Robotic End-Effector Force Control for Brake Lever Grasping
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Solution Overview
Problem
Current automated systems for disengaging air brakes in vehicles face challenges in accurately grasping the brake lever due to imprecise position estimations, leading to potential damage and inefficiency, and existing solutions lack effective force and torque control loops to handle such inaccuracies.
Innovation Solution
An automation system with a manipulator and end-effector equipped with force/torque sensors and a control circuit that adjusts the motion trajectory in real-time, using feedback from sensors like encoders and imaging sensors to ensure precise grasping of the brake lever, even with large perception errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated systems use position/velocity control with estimation of brake lever position, then the system can operate autonomously without human operators, but imprecise or inaccurate estimations lead to improper grasping and potential damage to the end-effector
Solution Approach 1:
The patent implements a force feedback control loop that continuously monitors the force exerted by the end-effector on the brake lever and adjusts the grasping force in real-time. This feedback mechanism allows the automated system to compensate for position estimation errors by sensing actual contact forces and adapting its control strategy, thereby maintaining reliable operation despite inaccuracies in initial position estimates.
Solution Approach 2:
The system transitions from static position/velocity control to dynamic force control by continuously adjusting the end-effector's grasping force based on real-time feedback. This dynamic adaptation enables the system to handle uncertainties in brake lever position estimation by modulating the interaction forces, ensuring proper grasping without causing damage even when position estimates are imprecise.
2Device complexity
If the automated system relies on imprecise position estimations without force control, then the system structure remains simpler, but the system may damage itself or fail to grasp the brake lever properly
Solution Approach 1:
By introducing force sensors and a feedback control loop, the system gains the ability to monitor and adjust grasping forces in real-time. This feedback mechanism provides a safety net that prevents damage from excessive force while ensuring reliable grasping, justifying the increased complexity through significant improvements in operational reliability and safety.
Solution Approach 2:
The force control system acts as a protective mechanism that prevents damage before it occurs. By continuously monitoring interaction forces and adjusting the end-effector's force output, the system cushions against potential damage from position estimation errors, ensuring that even with simpler initial positioning, the system will not harm itself or fail to grasp properly.
3Adaptability or versatility
If human operators manually disengage air brakes, then the operation can be performed with adaptability to various conditions, but safety risks to operators and increased operational costs are introduced
Solution Approach 1:
The automated system performs the brake disengagement task autonomously using force feedback control, eliminating the need for human operators to physically interact with the brake lever. The system serves itself by sensing forces, making decisions, and executing the grasping and disengagement actions, thereby removing operators from hazardous environments while maintaining adaptability through intelligent force control.
Solution Approach 2:
The patent replaces the human operator's manual mechanical interaction with an automated robotic system equipped with force sensors and control algorithms. This substitution eliminates safety risks to human operators while maintaining the ability to adapt to various brake lever positions and conditions through sensor feedback and dynamic control adjustments.
Data Source
AI summary
Systems and methods are provided for an automation system. The systems and methods calculate a motion trajectory of a manipulator and an end-effector. The end-effector is configured to grasp a target object. The motion trajectory defines successive positions of the manipulator and the end-effector along a plurality of via-points toward the target object. The systems and methods further acquire force/torque (F/T) data from an F/T sensor associated with the end-effector, and adjusts the motion trajectory based on the F/T data.