Collaborative Robot Torque Control for Safe Shared Workspaces
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Solution Overview
Problem
Conventional robot systems operating in shared workspaces with humans lack effective safety mechanisms to prevent collisions and optimize task performance, as they rely on separated workspaces and static safety barriers, which are not adaptable to dynamic human-robot collaboration.
Innovation Solution
A multi-axis robot system equipped with torque sensors and a controller that adjusts speed and path based on torque measurements relative to a threshold value, using machine learning to optimize performance and safety by iteratively adjusting the threshold to ensure task completion without exceeding safe torque limits, and dynamically controlling motion to prevent collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot operates at high speed to improve productivity, then productivity increases, but the risk of collision and injury to humans increases
Solution Approach 1:
The robot system dynamically adjusts its operating speed based on real-time torque measurements and human presence detection. When a human enters the workspace or torque exceeds threshold values, the robot automatically reduces speed or stops, transforming from a static speed operation to a dynamic adaptive speed control that resolves the contradiction between productivity and safety
Solution Approach 2:
The system implements continuous feedback through torque sensors that monitor forces on robot joints. This feedback loop enables the controller to detect potential collisions or human presence and adjust robot speed accordingly, allowing high-speed operation when safe while preventing collisions when humans are present
2Object-affected harmful factors
If static safety barriers are used to separate robot and human workspaces, then safety is improved, but workspace flexibility and collaboration capability deteriorate
Solution Approach 1:
The patent replaces physical mechanical barriers (fences and safety barriers) with a sensor-based control system. Torque sensors and controllers monitor robot operation and human presence, using software-based safety logic instead of physical separation to enable safe human-robot collaboration in shared workspaces
Solution Approach 2:
The robot system performs self-monitoring through torque sensors that detect forces indicating human presence or potential collisions. The controller automatically adjusts robot behavior based on this self-detected information, eliminating the need for external safety barriers while maintaining safety
3Object-affected harmful factors
If torque threshold values are set low to ensure safety, then safety is improved, but task completion capability deteriorates
Solution Approach 1:
The system dynamically adjusts torque threshold values based on the specific task being performed and real-time operating conditions. Different tasks have different safe torque ranges, and the controller adapts thresholds accordingly, enabling both safe operation and complete task execution without being constrained by fixed low thresholds
Solution Approach 2:
The patent changes the torque threshold parameter dynamically rather than using a fixed value. The controller adjusts threshold levels based on task requirements, robot speed, and human presence, allowing the system to operate at higher torque levels when safe and at lower levels when humans are present, thus resolving the contradiction between safety and task completion
Data Source
AI summary
A system for robot and human collaboration. The system comprises: a multi-axis robot; one or more torque sensors, each torque sensor being configured to measure a torque about a respective axis of the multi-axis robot; and a controller configured to: receive one or more torque measurements taken by the one or more torque sensors; compare the one or more torque measurements or a function of the one or more torque measurements to a threshold value; and control the multi-axis robot based on the comparison.