Manipulator Force Feedback for Package Transfer Abnormality Detection
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Solution Overview
Problem
Current transfer systems using robot arms for item transfer face challenges in accurately detecting and handling packages with discrepancies between registered data and actual measurements, leading to potential errors in gripping, lifting, and placing items, especially when packages have similar appearances or when their contents differ.
Innovation Solution
The transfer system employs a combination of sensors, image capturing apparatuses, and advanced control algorithms to detect package characteristics, plan precise trajectory paths, and adjust operations in real-time, incorporating a gripping member with force sensation sensors and a depressurization mechanism to ensure accurate handling and detection of abnormalities during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If robot arm transfer systems use standard gripping mechanisms without advanced sensing, then device complexity is reduced, but measurement precision and reliability of package detection deteriorate
Solution Approach 1:
The patent combines multiple sensing capabilities (force sensors, image capturing apparatus, acceleration sensors) with the robot arm control system into an integrated package detection and verification system. This merging allows the system to achieve high measurement precision by correlating force changes during gripping with image data and acceleration profiles, resolving the contradiction between improved detection accuracy and increased system complexity.
Solution Approach 2:
The system implements feedback mechanisms where force sensation sensors provide real-time information about package gripping status, and image capturing apparatus verify package characteristics. This feedback loop enables the control system to detect abnormalities and adjust operations, improving measurement precision while managing complexity through intelligent control algorithms that process sensor data.
2Reliability
If the system implements comprehensive abnormality detection and real-time adjustment mechanisms, then reliability of package transfer is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary detection of package characteristics using image capturing apparatus before the transfer operation begins. This preliminary action allows the control system to pre-plan the transfer trajectory and gripping parameters, improving reliability by identifying potential issues before they occur, while managing complexity through advance preparation rather than continuous complex control.
Solution Approach 2:
The system continuously monitors transfer operations using force sensors and acceleration sensors, comparing actual measurements with expected values. When abnormalities are detected, the control system adjusts operations in real-time. This feedback mechanism improves reliability by enabling dynamic correction of deviations, while the complexity is managed through algorithmic processing of sensor data.
3Productivity
If the robot arm operates at high speed for efficient transfer, then productivity is improved, but measurement precision of package characteristics deteriorates
Solution Approach 1:
The system uses periodic sampling of sensor data during the transfer operation, capturing force, image, and acceleration information at key moments in the trajectory. This periodic measurement approach allows the system to maintain high transfer speed while obtaining sufficient measurement data at critical points, resolving the contradiction between productivity and measurement precision.
Solution Approach 2:
The system performs preliminary image capture and package characteristic verification before high-speed transfer begins. By completing detailed measurements in advance when the package is stationary or moving slowly, the system can then execute high-speed transfer based on pre-acquired data, maintaining both productivity and measurement precision.
Data Source
AI summary
A control apparatus includes a force sensation information acquiring unit for acquiring force sensation information representing a magnitude of at least one of a force and a torque at a distal end of a manipulator while a target item is being transported; a mass information acquiring unit for acquiring mass information representing a mass of the item; a plan information acquiring unit for acquiring plan information representing content of a plan of a trajectory; a force sensation estimating unit for estimating a magnitude of at least one of a force and a torque to be detected at the distal end of the manipulator; and a first detecting unit for detecting an abnormality, based on the magnitude of at least one of the force and the torque represented by the force sensation information and the magnitude of at least one of the force and the torque estimated by the estimating unit.