stable collaborative robot operation.

[0474] The main configuration of the present invention according to the representative operation of the present invention is described as follows.

[0475] Referring to FIGS. 37 and 38, a precision motion calibration system (10) can perform precision motion calibration even in an extreme temperature environment by organically combining the collaborative robot (100) according to the present disclosure and each component constituting the collaborative robot (100), and can include a collaborative robot (100) and a control device (200).

[0476] In one embodiment, as illustrated in FIGS. 37 and 38, the collaborative robot (100) may include a plurality of joint parts (110), a robot arm (120), a base part (130), an encoder (140), a current sensor (140), a temperature sensor (160), and a driving part (170). For example, the collaborative robot (100) is a structure including multiple joint parts (110), and is configured as a basic platform that performs the operation of the entire system, and the robot arm (120) and the base part (130) are coupled together. The collaborative robot (100) can be utilized in various fields such as factory automation, logistics loading, assembly, and precision work, and can be designed for the purpose of ensuring stable operation even in extreme temperature environments (-10°C). The collaborative robot (100) is organically connected to a control device (200) through a power supply and communication network, along with mechanical coupling between each component, and can be configured so that data exchange between each part can be smoothly performed for accurate operation and correction of the entire system.

[0477] In one embodiment, each of the plurality of joints (110) may be equipped with a motor. Each joint (110) is a core component that precisely controls the movement of the collaborative robot (100), and generally adopts a multi-axis structure. Each joint (110) may be designed to perform precise rotational and linear movements by integrating individual motors, reducers, gearboxes, etc. through temperature sensors (160) and encoders (140) installed at each joint, thereby receiving temperature and position data in real time, and may be configured to detect mechanical expansion, contraction, and backlash phenomena that may occur even in extreme temperature environments, and may be configured to allow the control device (200) to correct errors caused thereby. For example, since each joint (110) may have play or wear at the connection with the robot arm (120), it may be designed to maintain a repeatability accuracy of ±0.05 mm through a precise calibration process.

[0478] In one embodiment, the robot arm (120) is configured with a mechanical link structure that enables the robot to approach a work target or manipulate an object based on the motion force transmitted from the joint unit (110), and may be manufactured using a material that takes lightweight and rigidity into consideration (e.g., aluminum alloy, carbon fiber, etc.). The robot arm (120) serves to expand the work range of the collaborative robot (100), and may be designed to enable fine adjustments to the work position based on accurate motion commands obtained through precise correction of the joint unit (110). The robot arm (120) may also secure the stability of the entire system through a solid connection with the base unit (130), and may include a damping structure that can absorb vibrations or shocks generated at the mechanical joint with the joint unit (110).

[0479] In one embodiment, the base (130) serves as a lower structure of the collaborative robot (100), and can support the weight of the entire system and stably maintain the operation of the robot arm (120) and the joint (110) in a fixed position. The base (130) can be manufactured using a sturdy metal frame and appropriate fixing devices (bolts, welding, etc.), and can be selected as a movable base or a fixed base depending on the work environment. The base (130) can be monitored in real time through power and data communication lines with the control device (200), and can ensure the operational stability of the entire system through precise coupling with the robot arm (120) and the joint (110).

[0480] In one embodiment, the encoder (140) can obtain position data of multiple joints. For example, the encoder (140) is a sensor that precisely measures the position data of each joint (110), and a high-resolution optical or magnetic encoder can be used, thereby detecting the rotation angle and movement distance of the joint in real time. The encoder (140) can be configured to be directly connected to the joint (110), accurately record minute differences in mechanical movement, and transmit this data to the control device (200) so that it can be utilized in backlash compensation and temperature compensation algorithms. In an actual implementation, since the measurement accuracy of the encoder (140) has a significant impact on the overall repeatability accuracy of the collaborative robot (100), a high-precision encoder can be selected and designed to minimize measurement errors.

[0481] In one embodiment, the current sensor (150) can obtain current data supplied to the motor. For example, the current sensor (150) can obtain current data supplied to the motor in real time and play a role in evaluating the load status and operating efficiency of the motor. The current sensor (150) can be integrated into the motor drive circuit and transmit a warning signal to the control device (200) when the motor consumes current exceeding the expected range or an abnormality occurs, thereby being configured to prevent problems such as overload or overheating of the motor in advance. As an actual implementation example, the current sensor (150) can analyze the current consumption pattern of the motor and contribute to a compensation algorithm that suppresses shock or unnecessary vibration during the operation of the robot arm (120).

[0482] In one embodiment, the temperature sensor (160) can measure the temperature of a plurality of joint parts (110). For example, the temperature sensor (160) is installed around each joint part (110) or a motor, and is a key sensor that provides real-time temperature data. A high-precision temperature sensor can be used so that accurate temperature measurement can be performed even in an extreme temperature environment (-10°C). The temperature sensor (160) receives data directly from the control device (200) and plays an important role in calculating the correction parameter Hi(t) to be used in the temperature compensation algorithm, and can be configured to correct temperature effects such as mechanical expansion or contraction, and changes in lubricant viscosity, in real time through this. For example, the temperature sensor (160) can be installed in close contact with each joint part (110) to simultaneously detect not only changes in the external environmental temperature but also a temperature increase due to internal heat generation, and this data can be used to automatically update the correction parameters by linking with the correction table of the control device (200).

[0483] In one embodiment, the driving unit (170) can drive a plurality of joint parts (110). For example, the driving unit (170) can be configured as a driving means for actually driving each joint part (110), such as a servo motor, a reducer, a gearbox, and a connecting link, and these components can be made of parts that have mechanical precision and durability for precise control. The driving unit (170) can rotate or linearly move each joint part (110) according to a control command transmitted from the control device (200), thereby performing a role of moving the robot arm (120) to a target position. As an example of an actual implementation, the driving unit (170) can be used in a work environment that requires high-speed response and precise control, and can be designed to offset minute errors due to temperature changes and mechanical backlash through a correction command of the control device (200).

[0484] In one embodiment, the control device (200) can perform motion calibration of the collaborative robot (100) based on the temperature and position data. For example, the control device (200), as a central control device of the system (10), can receive real-time data from a temperature sensor (160), an encoder (140), a current sensor (150), etc., analyze the data, and drive an algorithm that calculates static and dynamic backlash compensation parameters and temperature compensation parameters. The control device (200) can be configured to perform motion calibration of each joint part (110) based on the calculated compensation parameters and transmit a final control command to the drive part (170), thereby ensuring the operation accuracy and stability of the collaborative robot (100) even in an extreme temperature environment. The control device (200) can be implemented as a PLC, a dedicated embedded processor, or a PC-based control system, and can be designed to be connected in real time to each sensor and actuator through a high-speed data communication protocol (e.g., EtherCAT, CANopen, etc.) to maintain synchronization throughout the system.

[0485] In this way, the precision motion calibration system (10) according to the present invention is configured so that each component is precisely designed and organically connected to each other, thereby realizing stable and precise motion calibration even in an extreme temperature environment, thereby providing an effect of significantly improving the performance and reliability of the entire collaborative robot (100).

[0486] Figure 39 is a flowchart illustrating a method for generating backlash compensation parameters according to an example of the present invention.

[0487] Referring to FIG. 39, in one embodiment, in operation 31, the control device (100) may transmit a control command to the driving unit to move the collaborative robot to a reference position. For example, the control device (100) may generate a control command to restore the initial alignment state of the corresponding joint unit (110) and the robot arm (120) by referring to previously stored reference position data in order to move the collaborative robot (100) to the reference position, and transmit this control command to the driving unit (170), thereby controlling the collaborative robot to accurately reach the designated reference position. At this time, the control device (100) compares and analyzes the stored reference position and the current state of each joint to precisely calculate the movement path, speed, acceleration, etc., and such a control command may play an important role in increasing the overall operation precision of the collaborative robot.

[0488] In one embodiment, in operation 32, the control device (100) can receive the first positions of the plurality of joints from the encoder. For example, the control device (100) can receive the first position data of the plurality of joints (110) from the encoder (140) in real time. Here, the encoder (140) is configured as a sensor that measures the rotation angle and linear movement distance of each joint in high resolution, and the data collected through the encoder is converted into a digital signal and transmitted to the control device (100). The control device (100) can use the received first position data to confirm whether the collaborative robot has accurately moved to the reference position, and can use it as basic data for generating a correction command thereafter. This data can also contribute to precisely analyzing minute errors and backlash phenomena of the joints.

