Actuator Head Unit for Low-Latency Workpiece Pickup Control
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Solution Overview
Problem
Conventional actuator systems for picking up workpieces face delays in control response due to communication network latency, leading to increased tact time and potential damage to workpieces when sensing and controlling position or pressure.
Innovation Solution
An actuator system with a head unit connected directly to sensors and the actuator, bypassing the communication network, allows for immediate control of the actuator based on sensing results from external force detection sensors, reducing the time lag in picking up and placing workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If control signals are transmitted over a communication network between the control device and the actuator, then the system architecture is simplified and centralized control is achieved, but the control response time increases and tact time is extended
Solution Approach 1:
The control system is segmented into two parts: a centralized control device that sends commands, and a local head unit that executes real-time control. The head unit is connected directly to the actuator and sensor without communication network latency, enabling fast local response while maintaining simplified centralized architecture for overall system management.
2Extent of automation
If control is performed by a PLC connected over a communication network, then centralized control management is achieved, but the time from sensing to control execution increases
Solution Approach 1:
The head unit is pre-configured with the capability to receive sensor inputs and generate control signals locally. When a pickup request is received from the PLC, the head unit immediately executes the pickup operation using locally available sensor data and actuator control, without waiting for PLC processing and communication cycles.
3Device complexity
If sensor data is transmitted to the control device over the communication network, then centralized data processing is achieved, but the real-time control capability is reduced
Solution Approach 1:
The head unit acts as an intermediary between the sensor and the actuator. It receives sensor data locally, processes it in real-time, and directly controls the actuator. The PLC communicates pickup requests to the head unit over the network, but the actual sensing and control loop operates locally at the head unit, eliminating communication latency from the critical control path.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces tact time and minimizes damage to workpieces by enabling swift and direct control of the actuator based on real-time sensor feedback, improving the efficiency of the workpiece handling process.
Implementation Method 1
an external force detection sensor that detects a physical quantity that is correlated with an external force that is applied to the workpiece
Data Source
AI summary
An actuator system that picks up workpieces aims to shorten tact time and to reduce damages to workpieces. The actuator system includes an actuator that picks up a workpiece, an external force detection sensor that detects a physical quantity that is correlated with an external force that is applied to the workpiece, a head unit that is connected to the actuator and the external force detection sensor without a communication network, the head unit being configured to control the actuator based on a sensing result from the external force detection sensor when a pickup request signal that is a signal requesting pickup of the workpiece is received, and a control device that is connected to the head unit over the communication network, the control device being configured to transmit the pickup request signal to the head unit.