Manipulator Orientation Control via Inertial Sensor Drift Correction
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Solution Overview
Problem
Existing systems for spatial movement of objects by industrial robots face challenges in precise positioning and orientation, especially when dealing with large components, due to limitations in inertial sensor calibration and drift, leading to increased recalibration needs and production time.
Innovation Solution
A system that uses inertial sensors to detect changes in orientation and switches to a mode where orientation is determined based on control device data once the object is coupled, reducing recalibration frequency and maintaining accuracy by extrapolating orientation changes between update intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If inertial sensors are used to continuously determine orientation of the movement specification means, then ease of operation is improved, but measurement precision deteriorates due to sensor drift
Solution Approach 1:
The control device receives orientation data from inertial sensors and compares it with expected orientation values. When deviations exceed a threshold indicating drift, the system automatically triggers recalibration by detecting the actual orientation through object coupling and correcting the sensor data accordingly.
Solution Approach 2:
The system changes the operational mode of the inertial sensors based on detected conditions. During normal operation, sensors continuously provide orientation data for ease of operation. When drift is detected, the system switches to calibration mode where actual orientation is determined through mechanical coupling with the object, correcting the sensor parameters.
2Manufacturing precision
If frequent recalibration of inertial sensors is performed to maintain measurement precision, then manufacturing precision is improved, but productivity deteriorates due to increased downtime
Solution Approach 1:
The system performs self-calibration by utilizing the mechanical coupling between the movement specification means and the object. When coupling occurs, the system automatically determines the actual orientation through the control device and corrects the inertial sensor data without requiring external calibration equipment or manual intervention, thus maintaining precision without production downtime.
Solution Approach 2:
The system performs calibration actions at the moment of object coupling, which is a natural transition point in the assembly process. By detecting the coupling event and immediately performing orientation determination and sensor correction, the system ensures positioning accuracy is maintained without requiring separate recalibration steps that would interrupt production.
3Ease of operation
If the movement specification means is manually moved freely in space, then ease of operation is improved, but reliability deteriorates due to drift errors accumulating
Solution Approach 1:
The control device continuously monitors orientation data from inertial sensors during free movement and compares it with reference values. When drift errors exceed acceptable thresholds, the system automatically triggers a calibration event by detecting the coupling between the movement specification means and the object, thereby correcting the accumulated errors and restoring reliability.
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
This approach significantly reduces the frequency of recalibrations and maintains high positioning accuracy by minimizing drift errors, allowing for uninterrupted assembly processes and improved ergonomic handling of heavy components.
Implementation Method 1
Inertial sensors (7) in the movement specification means (5) are used to detect changes in orientation of the movement specification means (5) in relation to three-dimensional space
Data Source
Figure 1~2
AI summary
The invention relates to a system (1) and to a method for spatially moving an object (2) by means of a manipulator (3), which object (2) is kinematically coupled to the manipulator (3) at least temporarily. A motion specification means (5) is provided, which can be freely moved in space by an operating person at least temporarily and which is provided for at least temporary physical coupling to the object (2) to be moved. In the coupling state of the motion specification means, the motion specification means (5) is designed for the giving of motion commands to a control device (6, 6') of the manipulator (3) by the operating person. Inertial sensors for sensing at least orientation changes of the motion specification means (5) are integrated in the motion specification means (5). An orientation-determining unit (8, 8') serves to continuously determine the changing orientations of the motion specification means (5) in space, wherein the control execution of at least one of the motion commands is, at least at times, dependent on the orientation of the motion specification means (5).