Electromechanical System Reducing Operator Effort
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Solution Overview
Problem
Manual work tasks often require operators to bear significant force and torque loads, leading to fatigue and increased effort, particularly in manufacturing and assembly processes where supporting heavy tools or objects is necessary.
Innovation Solution
An electromechanical system with a combination of actuated and unactuated joints providing multiple degrees of freedom, including a robotic mechanism and an articulated compliance mechanism, which reduces the perceived effort by allowing greater displacement for a given force, thereby supporting the weight of objects and assisting operators in tasks like lifting, supporting, and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the operator manually supports heavy tools or objects during work tasks, then the task can be completed, but the operator experiences fatigue and increased effort
Solution Approach 1:
The patent introduces an electromechanical system as an intermediary between the operator and the heavy tool or object. This system includes a wearable support device that physically bears the weight of the tool, and a control system that detects operator intent and automatically adjusts the support force. The intermediary device transfers the load-bearing function from the operator's muscles to the electromechanical system, significantly reducing perceived effort while maintaining operational control.
Solution Approach 2:
The patent replaces the purely mechanical human operator system with an electromechanical system that combines sensors, processors, and actuators. Instead of relying solely on human muscular force and neural control, the system uses electronic sensors to detect operator state and control parameters, and electronic actuators to provide adaptive mechanical support. This substitution enables more precise and less fatiguing force application.
2Ease of operation
If the electromechanical system provides high compliance to reduce perceived effort, then operator ease of operation improves, but control precision may be compromised
Solution Approach 1:
The patent implements dynamic compliance control where the system's mechanical impedance is continuously adjusted based on real-time sensor feedback. The control system varies the level of compliance and support force according to the operator's instantaneous needs, the task requirements, and the detected operator state. This dynamic adjustment allows the system to be highly compliant when the operator needs assistance while maintaining precise control when accuracy is critical.
Solution Approach 2:
The patent employs multiple feedback loops that continuously monitor operator forces, joint positions, muscle activity, and system state. This feedback information is processed to dynamically adjust the electromechanical support and control parameters. The feedback mechanism enables the system to distinguish between intentional operator movements and fatigue-induced deviations, providing precise control while maintaining ease of operation through adaptive compliance.
Data Source
AI summary
An electromechanical system operates through physical interaction with an operator, and includes a plurality of joints providing multiple degrees of freedom (DOF), including actuated joints and unactuated joints. The unactuated joints are distal with respect to the actuated joints and are in redundant DOF to the actuated joints. The system includes a plurality of actuators each configured to actuate one or more of the actuated joints, and a plurality of sensors each positioned with respect to a respective one of the actuated and unactuated joints. Each sensor is configured to measure corresponding joint data indicative of a position or angle of the respective actuated or unactuated joints. A controller in communication with the sensors receives the measured joint data as feedback signals, generates control signals using the feedback signals, and transmits the control signals to the actuators to thereby control an actuation state of the actuators.