Haptic Robot Teaching for Force-Controlled Workpiece Interaction
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Solution Overview
Problem
Current robot programming methods are inefficient for defining force interactions with workpieces, as they are based on position-controlled motions, making it difficult for non-expert operators to intuitively program robots for tasks requiring specific force interactions, especially in dynamic environments where traditional kinematic approaches fall short.
Innovation Solution
A system comprising a master robot arm and a slave robot arm with a control unit that determines force interplay between the operator and the workpiece, using haptic feedback to calculate joint movement commands based on dynamic models, allowing for intuitive and efficient teaching of robot motions that account for both position and force constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If position-controlled motions are used for robot programming, then control functions are easier to provide and support, but force interactions become difficult to specify and control with reasonable bandwidth
Solution Approach 1:
The patent introduces a master robot arm as an intermediary device between the operator and the slave robot arm. The master arm serves as a haptic interface that allows the operator to intuitively specify force interactions through physical manipulation, while the control unit translates these intuitive inputs into precise force-controlled commands for the slave arm, thus bridging the gap between ease of operation and control precision
Solution Approach 2:
The patent replaces traditional position-based mechanical control with a haptic interface system that uses force feedback and dynamic modeling. The control unit computes force interactions based on the operator's manipulation of the master arm and translates them into force-controlled motions, substituting the purely mechanical position control system with a more sophisticated force-aware control mechanism
2Productivity
If traditional robot programming methods are used, then programming can be done with standard position control, but it becomes inefficient and complex for defining force interactions with workpieces
Solution Approach 1:
The system allows the operator to directly manipulate the master robot arm to teach the desired task, and the system automatically records the force interactions and motions. This self-service approach eliminates the need for complex manual programming of force interactions, as the operator's intuitive manipulation is automatically translated into executable robot instructions with embedded force control parameters
Solution Approach 2:
The patent implements a feedback mechanism where the control unit continuously monitors the operator's manipulation of the master arm and provides haptic feedback through the master arm's actuators. This feedback loop allows the operator to feel the force interactions in real-time during teaching, enabling intuitive specification of force parameters without requiring understanding of complex programming syntax or physics calculations
3Adaptability or versatility
If position-based motion definitions are used, then control functions are easier to support, but the resulting forces are difficult to specify and control
Solution Approach 1:
The patent fundamentally changes the control parameters from position-only to force-and-position hybrid control. The control unit computes both the desired position trajectory and the required interaction forces based on the operator's manipulation of the master arm, and simultaneously controls the slave arm's position and force output. This parameter transformation enables precise force control while maintaining the versatility of position-based motion planning
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 operators with little programming experience to intuitively teach robots to perform tasks with precise force interactions, reducing the complexity of programming and allowing for flexible adaptation to varying workpiece positions and robot configurations without the need for re-programming.
Implementation Method 1
A haptic interface module calculates joint movement commands for the master robot arm and the slave robot arm, based on the master external force data, the slave external force data, a dynamic model of the master robot arm, a dynamic model of the slave robot arm, and a relation between the dynamic models including forces/torques for accomplishing the kinematic coupling
Data Source
AI summary
The disclosure relates to a system (1) and method for instructing a robot. The system (1) comprising an immersive haptic interface, such that operator interaction with a master robot arm (2) is reflected by a slave robot arm (3) arranged for interaction with a workpiece (4). The interaction of the slave robot arm (3) is reflected back to the master robot arm (2) as haptic feedback to the operator. The dynamic system is continually simulated forward and new commands are calculated for the master robot arm and the slave robot arm.