[0489] In one embodiment, in operation 33, the control device (100) can generate static backlash compensation parameters based on an error between a reference position and the first position. For example, the control device (100) can calculate a difference between the first position data received in operation 32 and a predefined reference position, and calculate static backlash compensation parameters based on this difference. In this process, the control device (100) refers to the fixed mechanical characteristics of each joint part (110) and the reference backlash value measured in the initial manufacturing process, and calculates the static compensation parameters by applying constants and coefficients for correcting errors that occur during actual operation. The calculated static backlash compensation parameters are used to correct the initial position error of each joint part, and thereby modify the control command so that the collaborative robot can reach the reference position more precisely.

[0490] In one embodiment, in operation 34, the control device (100) may transmit a control command to the drive unit to cause the collaborative robot to perform repetitive motions along a pre-designated trajectory. For example, the control device (100) may transmit a control command based on the target position and motion path data of the pre-designated trajectory to the drive unit (170) so that the collaborative robot can perform repetitive motions along the pre-designated trajectory. At this time, the trajectory may be defined in various forms, such as a circular, linear, or complex curved path, and the control device (100) may generate a control command so that the robot arm (120) can move precisely along the designated trajectory by adjusting the motion range and speed of each joint part (110) with reference to the pre-designated trajectory data. Such a repetitive motion control command may play an important role in ensuring the repeatability precision of the collaborative robot, especially when repeatedly performing the same task in a production line or an automated system.

[0491] In one embodiment, in operation 35, the control device (100) can receive the second positions of the plurality of joint parts from the encoder. For example, the control device (100) can receive the second position data of the plurality of joint parts (110) from the encoder (140) in real time. At this time, the control device (100) can precisely measure the actual movement path and final position of each joint part (110) through the encoder (140) while the collaborative robot performs a pre-designated trajectory according to the control command transmitted in operation 34, and calculate the difference from the target trajectory. This second position data is used as basic data for calculating dynamic backlash compensation parameters, and the operating status of the collaborative robot can be continuously monitored according to the precision of the data received in real time.

[0492] In one embodiment, in operation 36, the control device (100) can generate a dynamic backlash compensation parameter based on the error between the trajectory target position and the second position. For example, the control device (100) can calculate the error between the second position data received in operation 35 and the target position of the predetermined trajectory, and calculate a dynamic backlash compensation parameter based on this error. At this time, the dynamic backlash compensation parameter is a value calculated to respond to minute movement errors of the joints, dynamic load changes, vibrations of the joints, and external shocks that occur when the collaborative robot performs repetitive movements, and the control device (100) can precisely correct the error of each joint part (110) through real-time data analysis and correction algorithms. The dynamic compensation parameter can be applied as a variable coefficient to compensate for the difference between the actual operation state of each joint and the target trajectory, and thereby the operation stability and repeatability of the collaborative robot can be greatly improved.

[0493] In one embodiment, in operation 37, the control device (100) can generate a backlash compensation parameter based on the static backlash compensation parameter and the dynamic backlash parameter. For example, the control device (100) can generate a final backlash compensation parameter by synthesizing the static backlash compensation parameter calculated in operation 33 and the dynamic backlash compensation parameter calculated in operation 36. This final backlash compensation parameter is used as a correction value to offset both the initial position error of each joint part (110) and the micro-error that occurs during repetitive operations, and the control device (100) can control the driving part (170) to minimize mechanical backlash and dynamic error when driving each joint part (110) by applying this parameter to calculate the final control command. The final compensation parameter can be calculated by a weighted average or summation of the static compensation and the dynamic compensation, and through this, the overall motion calibration of the collaborative robot (100) can be performed more precisely.

[0494] As such, in one embodiment with reference to FIG. 39, a series of steps from operation 31 to operation 37 constitute an overall system operation in which the control device (100) calculates static and dynamic backlash compensation parameters for each joint (110) of the collaborative robot (100) based on temperature and position data, integrates them, and generates a final compensation command. These operation steps can be designed to maximize the accuracy of the target trajectory and reference position of the collaborative robot through real-time data collection, analysis, and compensation algorithms. Consequently, the calculation and application of compensation parameters in each operation step can play a decisive role in precisely performing motion calibration of the collaborative robot (100) even in extreme temperature environments, improving repeatability and collision detection capabilities, and ensuring the operational stability of the entire system.

[0495] Figure 40 is a flowchart illustrating a method for generating temperature compensation parameters of a collaborative robot according to an example of the present invention.

[0496] Referring to FIG. 40, in one embodiment, at operation 51, the control device (100) may receive the current temperature from the temperature sensor. For example, at this time, the temperature sensor (160) may be installed near each joint part (110) and the motor, and may perform the function of measuring the temperature value according to the external environment and internal heat generation in real time, and such measured value may be converted into a digital signal and transmitted to the control device (100). The control device (100) can analyze the received temperature data to precisely identify temperature fluctuations affecting the operation of the collaborative robot in extreme temperature environments (-10℃ to 50℃), and this data can be used as basic data for calculating subsequent correction commands. For example, the temperature sensor (160) can separately measure the temperature inside the motor or gearbox of each joint part (110) to identify the temperature distribution for each joint, thereby allowing the control device (100) to consider detailed phenomena such as mechanical expansion, contraction, and viscosity changes of lubricating oil according to temperature. In this way, in operation 51, the control device (100) can secure basic information necessary for calculating temperature compensation parameters in the future by receiving accurate and reliable temperature data from the temperature sensor (160).

[0497] In one embodiment, in operation 52, the control device (100) may generate a temperature compensation parameter based on a preset temperature-specific compensation table. For example, the control device (100) may refer to a pre-built temperature-specific compensation table, calculate a difference between the received current temperature data and a reference temperature (Tref), and apply linear and nonlinear compensation coefficients (Ai, Bi, Ci, etc.) accordingly to derive a temperature compensation parameter (H_i(t)), which is a compensation parameter for each joint (110) or motor. For example, the temperature compensation table is configured to include data on changes in the mechanical characteristics of the joint according to temperature change, and the control device (100) may derive different compensation values ​​based on this table depending on whether the temperature is lower or higher than the reference temperature. The temperature compensation parameter H_i(t) calculated at this time can use an equation that includes linear and quadratic term corrections for the difference between the real-time temperature data T_i(t) and the reference temperature T_ref, and can be calculated as a value that can compensate for temperature-related errors that occur during the operation of the collaborative robot. In this operation 52, the reference values ​​and correction coefficients of the temperature-specific correction table are determined and stored in advance through experiments and calibration, and the control device (100) can apply these in real time to accurately generate the temperature compensation parameters.

[0498] In one embodiment, in operation 53, the control device (100) may generate a control command based on the backlash compensation parameter and the temperature compensation parameter. For example, the control device (100) may synthesize the static and dynamic backlash compensation parameters calculated in operations 33, 36, and 37, etc., and the temperature compensation parameter H_i(t) calculated in operation 52, and finally calculate a compensation command for motion calibration of each joint part (110). At this time, the control device (100) may consider the weights and priorities of the compensation parameters, and may calculate the final control command by, for example, simply adding the static compensation parameter and the dynamic compensation parameter, or applying a proportional or multiplicative formula depending on the situation. In addition, the control device (100) can control the entire motion trajectory of the robot arm (120) to reach the target position without a minute error by calculating an individual compensation command according to the temperature and backlash difference measured at each joint (110), and such a control command can provide an effect of greatly improving the motion stability and repeatability of the collaborative robot. The control device (100) can enable individual compensation to be applied according to the characteristics of each joint by clearly including temperature compensation and backlash compensation elements in the calculated control command, and in this way, in operation 53, the parameters calculated by the compensation algorithm are reflected in the final control command, so that the motion calibration of the collaborative robot (100) can be precisely performed.

