Manipulator Motion Simulation for Real-Time Collision Prediction
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Solution Overview
Problem
Existing methods for motion simulation in machining environments with manipulators struggle to effectively address collision risks in real-time, leading to potential collisions due to discrepancies caused by thermal effects or other irregularities, which can result in damage and downtime.
Innovation Solution
A method that computes a trajectory plan from a setpoint movement based on a kinematic model and environment model, performing a kinematic collision check to predict potential collisions, allowing for real-time feedback and preventing actuation when a collision risk is detected, using a control apparatus and separate computation apparatus for parallel execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If offline programming and simulation are used to create trajectory plans, then collision risks can be identified in advance, but real-time discrepancies due to thermal effects or irregularities cannot be detected
Solution Approach 1:
The system performs preliminary collision checks by computing potential collision situations in advance based on the trajectory plan and environment model, similar to offline programming but enhanced with real-time capabilities. This allows the system to prepare collision predictions before actual movement occurs, enabling proactive collision avoidance while maintaining real-time responsiveness to thermal effects and irregularities.
Solution Approach 2:
The system continuously monitors the actual manipulator state and compares it with the simulated trajectory, providing real-time feedback when discrepancies are detected. This feedback mechanism enables the system to adapt to thermal effects and environmental irregularities dynamically, resolving the contradiction between advance prediction and real-time detection by creating a closed-loop control system.
2Productivity
If the manipulator follows a pre-computed trajectory plan, then machining efficiency is maintained, but collision risks from unforeseen situations cannot be avoided
Solution Approach 1:
The system transforms the static trajectory execution into a dynamic process by continuously updating collision predictions based on actual manipulator state and environmental conditions. The collision check system adapts in real-time to thermal effects and irregularities, allowing the manipulator to maintain high productivity while dynamically adjusting to avoid collisions that were not predictable during offline programming.
Solution Approach 2:
The system performs preliminary collision assessments for upcoming trajectory segments and prepares avoidance actions in advance. This allows the manipulator to follow the efficient pre-computed trajectory while having collision avoidance actions ready to execute immediately when real-time conditions indicate potential collisions, thus maintaining both productivity and reliability.
3Ease of operation
If manual control is used to respond to collision risks, then immediate operator intervention is possible, but response time is delayed and human error increases
Solution Approach 1:
The system performs self-monitoring and self-protection by automatically detecting potential collision situations and executing avoidance actions without requiring operator intervention. The manipulator system serves itself by continuously checking for collisions and autonomously responding to threats, eliminating the delays and errors associated with manual control while preserving operator capability for complex decision-making.
Solution Approach 2:
The system provides automatic feedback to operators about collision risks and actions taken, maintaining operator awareness and control capability while eliminating the need for manual response. This feedback loop allows operators to monitor system status and intervene only when necessary, reducing response time and human error while preserving ease of operation.
Data Source
AI summary
Various embodiments relate to a method for motion simulation for a manipulator, such as an NC-controlled manipulator, in a machining environment, wherein the manipulator is moved in an operating mode by a control apparatus and the machining environment is at least partly mapped in an environment model and wherein the method comprises computation of a trajectory plan by the control apparatus from a setpoint movement of the manipulator starting from an initial situation and based on a kinematic model of the manipulator, performance of a kinematic collision check based on the trajectory plan, the kinematic model and the environment model, and production of a prediction result based on the kinematic collision check. The method is characterized in that the initial situation corresponds to the current manipulator state. Further, some embodiments relate to a corresponding computer program with program code and to a corresponding system for motion simulation for a manipulator.