Industrial Robot Control for Abnormal-State Manual Correction
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Solution Overview
Problem
Conventional industrial robot systems face inefficiencies when switching from automatic to manual operation modes due to excessive operator burden, inaccurate detection of abnormal states, and decreased work accuracy, especially when unskilled workers perform re-teaching tasks.
Innovation Solution
An industrial robot system with an abnormal state detecting device that provides haptics and visual information, allowing for automatic operation correction using a combination of automatic and manual control instructions, with a correction coefficient adjustment mechanism to refine the operation based on operator input and historical data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operating mode is completely switched from automatic operation mode to manual operation mode when abnormal state is detected, then the robot can avoid obstacles and perform given work, but the work efficiency is significantly degraded and excessive burden falls on the operator
Solution Approach 1:
The patent applies partial action by switching only the affected portion of the operation program to manual control while maintaining automatic control for the remaining portions. When an abnormal state is detected, the system identifies the specific operation steps involved and switches only those to manual mode, allowing the operator to correct only the problematic segments while the rest of the workflow continues automatically, thus maintaining high productivity while handling abnormal states effectively.
Solution Approach 2:
The operation program is segmented into multiple independent operation steps, and the abnormal state detection is performed for each segment. When an abnormality is detected in a specific segment, only that segment is switched to manual control mode while other segments continue to operate automatically. This segmentation allows selective manual intervention without halting the entire automated workflow.
2Reliability
If the operating mode is completely switched to manual operation mode when abnormal state occurs, then the robot can avoid interference with obstacles, but the prepared operation program cannot be used and excessive burden falls on the operator
Solution Approach 1:
The system applies partial action by switching only the specific operation steps that involve potential interference with obstacles to manual control mode, while maintaining automatic control for other steps. This allows the operator to focus only on correcting the problematic portions of the operation, significantly reducing the operator burden compared to complete manual control, while still ensuring safe operation during abnormal states.
3Reliability
If camera-based detection is used to detect abnormal states, then the robot can identify obstacles, but the detection accuracy is insufficient for complex abnormal states
Solution Approach 1:
The patent merges multiple detection methods including camera-based detection, force sensors, and other sensing devices to create a comprehensive abnormal state detection system. By combining the strengths of different detection methods, the system achieves higher detection accuracy for complex abnormal states while maintaining the ability to detect simple obstacles that cameras can identify.
4Adaptability or versatility
If unskilled workers perform re-teaching tasks to correct robot operations, then the robot can adapt to changes, but the work accuracy is significantly degraded
Solution Approach 1:
The system implements feedback mechanisms where the robot's actual operation results are monitored and compared with expected outcomes. When deviations occur, the system provides feedback to guide correction, whether through automatic adjustment or operator intervention. This feedback loop ensures that even unskilled workers can make accurate corrections by following system guidance, maintaining work accuracy while preserving adaptability.
Data Source
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AI summary
To provide an industrial robot and a method of operating the same which are capable of appropriately handling, when an abnormal state occurs during an automatic operation of the robot, the abnormal state without significantly degrading the work efficiency. The industrial robot includes a robot main body (1) having a robot arm, a robot control device (7) configured to control operation of the robot main body (1) and an abnormal state detecting device (8) configured to detect abnormality in a work state of the robot main body (1). The robot control device (7) includes an automatic operation performing means (9) for controlling the operation of the robot main body (1) to perform an automatic operation based on a given operation program, and an automatic operation correcting means (10) for correcting the operation of the robot main body (1) in the automatic operation based on a manual control performed by an operator according to a detection result of the abnormal state detecting device (8).