[0499] In one embodiment, in operation 54, the control device (100) can transmit the generated control command to the driving unit. For example, the control device (100) is connected to the driving unit (170) in a manner that enables high-speed data transmission through a communication protocol (e.g., EtherCAT, CANopen, etc.), and in operation 54, the generated control command can be converted into a digital signal and transmitted to the driving unit (170). The driving unit (170) can implement actual mechanical movement through a driving mechanism composed of a servo motor, a reducer, a gearbox, etc. that drives each joint unit (110) based on the control command transmitted from the control device (100), thereby allowing the robot arm (120) to move to a predetermined trajectory and reference position. The driving unit (170) can finely adjust the rotation angle and linear movement distance of each joint according to the correction command generated from the control device (100), thereby effectively offsetting errors that may occur due to temperature changes and backlash, and the application of such control signals can play a decisive role in maximizing the precision of the motion calibration of the collaborative robot (100). In operation 54, such control commands are quickly processed by the driving unit (170), thereby real-time correction is performed, and the actual motion of the collaborative robot can be accurately reproduced according to the corrected commands, and thereby the synchronization and stability of the entire system can be greatly improved.

[0500] In this way, the series of steps from operation 51 to operation 54 constitutes an overall calibration process in which the control device (100) calculates temperature compensation parameters and backlash compensation parameters based on real-time data received from the temperature sensor (160) and the encoder (140), and transmits the final control command that integrates them to the driving unit (170) to precisely drive each joint unit (110). This series of operations can contribute to maintaining the motion accuracy and repeatability of the collaborative robot (100) even in extreme temperature environments. This operation process consists of three main steps: real-time data analysis, application of a compensation algorithm, and high-speed control command transmission. Each step independently performs its own function, but overall, it can provide the effect of improving the overall performance of the system through a complementary role.

[0501] Figure 41 is a flowchart illustrating a temperature compensation parameter correction method of a collaborative robot according to an example of the present invention.

[0502] Referring to FIG. 41, in one embodiment, in operation 61, the control device (100) can measure the temperature change in real time through a temperature sensor. For example, at this time, the temperature sensor (160) is installed in close contact with each joint part (110) or near the motor, and is configured to precisely detect not only changes in the external environment but also temperature rise and fall phenomena due to internal heat generation. The control device (100) can calculate the temperature change by calculating the temperature difference between the previous time zone and the current time zone using continuous temperature data received from the temperature sensor (160), and in this process, data filtering and noise removal algorithms can be applied to secure an accurate change. In this way, in operation 61, the temperature change of each joint of the collaborative robot can be precisely measured through continuous comparison of real-time temperature data provided by the temperature sensor (160), and this result can be utilized as basic data for a subsequent correction algorithm.

[0503] In one embodiment, in operations 62 and 63, the control device (100) may compare the temperature change amount with a temperature threshold value. For example, the control device (100) analyzes the temperature change measurement result in real time to determine whether the temperature change occurring in each joint part (110) is greater than or less than a predefined temperature threshold value. At this time, the temperature threshold value may be a value previously set through experiments and calibration, taking into account the temperature range that the collaborative robot (100) must maintain during normal operation and the limit for rapid temperature change that may occur in an extreme temperature environment. Based on the comparison result, the control device (100) may execute control logic to distinguish between cases where the temperature change exceeds the threshold value and cases where it is below the threshold value, and to derive an appropriate correction command for each case. For example, in operation 62, an algorithm may be driven to compare the measured temperature change amount with the threshold value to determine whether the temperature change amount exceeds the temperature threshold value, and in operation 63, a process may be performed to confirm cases where the temperature change amount is below the threshold value. In this way, in operations 62 and 63, the control device (100) can compare the temperature change amount with the threshold value to detect in real time whether the temperature change may affect the stable operation of the system, and this information can play an important role in determining whether to further adjust the compensation parameters in the future.

[0504] In one embodiment, in operation 64, if the temperature change exceeds the temperature threshold value, the control device (100) may additionally compensate the temperature compensation parameter. For example, at this time, if the control device (100) receives a determination result that the temperature change exceeds the threshold value in operation 62, the control device (100) may execute a compensation algorithm that applies a compensation coefficient or an additional offset value to the previously calculated temperature compensation parameter H_i(t) in order to compensate for additional errors due to changes in the mechanical characteristics of the joint part or changes in the viscosity of the lubricant due to temperature change. For example, if the temperature change exceeds the threshold value, the control device (100) may additionally calculate a linear or nonlinear compensation equation for the temperature compensation parameter applied to the corresponding joint part, and update the compensation parameter so that the error due to the temperature change can be more significantly reflected, thereby effectively offsetting minute errors due to dynamic temperature changes that occur in extreme temperature environments. In operation 64, this additional compensation process is performed automatically, so that the control device (100) can readjust the compensation parameters in real time to maximize the operational stability of the collaborative robot even in situations where temperature changes are very large, and such compensation can have a positive effect on the overall performance and repeatability of the system.

[0505] In one embodiment, in operation 65, the control device (100) may maintain the temperature compensation parameter if the temperature change amount is less than or equal to the temperature threshold value. For example, if the control device (100) determines that the temperature change amount is less than or equal to the temperature threshold value, the control device (100) may perform a step of maintaining the previously calculated temperature compensation parameter as is. In this case, if the temperature change amount is less than or equal to the threshold value, it may be determined that the temperature change at the corresponding joint (110) has a relatively small impact on the operation of the collaborative robot, and thus it may be determined that no additional compensation is necessary. Based on this determination result, the control device (100) may maintain the compensation parameter, thereby preventing overshooting or excessive control commands due to unnecessary compensation, and ensuring the stability of the temperature compensation parameter. That is, in operation 65, if the temperature change amount is less than or equal to the threshold value, the control device (100) may maintain the calculated compensation parameter as is without readjustment, thereby minimizing the operational instability of the system and maintaining the effectiveness of the temperature compensation algorithm at a constant level.

[0506] In this way, steps from operation 61 to operation 65 include a series of processes in which the control device (100) receives real-time temperature data from the temperature sensor (160), accurately measures the temperature change, compares this change with a preset temperature threshold, evaluates the impact of the temperature change on the system operation, and additionally corrects or maintains the temperature compensation parameter based on the result. When the temperature change exceeds the threshold, the control device (100) can update the correction parameter by applying a correction coefficient to the existing temperature compensation parameter in order to offset additional errors that may occur in the joint (110), and when the temperature change is below the threshold, the existing correction parameter can be maintained as is to prevent unnecessary fluctuations in the control command. This process of additionally correcting or maintaining the temperature compensation parameter plays an important role in the motion calibration of the collaborative robot (100) and can contribute to maximizing the repeatability and stability of the collaborative robot even in extreme temperature environments. As a result, this operation process can effectively reflect the dynamic characteristics of the system according to temperature changes through real-time communication and control algorithms between the temperature sensor (160), the control device (100), and the driving unit (170), and quickly transmit a correction command based thereon to the driving unit (170), thereby providing the effect of allowing the motion calibration of the entire collaborative robot (100) to be maintained at a high level even under extreme temperature conditions.

[0507] Meanwhile, the control device (100) can measure the temperature in real time through a temperature sensor and calculate the thermal compensation parameter in real time through the following equation 1.

[0508] [Formula 1]

[0509]

[0510] Here, Hi(t) is a temperature compensation parameter, Ti(t) is the actual temperature measured at time t, Tref is the reference temperature during normal operation of the collaborative robot, Ai is the initial offset applied at the reference temperature at joint i, Bi is a linear coefficient reflecting the difference between the actual temperature and the reference temperature, and Ci is a nonlinear coefficient reflecting the difference between the actual temperature and the reference temperature.

[0511] According to the present embodiment, the control device (100) can utilize real-time temperature data of each joint part (110) measured through a temperature sensor to calculate a thermal compensation parameter Hi(t) based on the following equation 1. Here, the control device (100) analyzes the difference between the actual temperature Ti(t) collected from the temperature sensor corresponding to joint i and the reference temperature Tref during normal operation of the collaborative robot, and can calculate a temperature compensation value for each joint by applying an offset coefficient Ai, a linear coefficient Bi, and a nonlinear coefficient Ci set to correspond to the initial state or component characteristics of joint i. This calculation process is to quantify various temperature-influencing factors such as mechanical expansion and lubricant viscosity changes that occur in extreme temperatures (-10°C°C range), and to minimize errors during actual joint operation.

[0512] In this embodiment, the control device (100) periodically acquires temperature data from the temperature sensor installed in each joint part (110), and at the same time compares the difference with the correction value calculated at the previous point in time, and if it is within a specific reference range, the correction coefficient by Equation 1 is maintained as it is, and if a sudden temperature change that goes beyond the reference range is detected, additional correction can be performed. For example, if Ti(t) becomes significantly higher than Tref in a high temperature environment, Ci X (Ti(t)-Tref) 2Since the term has a large value, it can be set to compensate for the error occurring at joint i to a greater extent. Conversely, even in a low-temperature environment where Ti(t) is much lower than the reference temperature, the linear term (Ti(t)-Tref) and nonlinear terms can compensate for the operating deviation due to the operating load of the joint or the increase in lubricant viscosity.

