Handling Device Manipulator Collision Detection via Sensor Feedback
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Solution Overview
Problem
Current handling systems based on gantry or delta kinematics robots face challenges in reliably detecting unexpected events such as collisions or tool malfunctions due to their complex dimensioning and the limitations of existing collision avoidance strategies, which often fail to detect events below the registration threshold.
Innovation Solution
The method involves monitoring movement profiles and sensor data, including current consumption, pressure, and path-time profiles, to recognize unexpected events by comparing setpoint values with recorded sensor values, using sensors like strain, pressure, and acceleration sensors to detect deviations and trigger warnings or machine stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex dimensioning and existing collision avoidance strategies are used in handling systems, then the system structure is established, but the reliability of detecting unexpected events such as collisions or tool malfunctions deteriorates
Solution Approach 1:
The patent implements feedback by continuously monitoring sensor signals (acceleration, force, torque, current) during manipulator operation and comparing them against expected values. When deviations exceed predefined thresholds, the system triggers warnings or stops the machine, creating a closed-loop feedback mechanism that enhances detection reliability without requiring complex additional hardware
Solution Approach 2:
The patent replaces complex mechanical collision avoidance mechanisms with electronic sensor-based detection systems. By using acceleration sensors, force sensors, torque sensors, and current monitoring to detect unexpected events, the system achieves reliable collision and malfunction detection while avoiding the complexity of mechanical safety systems
2Measurement precision
If existing collision avoidance strategies are used, then the system operates with standard detection methods, but the detection precision for events below registration threshold deteriorates
Solution Approach 1:
The patent segments the detection function into multiple independent sensor types (acceleration sensors, force sensors, torque sensors, current monitoring) that each monitor specific aspects of manipulator operation. This segmentation allows the system to detect different types of unexpected events with high precision, including subtle events below traditional registration thresholds
Solution Approach 2:
The patent employs multiple sensors and monitoring methods beyond what a single detection system would provide. By using acceleration monitoring, force sensing, torque measurement, and current analysis simultaneously, the system achieves excessive detection capability that ensures even minor unexpected events are captured with high precision
Data Source
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AI summary
A handling device (10) and a method for gripping, grasping, positioning, handling, moving, rotating, regrouping and/or manipulating articles, containers or unit loads transported individually, in pairs or in groups on a horizontal conveying device (12) are disclosed. The handling device (10) comprises a manipulator (28) movably suspended and controllably movable in a movement space (30) above the horizontal conveying device (12), with one or more means (44) for gripping the articles, groups, containers or unit loads.The manipulator (28) and/or movable suspension parts of the device (10) connected to the manipulator (28) and/or at least one drive (50) for the manipulator (28) is/are assigned at least one sensor (36) for detecting and/or monitoring movement patterns of at least the manipulator (28) and/or for detecting current consumption values, pressure values and/or displacement-time profiles for at least one drive (50) of the handling device (10). The handling device (10) is coupled with a control and evaluation circuit (40) which, by evaluating the sensor values (38) with regard to sensor, pressure and/or current consumption values and/or distance-time relationships expected from the control commands for the manipulator movements and by comparing the target values with the recorded sensor values (38), detects and/or derives an unexpected event in the movement and/or handling process of the manipulator (28).