In-Line Motion Sensor Control for Precise Robotic Welding Positioning
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Solution Overview
Problem
Current robotic welding systems face challenges in intuitive and precise positioning, particularly when using direct human-robot collaboration methods, due to factors like friction and cogging characteristics, which can make manual guiding difficult and require operators to switch between control modes, slowing down the training process.
Innovation Solution
A six-degree-of-freedom motion sensor is mounted in-line with the last joint of the robot manipulator, allowing for intuitive control and amplification of motion resolution, enabling precise positioning without the need for traditional teach pendants, and allowing for both high-precision and high-speed motion control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct human-robot collaboration is used for manual guiding, then ease of operation is improved, but manufacturing precision deteriorates due to friction and cogging characteristics
Solution Approach 1:
A motion sensor is introduced as an intermediary device between the operator and the robot manipulator. The sensor is mounted on the robot and detects motion inputs from the operator, translating them into precise robot movements. This intermediary mechanism eliminates the direct mechanical connection that causes friction and cogging, allowing the operator to guide the robot intuitively while maintaining high positioning accuracy through sensor-based control.
2Manufacturing precision
If teach pendant is used for precise positioning, then manufacturing precision is improved, but ease of operation deteriorates requiring significant training
Solution Approach 1:
The traditional mechanical teach pendant interface is replaced with a motion sensor-based system. Instead of requiring operators to learn complex teach pendant operations, the motion sensor captures natural human movements and translates them directly into robot motions. This substitution of mechanical control with sensor-based detection maintains positioning accuracy while dramatically improving ease of operation and reducing training requirements.
3Manufacturing precision
If switching between control modes is required, then manufacturing precision is maintained, but productivity deteriorates due to slowed training process
Solution Approach 1:
The motion sensor system provides multi-functionality by combining both precise positioning capabilities and intuitive manual guiding in a single unified interface. Unlike traditional systems that require switching between different control modes (teach pendant for precision, manual guiding for ease), the motion sensor accomplishes both functions simultaneously, eliminating mode-switching overhead and accelerating operator training while maintaining manufacturing precision.
Data Source
AI summary
This patent defines a method for making robot programming more intuitive for tasks such as welding. The method further is an enhancement of manual guiding methods of robot positioning and can improve situations in which finer resolution or control of the robot end-effector is required. A motion sensor is mounted in series with the n−1 joint and in parallel with the nth joint, where n is the number of degrees of freedom or number of joints of the serial manipulator. The motion sensor is further mounted directly in-line with the nth joint and becomes part the opposing portion of the nth joint. The motion sensor further is uniquely adapted to apply to non-spherical wrist robots. The motion sensor senses input movements by a robot operator and controls the output tool motion in a controlled manner with resolution defined by user input at the motion sensor.