[0513] Such a thermal compensation parameter Hi(t) can be linked to the backlash compensation algorithm of the control device (100) and can act as a comprehensive correction value to maintain the repeatability precision of each joint. The control device (100) can fine-tune the motor driving torque or position command by reflecting Hi(t) calculated from each joint based on Equation 1 in the final control command, thereby supporting the collaborative robot (100) to operate stably regardless of changes in the working environment temperature. Consequently, the present embodiment can effectively solve the problem of precision deterioration that may occur when operating a collaborative robot in an industrial site with severe temperature changes or in a refrigerated / high-temperature warehouse, and can contribute to improving the quality of calibration of each joint.

[0514] Figure 42 is a flowchart illustrating a method for correcting backlash compensation parameters of a collaborative robot according to an example of the present invention.

[0515] Referring to FIG. 42, in one embodiment, at operation 71, the control device (100) can measure the position error of the joint part in real time through an encoder. For example, at this time, the encoder can include a high-resolution sensor to precisely detect the rotation angle, movement distance, etc. of each joint part (110), and can be directly connected to a mechanical element such as a gearbox or a reducer to measure the actual operating state in millisecond units. Based on the encoder measurement value, the control device (100) can calculate the difference between the actual position and the target position and define this as a “position error amount”, and the position error amount can be interpreted as a value that quantifies how accurately the joint part (110) has reached the target trajectory or position. For example, if the target rotation angle is 30 degrees and the actual measurement value is 29.8 degrees, the position error amount is approximately 0.2 degrees, which can be an indicator reflecting a minute error that may occur in the joint part (110) due to backlash, inertia, or external load changes. In operation 71, the control device (100) continuously receives position data from the encoder and calculates the position error amount of the joint part (110) in real time, thereby securing information necessary for backlash correction or dynamic compensation algorithm to be performed in a future step.

[0516] In one embodiment, in operations 72 and 73, the control device (100) may compare the position error amount with the driving threshold value. For example, the driving threshold value is a reference value that defines the normal operating range of the joint part (110), and may be a numerical value that indicates the extent of minute errors that are allowed or the error amount that is required to maintain system stability. The control device (100) may collect position data at regular intervals (e.g., in units of several milliseconds to several tens of milliseconds) to determine in real time whether the position error amount exceeds the driving threshold value, and may calculate a more reliable error amount by accumulating, averaging, and filtering the data. For example, if the driving threshold value is 0.2 degrees and the position error amount is 0.25 degrees, this means that the joint part (110) is performing a movement outside the expected range, and thus, it may be considered a situation in which additional backlash compensation is required. On the other hand, if the position error is less than 0.1 degree, this means that it is still within a stable range below the driving threshold, and it can be determined that the precision of the collaborative robot movement can be maintained without significantly changing the compensation parameters. In operation 72, it is first determined whether the position error exceeds the threshold value, and in operation 73, it is confirmed whether it is less than the threshold value, so that the control device (100) can drive the logic so that different compensation strategies can be adopted for each case.

[0517] In one embodiment, in operation 74, the control device (100) may additionally correct the backlash compensation parameter if the position error exceeds the driving threshold value. For example, if the control device (100) determines that the position error exceeds the driving threshold value, the control device (100) may perform a step of additionally correcting the previously calculated backlash compensation parameter. Backlash occurring in the joint (110) may be caused by various factors such as clearance between gears or reducers, wear due to long-term use, tolerances in the assembly process, etc., which may ultimately cause an error between the target position and the actual position. If the position error exceeds the threshold value, the control device (100) may determine that simply retransmitting the position command is not sufficient, and may select a method of recalculating the backlash compensation parameter or applying an additional offset value. For example, if the backlash compensation parameter was previously a value to offset a play of 0.02 mm, considering that the error amount is larger, the algorithm can be updated by adjusting it upward to 0.03 mm, or by applying differential compensation for each joint speed or acceleration section. This additional compensation can prevent the accumulation of micro-errors due to backlash even when the collaborative robot performs high-speed repetitive motions by considering not only static compensation but also dynamic compensation elements. In addition, the control device (100) can simultaneously refer to the temperature data collected from the temperature sensor (160) and comprehensively readjust the compensation parameters considering the possibility of backlash being different in high and low temperature situations. In operation 74, through this additional compensation process, the system can be quickly stabilized so that the position error exceeding the driving threshold no longer occurs.

[0518] In one embodiment, in operation 75, the control device (100) may maintain the backlash compensation parameter if the position error is less than or equal to the driving threshold value. For example, this may be due to the determination that the joint part (110) is moving within a normal operating range and therefore does not require additional compensation, thereby preventing unnecessary algorithm updates or overshooting. For example, if the joint part (110) is already stably maintaining an error of less than or equal to 0.05 mm from the target position, this means that the collaborative robot is securing the desired trajectory and precision without requiring a separate compensation parameter change. Therefore, the control device (100) may maintain the current compensation parameter while only monitoring the state where the error is less than or equal to the threshold value. The compensation parameter maintained in this way is applied in the same manner until the position error increases again due to temperature fluctuations, load changes, etc., thereby ensuring stable operation of the collaborative robot. In operation 75, through this judgment process, the system can provide the advantage of increasing work efficiency without consuming unnecessary computational resources or communication delays.

[0519] In this way, steps from operation 71 to operation 75 include a process in which the control device (100) analyzes real-time errors based on position data collected from the encoder, compares them with the driving threshold value, and additionally adjusts or maintains the backlash compensation parameter. This immediately detects minute errors or wear occurring during the repetitive operation of the collaborative robot, and, if necessary, upwardly adjusts the backlash compensation value. If the error is not severe, the current state is maintained, thereby maintaining the stability and efficiency of the system in a balanced manner. In addition, these steps may be linked to a temperature compensation algorithm, and may operate with extended logic that responds to the physical characteristics of the joint part (110) that change in an extreme temperature environment and allows the backlash compensation algorithm to take temperature changes into account as well. Consequently, the collaborative robot system according to the present invention can precisely monitor the positional error of each joint part and adjust or maintain the compensation parameter in real time depending on whether the threshold value is exceeded, thereby ensuring a collaborative robot operation with a high level of precision and stability.

[0520] Meanwhile, the control device (100) can measure the positions of the plurality of joints in real time through an encoder and calculate backlash compensation parameters in real time through Equation 2 below.

[0521] [Formula 2]

[0522]

[0523] Here, Bi(t) is a backlash compensation parameter, BLi(t) is the actual backlash value measured at time t, Bref is the initial backlash value of the joint, Ai is the initial offset at joint i, Xi is a linear coefficient reflecting the difference between the actual backlash and the initial backlash, and Yi is a nonlinear coefficient reflecting the difference between the actual backlash and the reference backlash.

[0524] According to the present embodiment, the control device (100) can periodically measure the actual position of the joint part (110) through an encoder, and calculate the backlash compensation parameter Bi(t) presented in Equation 2 below in real time based on the measured data. At this time, the backlash value BLi(t) of joint i means the actual backlash measured at time t, and the play between the gears or reducers constituting the joint may vary due to various causes such as wear, impact, temperature change, etc. On the other hand, Bref is a reference backlash value confirmed at the beginning of manufacturing or through a separate calibration, and can represent the play size expected during normal operation at joint i. The control device (100) can precisely reflect the influence of the play on the actual operation according to the mechanical characteristics of each joint by applying the linear coefficient Xi and the nonlinear coefficient Yi, respectively, based on the difference between these two values, i.e., (BLi(t)-Bref)). Additionally, Ai is a value used as an initial offset at joint i, and can be used as a basic constant to offset the minimum play resulting from the assembly tolerance of the joint or the installation environment.

