Adaptive Drive Unit Control for Worker Posture Load on Production Lines
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Solution Overview
Problem
Workers on production lines collaborating with robots often become physically overloaded due to the need to match their movements with those of skilled workers, leading to exhaustion and reduced productivity.
Innovation Solution
A control device that monitors a worker's physical information, such as posture and movement variations, to determine if adjustments to the drive unit are needed, allowing for dynamic control based on the worker's load, using sensors and a control computer to accumulate and analyze data for optimal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the robot is controlled to match the worker's movement with reference data from skilled workers, then the working movement precision is improved, but the worker becomes physically overloaded and exhausted
Solution Approach 1:
The robot control system dynamically adjusts the amount of control based on real-time detection of worker physical state. The control amount is not fixed but varies according to the worker's current condition, transitioning from static reference-based control to dynamic adaptive control that responds to changing worker states.
Solution Approach 2:
The system implements feedback by detecting the worker's physical information (posture, movement variations) and using this feedback to adjust the robot's control amount. The detection unit continuously monitors worker state and feeds this information back to the control unit, creating a closed-loop system that adapts to worker conditions.
2Productivity
If the robot control amount is increased to maintain productivity, then the productivity is improved, but the worker becomes easily exhausted
Solution Approach 1:
The control amount is made dynamic rather than fixed, allowing the system to optimize productivity while adapting to worker physical conditions. The robot adjusts its level of assistance in real-time, providing more support when the worker shows signs of fatigue and less support when the worker is in stable condition, thereby maintaining productivity without causing exhaustion.
Solution Approach 2:
The system changes the control parameter (amount of robot control) based on detected worker physical state. When the worker's posture variation exceeds thresholds or stability deteriorates, the control parameter is adjusted to provide more assistance, thereby maintaining productivity while preventing worker overload.
3Reliability
If the robot control is adjusted frequently based on worker state, then the worker load management is improved, but the control system complexity increases
Solution Approach 1:
The control system automatically adjusts the control amount based on detected worker physical state without requiring external intervention or complex decision-making processes. The system serves itself by using its own detection capabilities to make control decisions, reducing the need for external monitoring and manual adjustment mechanisms.
Solution Approach 2:
The patent replaces complex mechanical monitoring systems with sensor-based detection of worker physical information. Instead of using complex mechanical devices to monitor worker state, the system uses sensors to detect posture and movement variations, thereby simplifying the overall system architecture while maintaining effective worker load management.
Data Source
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AI summary
A control device that controls a drive unit included by a production line includes: an obtaining unit (103) that obtains physical information (107) indicating a variation with time of a posture of a worker at work; a storage for storing physical information of the worker obtained when the worker works in a stable posture; a detection unit that detects a difference between a magnitude of the variation with time indicated by the physical information obtained and a magnitude of a variation with time indicated by the physical information stored in the storage; and a determination unit that determines from the detected difference whether to change an amount of controlling the drive unit.