Robot Arm Force Sensor Initialization During Uniform Motion

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Solution Overview

Problem

Existing robot systems with force sensors face accuracy issues due to temperature changes and noise from high-speed rotating tools, leading to increased cycle times and inaccurate force control during tasks like polishing, as zero-point correction of the force sensor is typically required when the robot arm is stationary.

Innovation Solution

A robot system with a force sensor integrated into the robot arm itself, allowing for initialization of the force sensor during uniform movement, reducing cycle time and minimizing noise interference by maintaining contact state control based on noise-free output values.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If zero-point correction of the force sensor is performed when the robot arm is stopped, then measurement precision is improved, but productivity deteriorates due to increased cycle time

Engineering Contradiction:
Improveforce detection accuracyVSAvoidcycle time
Core Design Contradiction:
Measurement precisionVSProductivity

Solution Approach 1:

The patent applies the dynamics principle by enabling zero-point correction to be performed during the robot arm's movement phase rather than requiring the arm to be stationary. The control unit dynamically adjusts the force sensor output by subtracting the detection value during movement from the detection value during work, allowing initialization to occur throughout the movement period. This transforms a previously static correction process into a dynamic one that occurs during normal operation, thereby improving productivity without sacrificing measurement precision.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements continuity of useful action by making the zero-point correction process continuous throughout the robot arm's movement rather than being a discrete stop-and-correct operation. The control unit continuously accumulates force sensor detection values during movement and uses them for correction during subsequent work phases. This eliminates idle time and ensures that the correction process is integrated into the continuous workflow, improving cycle time while maintaining accurate force detection.

Inventive Principle:
Principle #20Continuity of useful action

2Ease of operation

If the force sensor is placed on the rotating tool side, then ease of operation is improved, but measurement precision deteriorates due to vibration and noise from high-speed rotation

Engineering Contradiction:
Improvepolishing force measurementVSAvoidforce detection accuracy
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

The patent applies the extraction principle by separating the force sensor from the high-speed rotating tool and placing it on the robot arm instead. This removes the force sensor from the noisy, vibrating environment of the rotating tool while maintaining its ability to measure polishing forces. The control unit then processes the sensor data to compensate for any distance-related measurement variations, thereby eliminating the harmful effects of vibration and noise while preserving ease of operation.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses the robot arm as an intermediary between the control system and the polishing tool. By placing the force sensor on the robot arm rather than directly on the rotating tool, the arm acts as a mediator that transmits force information from the tool to the sensor in a more stable environment. This intermediary positioning reduces the direct impact of high-speed rotation vibrations on the sensor while still allowing accurate measurement of the polishing forces applied to the workpiece.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentUS9342066B2Robot, robot system, and robot control device
Publication Date: 2016.05.17 SEIKO EPSON CORP
  • US9342066B2 patent drawing
  • US9342066B2 patent drawing
  • US9342066B2 patent drawing

AI summary

A robot includes a robot arm, a force sensor, and a control unit configured to control the operation of the robot art. The control unit initializes the force sensor while the robot arm is moving at uniform speed. It is preferable that the control unit initializes the force sensor while the robot arm is moving at the uniform speed and the amplitude of a detection value of the force sensor is smaller than a threshold.