[0525] In this embodiment, the control device (100) can directly reflect the backlash compensation parameter Bi(t) calculated using Equation 2 into the joint drive command, thereby reducing the spinning section or rotational non-responsive phenomenon that occurs when the joint part (110) moves to the target position. In particular, in a situation where high-speed repetitive motion is required, there is a concern that the backlash may accumulate and the error may increase. Therefore, the control device (100) can minimize the influence of the play on the work accuracy by applying a large compensation term according to Xi and Yi when (BLi(t)-Bref)) increases beyond a certain range based on real-time encoder data. For example, if gear wear accumulates during the repetitive motion process and BLi(t) increases, the control device (100) can apply the nonlinear term Yi X (BLi(t)-Bref) 2By expanding the error compensation amount through this, the play that has increased significantly compared to the existing one can also be appropriately offset. In this way, Equation 2 can dynamically reflect the complex backlash changes according to the usage environment or the passage of time, which are difficult to cover with simple linear compensation alone, and the control device (100) can thereby maintain the repeatability of the joint part (110) even in extreme temperature environments or when used for a long time. Consequently, this embodiment can provide the advantage of reducing maintenance costs and increasing system expandability by resolving the error due to backlash through software compensation without drastically changing the mechanical structure.

[0526] Figure 43 is a block diagram illustrating a detailed configuration of a complex process execution system according to an example of the present invention. Figure 44 is an exemplary diagram illustrating a collaborative robot according to an example of the present invention. Figure 45 is an exemplary diagram illustrating a system according to an example of the present invention.

[0527] Referring to FIGS. 43 to 45, a complex process performing system (10) according to the present disclosure performs a complex process using multi-axis real-time motion synchronization control of a collaborative robot (100), and may include a collaborative robot (100), a control unit (200), and an additional axis device (300).

[0528] In one embodiment, as illustrated in FIG. 44, the collaborative robot (100) may include a plurality of joints (110), a robot arm (120), a base (130), a gripper (140), an encoder (150), a current sensor (160), a temperature sensor (170), and a driving unit (180).

[0529] For example, a collaborative robot (100) may be configured to have multiple joints (110) to form multiple axes of rotation, and each joint (110) may be mechanically and firmly connected to a robot arm (120) so that the robot arm (120) may move freely along multiple axes of rotation. This configuration may enable the robot arm (120) to secure a high degree of freedom in various work environments, and may support precise access to and manipulation of a workpiece (1) when performing a complex process. For example, a collaborative robot (100) may be applied to an automobile parts assembly process in a production line, and each joint (110) may receive position and angle information in real time through a sensor such as a high-resolution encoder (150), so that the robot arm (120) may implement finely tuned movements.

[0530] In addition, the robot arm (120) can perform linear or rotational motion in a complex manner depending on the kinematic structure combined with the joint part (110), thereby enabling the path for approaching the workpiece (1) to be optimized in various angles. For example, the robot arm (120) can be simultaneously extended or contracted in the horizontal and vertical directions, thereby enabling it to operate effectively even in a narrow space to stably pick up or place the workpiece (1). This function can serve as a core technology that allows the robot arm (120) to be utilized in various fields, such as automated assembly lines, logistics warehouses, or surgical support systems in the medical field.

[0531] Furthermore, the collaborative robot (100) can apply an advanced control algorithm and an integrated sensor network to minimize motion errors that may occur in multiple rotation axes based on the continuous and flexible movement of the robot arm (120) installed between each joint part (110). The control unit (200) can collect such sensor data in real time to correct the movement of the robot arm (120) and generate precise control commands to maintain a constant relative positional relationship with the workpiece (1). For example, even in a situation where the collaborative robot (100) moves at high speed, the movements of each joint part (110) and the robot arm (120) are consistently maintained, so that access to the workpiece (1) can be stably achieved, and this can greatly improve the efficiency and safety of the entire process.

[0532] In addition, the collaborative robot (100) of the present invention is designed to be applicable to various work environments, so that it can flexibly respond even in dynamic situations where the workpiece (1) moves or its position changes, and can immediately respond to minute changes in position or angle of the workpiece (1) through the multi-axis movement of the robot arm (120). For example, the collaborative robot (100) can be applied to the task of precisely picking up and placing very small-sized parts at a specific position in an electronic component assembly process, and at this time, the rotation and extension movements of the robot arm (120) can be finely adjusted to minimize gaps or errors between parts.

[0533] In one embodiment, the base (130) positioned at the lowest end of the collaborative robot (100) can be designed to firmly fix the entire robot structure, thereby ensuring the stability of the entire robot from vibrations or external impacts that may occur within the work environment. The base (130) can be made of a strong material, such as a high-strength metal or composite material, and can perform a support function so that the robot can precisely maintain its position without micro-vibrations or shaking caused by external impacts even when handling heavy loads or moving at high speeds. For example, in an automobile assembly line or an aerospace parts production process, the base (130) can ensure stable posture control even under conditions of heavy materials and high-speed movement, thereby improving the reliability of the production process.

[0534] In one embodiment, the robot arm (120) may be configured to be positioned between a plurality of joints (110) and expand or contract by effectively receiving the rotational motion of each joint (110), thereby playing an important role in precisely adjusting the distance to the workpiece (1) and enabling manipulation at various angles and positions within the workspace. The robot arm (120) may be designed to have a built-in precision gear mechanism and a high-resolution sensor to enable fine position adjustment and speed control, and may significantly improve work efficiency and quality by optimizing the path and angle of approach to the workpiece (1) in applications such as electronic component assembly, medical surgical assistance, or precision welding. In addition, the robot arm (120) supports various operation modes through its connection structure with the joints (110), and may stably handle the workpiece (1) by maintaining precise linkage between the joints even while moving along a complex path.

[0535] In one embodiment, the gripper (140) may be installed at the end of the robot arm (120) and configured to directly grasp or place a workpiece (1), and may adopt a multi-functional gripper structure to efficiently handle objects of various shapes and sizes. The gripper (140) may apply various drive methods such as pneumatic, electric, and hydraulic, and each drive method may be designed to simultaneously satisfy the clamping force applied to the workpiece (1) and precise control. For example, an electric gripper can be finely adjusted through electronic control, a hydraulic gripper can provide strong pressure to be suitable for handling large parts, and a pneumatic gripper can advantageously operate in high-speed operations of a production line due to its fast response speed. In addition, the gripper (140) may be equipped with a replaceable tip or extension module to apply various clamping methods according to the characteristics of the workpiece (1), which may greatly improve the flexibility and efficiency of the production process.

[0536] In this way, the base (130), robot arm (120), and gripper (140) of the collaborative robot (100) can perform complementary roles to support the entire system to accurately and safely handle complex work objects (1), and each component can be applied with optimized materials, mechanical design, and sensor technology to ensure stable operation even in high-speed and high-precision work environments. This integrated system can be applied in various industrial fields such as manufacturing, logistics, medical, and others, to significantly improve work quality and productivity when performing complex processes, and to ensure the stability and reliability of the entire process.

[0537] In one embodiment, the encoder (150) may be configured as a key element that precisely measures the rotational angle or position of each joint part (110) and detects the movement state of the collaborative robot (100) in real time and transmits it to the control part (200). For example, the encoder (150) may convert the rotational movement of each joint part (110) into a digital signal, thereby enabling the control part (200) to precisely determine the angle and position of the robot arm (120). Such measurement data may be utilized as essential input values ​​for setting a work path, synchronization control, PID control, and real-time compensation algorithms, thereby maximizing the precision and reliability of the entire system.

[0538] In addition, the encoder (150) is designed to have high resolution, so that even minute position changes or angle differences can be accurately detected, and thus even minute errors between each joint (110) of the collaborative robot (100) can be detected and corrected in real time. For example, even minute angle changes that occur when the robot arm (120) rotates at a high speed or approaches a workpiece (1) can be detected through precise measurement by the encoder (150), so that the control unit (200) can immediately output a correction command. In this way, the encoder (150) can be implemented in an incremental or absolute manner, and each manner can be selectively applied depending on a specific application or work environment.

[0539] Furthermore, the encoder (150) can provide a real-time data stream through communication with the robot arm (120) and each joint (110), thereby enabling the control unit (200) to accurately grasp the movement status of the entire system and derive optimal control commands accordingly. For example, the real-time trajectory of the collaborative robot (100) can be predicted based on data generated from the sensor, and a correction value for synchronization with the additional axis device (300) can be calculated, thereby preventing the accumulation of minute errors that may occur during operation.

[0540] In addition, the encoder (150) can be installed in combination with a high-precision gear mechanism, and this structure can be designed to minimize measurement errors caused by external shocks or vibrations, and to provide stable position data through a continuous correction process. For example, even when the collaborative robot (100) moves at high speed, the encoder (150) can transmit accurate position information of each joint (110) in real time, thereby supporting the stable and precise operation of the entire system.

