Door-Opening Robot Torque Sensing for Collision-Free Coating

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Solution Overview

Problem

Existing door opening and closing systems in automobile body coating processes face challenges in accurately detecting and interacting with doors to ensure precise and collision-free operation, particularly in automated coating lines.

Innovation Solution

A door opening and closing robot equipped with a robot arm, driver, and door operating tool that rotates and detects door presence through torque changes, allowing for precise door opening and closing operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a door opening and closing robot is installed in an automobile body coating line to enable coating of the back side of the door, then the coating completeness is improved, but the risk of mechanical interference and collision increases

Engineering Contradiction:

Improvecoating completenessVSAvoidmechanical interference

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The robot performs preliminary detection of the door's presence and position before initiating the door opening/closing operation. This preliminary action allows the system to adjust its trajectory and avoid collisions with the door or surrounding structures, thereby enabling safe coating of the back side of the door.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The robot uses torque sensing feedback from its joints to detect contact with the door during operation. When abnormal torque is detected, the system adjusts its motion in real-time to avoid mechanical interference, ensuring both coating completeness and operational safety.

Inventive Principle:

Principle #23Feedback

2Productivity

If the robot arm moves to the open position of the door without detecting door presence, then the operational speed is improved, but the accuracy of door interaction deteriorates

Engineering Contradiction:

Improveoperational speedVSAvoiddoor presence detection accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The robot performs a quick preliminary detection of door presence using torque sensing before moving to the open position. This preliminary action is executed rapidly to minimize impact on operational speed while ensuring accurate door interaction through torque-based detection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces traditional mechanical sensors with torque sensing capabilities inherent in the robot's drive system. This substitution allows for contactless detection of door presence and interaction forces, maintaining high operational speed while improving measurement precision through electronic sensing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If the door operating tool is designed to rotate and detect door presence through torque changes, then the detection accuracy is improved, but the device complexity increases

Engineering Contradiction:

Improvedoor presence detection accuracyVSAvoidrobot arm mechanism complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The robot's drive system serves dual purposes: it provides the rotational motion needed for door operation and simultaneously functions as the detection sensor through torque sensing. This self-service approach eliminates the need for separate detection mechanisms, improving measurement precision without increasing device complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The door operating tool is designed to perform multiple functions: it rotates to operate the door, detects door presence through torque changes, and provides the mechanical force needed for door opening/closing. This multi-functionality reduces overall system complexity while maintaining high detection accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables accurate and collision-free door opening and closing in automobile body coating processes, enhancing operational efficiency and reducing mechanical interference.

Implementation Method 1

The robot arm may drive the driver to rotate the door operating tool and detect the presence of the door based on a change in the torque of the motor.

Methodology Applied

Scientific EffectTorque: Torque

Data Source

PatentUS12589501B2Door opening and closing robot and method of opening and closing door using the same

Publication Date: 2026.03.31 KAWASAKI JUKOGYO KK

AI summary

A door opening and closing robot according to one or more embodiments may include a base; a robot arm connected to the base that includes an arm that is rotatable and a motor that rotates the arm; and a door operating tool that is connected to the robot arm and moves with a rotation of the arm. The robot arm drives the motor to rotate the door operating tool and detects presence of the door based on a change in torque of the motor.