Moving-Line Robot Force Control for Precise Part Attachment
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Solution Overview
Problem
In production lines, attaching parts to large objects like vehicle bodies using conveying apparatuses often requires stopping the apparatus, leading to inefficiencies due to the need for precise alignment and synchronization between the robot and the object's movement.
Innovation Solution
A work robot system that includes a conveying apparatus, a robot, a controller, a sensor for detecting the object's position, and a force detector, allowing the controller to perform force control and maintain precise alignment and contact management between the robot's tool and the object's target portions while the object is in motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conveying apparatus is stopped to attach parts to large objects with precision, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The system transitions from static positioning (stopping the conveying apparatus) to dynamic positioning (moving the robot along rails at the same speed as the conveying apparatus). The robot moves dynamically along the rails while performing attachment operations on the moving object, eliminating the need to stop the conveying apparatus while maintaining precise attachment through real-time position synchronization.
Solution Approach 2:
The system uses sensors to detect the position of the object on the conveying apparatus and feeds this information back to the controller. The controller then adjusts the robot's position and movement in real-time based on this feedback, enabling precise attachment operations while the object is in motion. This closed-loop control ensures the robot remains accurately positioned relative to the moving target.
2Productivity
If the robot moves along rails at the same speed as the conveying apparatus, then productivity is improved, but control complexity increases
Solution Approach 1:
The controller acts as an intermediary that coordinates between the conveying apparatus and the robot. It receives position information from sensors about the object's location on the conveying apparatus and translates this into appropriate robot movement commands along the rails. This intermediary control layer simplifies the overall system by centralizing the coordination logic rather than requiring complex direct coupling between the conveying apparatus and robot systems.
3Manufacturing precision
If force control is performed while the object is being conveyed, then manufacturing precision is improved, but the risk of damage increases
Solution Approach 1:
The force control system operates dynamically during the attachment process rather than requiring static positioning. The robot applies controlled forces to attach parts while the object is moving, with the force magnitude and direction continuously adjusted based on real-time position feedback. This dynamic force control enables precise attachment while minimizing damage risk through controlled, adaptive force application.
Solution Approach 2:
The system dynamically changes force control parameters (magnitude, direction, application point) based on the real-time position and movement state of the object. As the object moves along the conveying apparatus, the controller adjusts these parameters to maintain optimal attachment conditions while preventing excessive forces that could cause damage. This adaptive parameter adjustment enables precise attachment with minimized damage risk.
Data Source
AI summary
A work robot system including a conveying apparatus that conveys an object, a robot that performs a predetermined task on a target portion of the object being conveyed by the conveying apparatus, a controller that controls the robot, a sensor that is attached to the robot and successively detects a position, relative to the robot, of the target portion of the object being conveyed by the conveying apparatus, and a force detector that detects a force generated by a contact between the object and a part supported by the robot. When the robot is performing the predetermined task, the controller performs force control based on a detection value of the force detector while controlling the robot by using a detection result of the sensor.