[0541] As a result, the encoder (150) plays a key role within a control system integrated with a collaborative robot (100) and an additional axis device (300), and by providing real-time position and angle information, it can improve the precision of work path setting, synchronization control, and compensation algorithms, thereby significantly increasing the stability and reliability of the entire system.

[0542] In one embodiment, the current sensor (160) may be designed to monitor in real time the current consumed when the driving unit (180) drives each joint unit (110), thereby optimizing the energy efficiency of the system. The current sensor (160) precisely detects changes in the electrical load of the servo motor and reducer connected to each joint unit (110), thereby providing real-time data to the control unit (200), thereby enabling analysis of the power consumption pattern of the entire system.

[0543] For example, when a collaborative robot (100) moves at high speed, the current sensor (160) can detect a sudden increase in current and transmit the point where an overload occurs to the control unit (200) in real time, thereby enabling an immediate safety control command to be issued. In addition, the current sensor (160) can apply high-sensitivity sensor technology to detect even a minute change in the electrical load, and through this, the operating status of the driving unit (180) can be precisely determined, which can be utilized as data for optimizing power consumption and improving energy efficiency. The current sensor (160) can quickly detect, for example, a short circuit or overload situation when an abnormal current occurs during the operation of the driving unit (180), and transmit an immediate safety control signal to the control unit (200), thereby ensuring that the entire system can quickly respond to an emergency situation.

[0544] In this way, the current sensor (160) can be configured to determine whether the driving unit (180) is operating normally through electrical load detection, analyze energy consumption patterns according to the external environment or working conditions, reduce unnecessary energy loss during the process, and control optimal operating conditions in real time in terms of power management. Consequently, the current sensor (160) can serve as a key technology that can increase the operational reliability of the collaborative robot (100) and the additional axis device (300) and simultaneously maximize the safe operation and energy efficiency of the system.

[0545] In one embodiment, the temperature sensor (170) can precisely detect the heating status of the driving unit (180) or each joint unit (110), measure the temperature data in real time, and transmit it to the control unit (200), thereby ensuring the safe operation of the system and the reliability of the equipment. The temperature sensor (170) can apply high-sensitivity sensor technology to detect even a slight temperature increase that occurs during operation of major components such as the servo motor or reducer of the driving unit (180), thereby detecting unexpected overheating situations or abnormal signs of components at an early stage, and can perform safety control functions such as generating a warning signal to the control unit (200) or automatically stopping operation.

[0546] For example, if the temperature of the driving unit (180) exceeds a preset reference value due to heat generation during high-load work or high-speed movement of the collaborative robot (100), the temperature sensor (170) detects this in real time and transmits abnormal temperature information to the control unit (200), so that the system can be switched to emergency stop mode or the operating speed can be automatically reduced to prevent damage to the equipment.

[0547] In addition, the temperature sensor (170) monitors the heat generation status of each joint part (110), thereby preventing mechanical deformation or performance degradation due to overheating of the drive mechanism or gear part built into the joint part (110) in advance, thereby supporting the maintenance of the overall precision and work quality of the collaborative robot (100). In addition, the temperature sensor (170) records the measured temperature data, thereby analyzing changes in the thermal pattern and operating environment over a long period of time, which can be utilized to optimize the maintenance cycle and predict the timing of component replacement.

[0548] For example, when a temperature sensor (170) detects a repetitive high temperature state, the control unit (200) can analyze this to identify the aging trend of the component and issue a warning in advance or establish an automatic maintenance plan, thereby extending the life of the equipment and preventing unexpected failures. In addition, the temperature sensor (170) reacts sensitively to temperature changes due to changes in the external environment or working conditions, and can provide stable data even when the working environment changes rapidly, and such information can play an important role in energy efficiency management and safe operation of the entire system. Consequently, the temperature sensor (170) can quickly detect temperature abnormalities that occur during the operation of the collaborative robot (100) and the auxiliary axis device (300), and based on this, support the control unit (200) to take appropriate safety measures, thereby acting as a key component that can significantly improve the overall safety and reliability of the system.

[0549] In one embodiment, the driving unit (180) may be configured with a servo motor and a reducer to precisely drive each joint (110) of the collaborative robot (100), and this configuration may serve to provide the necessary power so that each joint (110) can move stably and precisely along a required motion path. The driving unit (180) may be designed by integrating the latest electronic control technology and a high-performance motor driver so that the position and angle of the joint (110) can be finely controlled even during high-speed operation, and as a result, the manipulation accuracy for the workpiece (1) and the productivity of the work process can be greatly improved.

[0550] For example, the driving unit (180) can process minute electrical signals generated when each servo motor operates individually at high speed and control them in real time in conjunction with a reducer, thereby enabling smooth acceleration and deceleration even during high-speed movement. In addition, the driving unit (180) can be designed to minimize performance degradation due to mechanical wear or heat generation even during long-term continuous operation or under heavy loads by adopting a high-precision gear mechanism and highly durable materials, thereby ensuring the reliability and safety of the entire system.

[0551] In addition, the driving unit (180) can be configured to continuously monitor the operating status of each joint unit (110) through real-time communication with the control unit (200) and perform immediate correction when necessary, which can effectively offset external disturbances or internal errors that may occur during the work process, thereby supporting the collaborative robot (100) to move accurately along the predicted path. In addition, the driving unit (180) can be applied with a control algorithm that optimizes the rotation speed and torque of the servo motor, the gear ratio and efficiency of the reducer, so that the entire system can maintain stable and smooth movement performance even in a high-speed operation environment, and such performance improvement can play an important role in complex palletizing work or precise assembly processes.

[0552] As a result, the driving unit (180) can accurately implement the motion path required by each joint (110) of the collaborative robot (100) through a combination of the latest electronic control technology, high-performance motor drivers, and highly durable mechanical components, and can serve as a key element that can significantly improve the efficiency and safety of the entire process by enabling stable and precise position control even under high-speed and high-load conditions.

[0553] In addition, each component linked to the collaborative robot (100) can operate complementarily to each other, thereby helping to efficiently handle the workpiece (1) and significantly improving the overall productivity and stability of the complex process performance system. For example, the precise position information provided by the encoder (150) can be combined with the status information monitored by the current sensor (160) and the temperature sensor (170), thereby contributing to the stable driving of the driving unit (180) to each joint unit (110), which can play a crucial role in the synchronization and precise control of the entire system.

[0554] In one embodiment, as illustrated in FIG. 45, an additional axis device (300) is coupled to the collaborative robot (100) and may provide an additional axis different from a plurality of axes corresponding to the plurality of joints (110), and the additional axis device (300) may include a lift (310) for vertically moving the collaborative robot (100), a rail (320) for horizontally moving the collaborative robot (100), and a positioner (330) for moving a workpiece (1) of the collaborative robot (100). The additional axis device (300) may increase the flexibility of the entire system, thereby supporting maximizing accessibility to the workpiece (1) and work precision when performing a complex process.

[0555] In one embodiment, the lift (310) may serve to vertically move the collaborative robot (100) within the auxiliary axis device (300). The lift (310) may be designed to adjust the height of the collaborative robot (100) to enable the robot to perform work at a high or low position, and to effectively overcome the height difference between the position where the workpiece (1) is placed and the working range of the robot. For example, the lift (310) may precisely adjust the vertical position of the collaborative robot (100) using an electric or hydraulic actuator, thereby assisting the robot to work stably in high loads or complex assembly processes. The lift (310) may also communicate with the control unit (200) to receive real-time feedback and perform fine position corrections according to synchronized control commands, thereby ensuring that the vertical movement motion of the entire system is maintained within a certain error range.

[0556] In one embodiment, the rail (320) may perform a function of moving the collaborative robot (100) horizontally within the auxiliary axis device (300). The rail (320) is installed on a fixed structure such as a factory floor or ceiling, and supports the collaborative robot (100) to be smoothly moved left and right or forward and backward, and may enable the robot to move efficiently even when the workpiece (1) is distributed in multiple locations. The rail (320) is manufactured with a structure including a linear guide and a precision bearing, so as to minimize vibration or unnecessary shaking that may occur during movement, and increase the position control accuracy of the collaborative robot (100). In addition, the rail (320) exchanges data with the control unit (200) in real time, and can enable smooth and stable position changes of the robot during the work process through a synchronization command that adjusts the movement speed and acceleration.

