Master-Slave Robot Control for Limit Feedback and Overload Prevention
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Solution Overview
Problem
Existing master-slave manipulators face issues such as damage to the master arm due to excessive load when the slave arm contacts a hard object and inability to notify the operator about contact with a workpiece, making it difficult to distinguish between contact with the workpiece and regulation of the operating range.
Innovation Solution
A robot system that includes a slave unit with a slave arm, actuator, and controller, and a master unit with a master arm and controller, utilizing a system controller to generate operating commands and provide perception to the operator when approaching limits, detect forces, and adjust operating modes to prevent overload and notify the operator of operating limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the slave arm contacts a hard work object and the operator tries to forcibly move the master arm, then the slave arm can be moved against resistance, but an excessive load is applied to the master arm which may damage the force sensor or master arm
Solution Approach 1:
The system applies preliminary anti-action by detecting when the slave arm contacts a work object and generating a virtual repulsive force before the operator can apply excessive force to the master arm. This repulsive force is fed back to the master arm control, creating resistance that prevents the operator from applying damaging loads to the master arm or force sensor.
Solution Approach 2:
The system introduces an intermediary virtual force field between the slave arm and the master arm. When the slave arm contacts the work object, this intermediary force field generates a repulsive force that is transmitted to the master arm control system, mediating the interaction and preventing direct transmission of excessive forces that could cause damage.
2Adaptability or versatility
If the slave arm contacts a workpiece, then the slave arm can perform contact operations, but the operator cannot distinguish whether the slave arm contacts the workpiece or the contact contacts the position regulating member
Solution Approach 1:
The system implements feedback by continuously monitoring the slave arm's contact status with workobjects and providing perceptible feedback to the operator through the master arm. When contact is detected, the system generates force feedback or visual indicators that inform the operator of the contact state, enabling distinction between workpiece contact and position regulating member contact.
Solution Approach 2:
The system uses visual indication changes (analogous to color changes) to communicate contact status to the operator. When the slave arm contacts a workobject, the system changes visual indicators on the master arm or display interface to signal the contact state, enabling the operator to perceive and distinguish different contact conditions.
Data Source
AI summary
A robot system (100) includes a slave unit (1) including a slave arm (11) having a working end (11a), a slave arm actuator (13) configured to drive the slave arm, and a slave-side controller (14) configured to control the slave arm actuator based on a slave operating command for defining a target position of the working end, a master unit (2) including a master arm (21) having a manipulation end (21a) into which the content of manipulation is inputted by an operator, and a system controller (3) configured to generate the slave operating command based on the content of manipulation inputted into the manipulation end. When a command corresponding to the content of manipulation is a command corresponding to a limit equivalent range corresponding to a limit of operation of at least one of the slave arm and the master arm, the system controller performs processing to give perception to the operator.