Production Line Drive Control Using Worker Posture Feedback
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Solution Overview
Problem
When workers collaborate with machines like robots on production lines, existing control systems can lead to worker overload, resulting in physical exhaustion and reduced productivity, as they are directed to mimic the movements of skilled workers without considering their individual load.
Innovation Solution
A control device that monitors a worker's physical information, such as posture and movement, to detect variations and determine if adjustments to the robot's operation are needed, thereby adjusting the workload to prevent overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot is controlled to operate in accordance with the worker's movement data compared with reference data from skilled workers, then the worker is directed to move to the working movement of the skilled worker, but the worker may physically be overloaded resulting in exhaustion and poor productivity
Solution Approach 1:
The system continuously monitors the worker's movement data via sensors and provides real-time feedback to adjust robot operations. The control device compares actual movement data with reference data and dynamically adjusts robot speed and position to prevent worker overload while maintaining productivity targets.
Solution Approach 2:
The robot control system transitions from static reference-based control to dynamic adaptive control. The robot's operating parameters (speed, position, acceleration) are continuously adjusted based on real-time worker physical state detection, allowing the system to adapt to varying worker conditions throughout the workday.
2Productivity
If the robot operates at high speed to maintain productivity, then output increases, but the worker becomes overloaded and exhausted reducing long-term productivity
Solution Approach 1:
The system uses continuous feedback from movement sensors to monitor worker fatigue levels and adjusts robot speed accordingly. When worker exhaustion is detected, the robot automatically reduces speed or assists more, extending the worker's effective working duration without compromising overall production output.
Solution Approach 2:
The control system dynamically changes robot operating parameters (speed, acceleration, position) based on detected worker physical state. This allows the system to optimize the balance between production speed and worker endurance, adjusting parameters in real-time to prevent exhaustion while maintaining high productivity.
3Stability of the object's composition
If the robot is controlled based on reference data from skilled workers, then standardization is achieved, but individual worker differences are ignored causing physical strain
Solution Approach 1:
The system applies different control strategies to different aspects of the worker-robot interaction. Standardized reference data guides overall workflow, while local adjustments are made to speed, position, and acceleration based on individual worker physical characteristics detected in real-time, accommodating individual differences without sacrificing standardization.
Solution Approach 2:
The control system evolves from rigid standardized control to dynamic adaptive control that preserves standardization where needed while allowing flexibility for individual worker characteristics. The robot adjusts its behavior dynamically based on continuous monitoring of worker physical state, maintaining production standards while adapting to individual worker capabilities.
Data Source
AI summary
A control device that controls a drive unit included by a production line includes: an obtaining unit that obtains physical information 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.