[0557] In one embodiment, the positioner (330) can perform the function of rotating or tilting the workpiece (1) of the collaborative robot (100) within the additional axis device (300). The positioner (330) can provide an optimal working environment in a complex assembly, inspection, or processing process by changing the posture of the workpiece (1), and can maximize work efficiency by exposing a specific surface or angle of the workpiece. The positioner (330) includes a multi-axis rotation mechanism, and can rotate or tilt the workpiece (1) at various angles. In this process, the control unit (200) can adjust control parameters such as the rotation angle, speed, and acceleration in real time to support the workpiece (1) to accurately maintain the desired posture. The positioner (330) can also be designed to respond to workpieces (1) of various shapes by applying a correction factor that can be set differently depending on the weight, size, shape, etc. of the workpiece.

[0558] The auxiliary axis device (300) configured in this way can be combined with the collaborative robot (100) to enable additional operations such as vertical and horizontal movement and rotation or tilting of the workpiece (1) that the collaborative robot (100) has difficulty performing alone, and can greatly expand the working range of the entire system when performing a complex process. The auxiliary axis device (300) receives in real time the operating status of the collaborative robot (100) and the positional information of the workpiece (1) through communication with the control unit (200), and based on this, receives control commands so that each auxiliary component, such as the lift (310), the rail (320), and the positioner (330), can operate in precise synchronization, so that the entire system can operate organically as a single integrated operating system.

[0559] In addition, the additional axis device (300) can be designed to have a structure that can expand the range of motion of the collaborative robot (100), enable the workpiece (1) to be handled at various angles and positions, and significantly improve the flexibility and productivity of process execution. The additional axis device (300) can overcome the limitations of the operation of the existing collaborative robot (100) alone by having each of the lift (310), the rail (320), and the positioner (330) operate through individually optimized control modules, and can support efficient performance of high-speed, high-precision tasks required in various industrial fields such as complex assembly, inspection, processing, and palletizing processes.

[0560] The additional axis device (300) of the present invention can apply various types of additional axes in addition to the lift (310), rail (320), and positioner (330), and these can be flexibly changed according to the characteristics of the work process and on-site requirements. For example, the additional axis device (300) can include a telescopic arm to expand the work range of the collaborative robot (100) horizontally and vertically, while further improving accessibility to the work object. In addition, by applying a rotary module, the work object can be additionally rotated to precisely adjust the angle, thereby enabling the response to complex assembly processes or precise inspection tasks.

[0561] In addition, the additional axis device (300) can include modular additional axes such as an interchangeable gripper or a multi-tool attachment, so that various work tools can be quickly replaced and multiple processes can be performed within a single system. In addition, by integrating a vision sensor module or a LiDAR sensor into the additional axis device (300), a function can be added to recognize the surrounding environment in real time, more precisely determine the position or shape of the workpiece, and reflect it in synchronization control.

[0562] Additionally, additional axes specialized for specific processes, such as an automatic tool changer (ATC) or a spraying device, can be introduced, thereby further increasing the efficiency of process automation. In this way, the additional axle device (300) can be configured to include various additional axes in addition to the lift (310), rail (320), and positioner (330), thereby expanding the scope of application of the complex process performance system and providing an optimal working environment tailored to the requirements of each process.

[0563] In one embodiment, the control unit (200) can control each axis so that the plurality of axes and the auxiliary axes are synchronized in real time. For example, the control unit (200) is a core component for integrating and controlling the collaborative robot (100) and the auxiliary axis device (300) into a single system, and can control each axis so that the plurality of joints (110) and auxiliary axes (lift (310), rail (320), positioner (330), etc.) can perform tasks in real time by synchronizing. The control unit (200) can include a high-speed processor and continuously update the control commands of each axis in short cycles of 1 ms or less, thereby commanding all axes to form synchronized paths simultaneously. This control method can be configured to detect the difference between the current operation state and the target operation state of each axis in real time, and immediately transmit a correction command when such a difference occurs, thereby drastically reducing the synchronization error of the entire system.

[0564] In addition, the control unit (200) can precisely collect trajectory information generated from multiple joints (110) of the collaborative robot (100), and simultaneously analyze the operating status of the lift (310), rail (320), and positioner (330) of the additional axis device (300) in real time. Through this, the control unit (200) can plan the work sequence of the entire process in advance, calculate control parameters such as target position, speed, acceleration, and deceleration for each axis, and distribute control commands so that all axes can move organically in cooperation. In this process, an integrated control algorithm that considers not only the individual operation of each axis but also the interconnectivity of the entire system is applied, so that it can quickly respond to unexpected errors or disturbances that may occur during the process.

[0565] The control unit (200) can also continuously monitor and correct the synchronization status based on the sensor data transmitted from each joint unit (110) and the additional axis device (300) through a real-time feedback loop. For example, the control unit (200) can comprehensively analyze position data obtained from the encoder (150) and various sensor information such as the current sensor (160) and the temperature sensor (170) to minimize the difference between the command transmitted from the driving unit (180) and the actual operation, and apply various control techniques such as PID control. In this way, the control unit (200) can efficiently manage control commands for multiple axes in real time and maintain the entire system to operate stably and precisely, which can provide the effect of significantly improving work efficiency and quality when performing a complex process.

[0566] The collaborative robot (100) illustrated in Fig. 44 has a plurality of joint parts (110) and a robot arm (120) axially connected to cover various work spaces, and the base part (130) can be coupled to the ground or a fixed device to support the robot arm (120) so that it can move without shaking. The gripper (140) performs the function of holding and placing a work object (1), and the encoder (150), current sensor (160), and temperature sensor (170) can measure the operating status of the collaborative robot (100) and transmit it to the control part (200). The driving part (180) is composed of a servo motor and a reducer, and can support each joint part (110) to accurately implement the required motion.

[0567] The auxiliary axis device (300) illustrated in FIG. 45 includes a lift (310), a rail (320), a positioner (330), etc., and each can actively change the installation position of the collaborative robot (100) or the posture of the workpiece (1). The lift (310) can adjust the height of the collaborative robot (100), thereby helping the multiple joints (110) to perform work even in difficult-to-access locations, and the rail (320) can move the collaborative robot (100) left and right to cover a wide work area, thereby enabling automated work to be performed at multiple locations within the factory. The positioner (330) can rotate or tilt the workpiece (1) at a certain angle, thereby facilitating processes such as welding, coating, and inspection.

[0568] Ultimately, the control unit (200) can accurately and quickly perform a complex process on the workpiece (1) by synchronously controlling all axes of the collaborative robot (100) and the auxiliary axis device (300). In particular, even if multiple joints (110) rotate at different angles and the lift (310), rail (320), and positioner (330) operate simultaneously, the control unit (200) can compensate to minimize errors based on the target position of each axis and real-time feedback. Such synchronous control can provide great advantages in shortening the process time, improving work precision, and ensuring the stability of the entire system.

[0569] Figure 46 is a flowchart illustrating a method for performing a composite process according to an example of the present invention.

[0570] Referring to FIG. 46, in one embodiment, in operation 21, the control unit (200) can set a work path of the collaborative robot (100). For example, the control unit (200) can apply various algorithms and techniques to set the entire work path that the collaborative robot (100) should perform. The control unit (200) can comprehensively analyze the kinematic characteristics of the robot arm (120) and the gripper (140) based on the position, rotation angle, and other kinematic information collected in real time from the plurality of joints (110) of the collaborative robot (100).

[0571] Based on the analysis results, the control unit (200) can calculate a straight, curved, or complex path by considering obstacle information around the work object (1), constraints of the work environment, and collision risks that may occur when the robot moves. At this time, the control unit (200) precisely calculates the coordinate points that each joint (110) must reach, and determines the optimal distribution of acceleration and deceleration for each section of the work path, thereby setting the path so that errors due to inertia and the risk of collision can be minimized even when the collaborative robot (100) moves at high speed. Since the control unit (200) can dynamically update this work path setting by combining pre-stored process data and real-time sensor feedback, a stable work path can be secured even in a complex work environment.

[0572] In one embodiment, in operation 22, the control unit (200) can set control parameters of the plurality of joint units (110) and the additional axis device (300) so that the plurality of joint units (110) and the additional axis device (300) are synchronized in real time.

