Cooperation Robot Bumper Mounting with Force Torque Sensor
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Solution Overview
Problem
Current cooperation robots in vehicle production systems face challenges in efficiently and accurately mounting bumpers due to difficulties in controlling exact positions, leading to increased worker load and limited applicability across various vehicle types, resulting in musculoskeletal injuries and reduced operational efficiency.
Innovation Solution
A cooperation robot equipped with a multi-axis arm, a force torque sensor, and a gravity compensation apparatus, which allows precise positioning and movement of bumpers using a gripper, while detecting external forces and objects to prevent collisions and stabilize the robot's operation, thereby enhancing control performance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If energy saving equipment of weight balance type is used to reduce worker load during trunk lead hinge mounting, then worker load is reduced, but control precision of the equipment deteriorates and it cannot be applied to various types of vehicles
Solution Approach 1:
The patent replaces the mechanical weight balance system with an intelligent control system that includes sensors (force torque sensor, neighboring sensor), controllers, and motors. This substitution allows the system to maintain ease of operation while achieving high positioning precision through electronic control and feedback mechanisms, resolving the contradiction between mechanical simplicity and control precision.
Solution Approach 2:
The patent implements multiple feedback loops including force torque sensors that detect external forces applied to the gripper, neighboring sensors that detect objects in the workspace, and controllers that adjust motor operations based on detected positions and forces. This feedback mechanism enables precise position control while maintaining ease of operation, directly resolving the technical contradiction.
2Productivity
If conventional robots are used for bumper mounting, then repetitive operations are automated, but adaptability to various vehicle types and precise position control are limited
Solution Approach 1:
The patent designs the cooperation robot with universal applicability through adjustable parameters, interchangeable grippers, and adaptive control algorithms that can accommodate different vehicle types and bumper configurations. The system maintains high productivity through automation while achieving versatility by adapting to various mounting scenarios across different vehicle models.
Solution Approach 2:
The patent implements dynamic adaptability through real-time sensor feedback and adjustable control parameters. The robot can dynamically adjust its operation mode, gripping force, and positioning accuracy based on the specific vehicle type and bumper characteristics, enabling both high productivity and adaptability to various vehicle types.
3Manufacturing precision
If precise position control is implemented for bumper mounting, then mounting accuracy is improved, but system complexity and control difficulty increase
Solution Approach 1:
The patent introduces intermediate components such as force torque sensors, neighboring sensors, and controllers that mediate between the operator's input and the final positioning action. These intermediaries simplify the control process by providing real-time feedback and automatic adjustments, achieving high mounting accuracy without requiring overly complex direct control mechanisms.
4Productivity
If the robot operates autonomously with high precision, then productivity is improved, but collision detection and safety mechanisms become more complex
Solution Approach 1:
The patent implements preliminary safety actions by placing neighboring sensors that detect objects in the workspace before the robot executes its positioning maneuver. The system proactively detects potential collisions and can halt or adjust its operation before contact occurs, maintaining high productivity while using relatively simple sensor-based safety mechanisms rather than complex post-collision detection systems.
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
The solution improves manufacturing efficiency by reducing worker load, enhancing precision, and ensuring stable operation across various vehicle types, minimizing musculoskeletal injuries and improving the overall durability and control performance of the robot.
Implementation Method 1
a force torque (FT) sensor disposed between the multi-axis arm and the gripper, and detecting a direction of external force that is applied to the gripper and the bumper gripped by the gripper
Implementation Method 2
a gravity compensation apparatus mounted on an opposite side of the multi-axis arm on the basis of the robot body, and decreasing rotational torque applied to the robot body by the multi-axis arm by moving weight becoming close to or far from the robot body
Implementation Method 3
decreasing rotational torque applied to the robot body by the multi-axis arm
Implementation Method 4
an elastic member elastically supporting the weight toward the robot body
Data Source
AI summary
A cooperation robot for moving a bumper to a predetermined position of a vehicle in a vehicle production system includes: a multi-axis arm, a front end portion of which is connected to and a rear end portion of which is connected to a robot body so that the multi-axis arm is movably disposed to upper, lower, left and right sides on the basis of the robot body. The multi-axis arm is disposed to rotate the gripper. A force torque (FT) sensor is disposed between the multi-axis arm and the gripper and detects a direction of external force which is applied to the gripper and the bumper gripped by the gripper. An operator controls the multi-axis arm so that positions of the gripper and the bumper vary. A controller controls the operator according to the direction of the external force detected by the FT sensor when the multi-axis arm is in a stand-by condition to move the gripper in the direction the external force.