[0573] For example, the control unit (200) can precisely calculate control parameters to be applied to each axis so that each axis of the collaborative robot (100) and the auxiliary axis device (300) are synchronized in real time. At this time, the control parameters can include various elements such as position, rotation angle, movement distance, torque, speed, acceleration, and deceleration, and can be set individually or collectively according to the characteristics of each axis and the working environment. The control unit (200) can calculate the error between the current state and the target state of each joint unit (110) and the auxiliary axis (300) by utilizing real-time feedback information received from a position sensor such as an encoder (150) and an environmental sensor such as a current sensor (160) and a temperature sensor (170).

[0574] Based on this, the control unit (200) can set the corrected control parameters so that each axis can ultimately reach the same working point even if it has different initial operating conditions or movement timings, and since this parameter correction process can be dynamically updated as the control unit (200) continuously monitors and analyzes real-time data, the synchronization state of the entire system can be constantly maintained.

[0575] In one embodiment, in operation 23, the control unit (200) can transmit a control command based on a control parameter to the collaborative robot (100) and the additional axis device (300). For example, the control unit (200) can generate a control command suitable for each joint part (110) and the components of the additional axis device (300) based on the calculated control parameter and transmit the same.

[0576] The control unit (200) can transmit command data regarding position information, speed, acceleration, and torque to each joint unit (110) through an integrated network or a dedicated communication bus, and at the same time, can transmit control commands to the lift (310), rail (320), positioner (330), etc. belonging to the additional axis device (300) according to the same principle.

[0577] At this time, the control command includes correction values ​​to minimize the difference between the operation target value of each axis and the current state, thereby enabling the driving unit (180) composed of a servo motor and a reducer to be precisely driven within a minute error range. The control unit (200) can immediately apply correction commands to minute errors or disturbances occurring in real time by repeatedly transmitting commands while maintaining a short control cycle of 1 millisecond or less, thereby allowing the synchronization state of the entire system to always be maintained at an optimal state.

[0578] In one embodiment, in operation 24, the collaborative robot (100) and the auxiliary axis device (300) can be driven in real time in synchronization. For example, the collaborative robot (100) and the auxiliary axis device (300) can be driven simultaneously in real time according to a synchronization control command received from the control unit (200).

[0579] Each joint part (110) of the collaborative robot (100) moves precisely according to the path and control parameters set by the control part (200), and the gripper (140) can approach the work object (1) through the robot arm (120) and perform the necessary operation. At the same time, the lift (310) belonging to the auxiliary axis device (300) can adjust the vertical position of the collaborative robot (100) to support the robot to work stably even in a high or low position, and the rail (320) can move the collaborative robot (100) left and right or forward and backward to maximize work efficiency in a wide work area.

[0580] In addition, the positioner (330) can change the posture of the workpiece (1) by rotating or tilting it, thereby providing an optimal working environment in complex assembly, inspection, and processing processes. By precisely adjusting the operation timing of each component in this way, the control unit (200) can detect and correct in real time any unexpected errors or disturbances that may occur during the work, thereby enabling the collaborative robot (100) and the auxiliary axis device (300) to stably perform high-speed, high-precision work in a perfectly synchronized state. This synchronization control can be particularly usefully applied in complex processes where the relative position between the robot arm (120) and the workpiece (1) is maintained constant during the process, or work is performed simultaneously at multiple work points, and can greatly improve the productivity and safety of the entire system.

[0581] Figure 47 is a flowchart illustrating a method for synchronizing a joint and an additional axis device according to an example of the present invention.

[0582] Referring to FIG. 47, in one embodiment, in operation 31, the control unit (200) can set the target position of the additional axis according to Equation 1 below.

[0583] [Formula 1]

[0584]

[0585] Here, Qad(t) is the target position of the additional axis, Qi(t) is the actual position of the six axes of the collaborative robot, a is a scaling constant for the average motion of the basic six axes, and b is the position compensation value (offset) of the additional axis.

[0586] For example, the control unit (200) can set the target position Qad(t) so that the additional axis (e.g., lift, rail, positioner, etc.) operates in harmony with the main motion trajectory of the collaborative robot (100). To this end, the control unit (200) can collect the positions Qi(t) measured from each of the six joints (110) of the robot in real time with reference to Equation 1, and calculate the target position of the additional axis by applying a scaling constant a and a position compensation value (offset) b to the result of averaging these position values.

[0587] For example, the control unit (200) can continuously monitor the motion trajectory of the joint unit (110) to derive an average value for Qi(t), multiply the average value by a, and then add an offset b to determine Qad(t). At this time, a is a coefficient indicating the ratio at which the additional axis should operate compared to the average motion range of the robot, and b can be applied when fine adjustment is required depending on the field environment or process characteristics. This setting can prevent problems such as collisions or overshoots from occurring during the complex process by preventing unnecessary gaps from occurring between the motion path of the collaborative robot (100) and the motion path of the additional axis device (300).

[0588] In addition, the control unit (200) can control the additional axis to respond in real time to the movement of the collaborative robot (100) by periodically recalculating Qad(t) by reflecting the position information of the robot joint (110) that is updated every moment.

[0589] For example, even if the robot joint part (110) moves at a faster speed than expected or a positional deviation occurs due to external factors, the control unit (200) can immediately recognize the error between the Qad(t) calculated through Equation 1 and the actual position Qa(t) of the auxiliary axis, and issue a correction command through various algorithms such as PID control. Through this, the auxiliary axis can maintain synchronized movement within a certain error range without excessively leading or lagging behind the main trajectory of the robot, and ultimately, an accurate and stable work environment can be implemented even in complex processes. Furthermore, since the scaling constant a and the offset b can be set differently depending on the shape or weight of the workpiece (1), process characteristics, etc., the control unit (200) can flexibly respond to various industrial sites by defining the corresponding values ​​in advance or adjusting them in real time.

[0590] Ultimately, the process of setting the target position of the additional axis by using Equation 1 by the control unit (200) in operation 31 can play an important role in reducing the risk of collision between multiple axes and maximizing process efficiency by precisely controlling the additional axis based on the average motion of the six joints (110) of the collaborative robot (100).

[0591] In one embodiment, in operation 32, the control unit (200) can calculate the control input function U(t) of the additional axis according to Equation 2 below based on the PID (proportional integral derivative) control method.

[0592] [Formula 2]

[0593] ,

[0594] Here, E(t) is the control error, Qad(t) ...

Claims

In a collaborative robot system operating in an industrial environment where workers collaborate, A collaborative robot body with a multi-joint structure, A control unit for controlling each joint or additional axis of the above collaborative robot, One or more sensors that detect the operating status of the collaborative robot in real time, A collaborative robot system characterized by including a status diagnosis and response module that diagnoses the status of the collaborative robot based on data received from the sensor and controls the operation of the collaborative robot according to the diagnosis result. In claim 1, The above condition diagnosis and response module, Analyze the status based on at least one piece of information from the speed, acceleration, torque, position, and temperature of the above collaborative robot, A collaborative robot system characterized in that it is configured to slow down or stop the robot's movement and perform a recovery operation based on the analysis results. In claim 1, The above control unit synchronizes the movements between the multi-joint and auxiliary axis devices of the collaborative robot in real time. A collaborative robot system characterized in that it is configured to automatically correct a trajectory according to a change in the position of a work target. In claim 1, The above collaborative robot system supports work linkage between multiple collaborative robots, A collaborative robot system characterized in that each collaborative robot is configured to share a work sequence and adjust its path to avoid collisions. In claim 1, The above collaborative robot system visually displays at least one of the robot's status, motion trajectory, and alarm information, A collaborative robot system characterized by including a graphical user interface through which a user can input work commands. In claim 5, The above graphical user interface is linked to a virtual space based on digital twins, A collaborative robot system characterized in that the user is configured to set or modify a work path based on virtual simulation results. In claim 1, The above collaborative robot system stores at least one of the robot's operation log, status change history, and work result record, A collaborative robot system characterized by including a function for performing autonomous learning or trajectory optimization based on the data. In claim 1, The above collaborative robot body includes a modular structure that can be combined or separated depending on the work environment or work purpose. A collaborative robot system characterized in that the control criteria are automatically updated according to changes in the coupling structure. In claim 1, The above collaborative robot system determines whether the workpiece is grasped or not, A collaborative robot system characterized by including a function to automatically retry or perform an alternative action when a phage fails. In claim 1, The above collaborative robot system communicates with an external control server or cloud control system, A collaborative robot system characterized by being configured to comprehensively manage the status information and work progress of each robot.

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