Industrial Robot Arm Control With Virtual Sensor Coupling
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Solution Overview
Problem
Existing methods for controlling industrial robot movements, such as hand-held devices and mechanical couplings, pose safety risks and are not user-friendly due to the need for close proximity to the robot and complex mechanical connections, which can lead to errors and injuries.
Innovation Solution
A control method and system that uses a movement specification means with imaging and distance-sensitive sensors to create a virtual or semi-mechanical coupling, allowing intuitive and safe control of industrial robots by guiding the movement specification means to define a coupling condition and track the robot's movements, eliminating the need for close proximity and complex mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct manual guidance is used with mechanical coupling to the robot, then control precision and intuitiveness are improved, but safety deteriorates due to the need for close proximity and potential mechanical instability
Solution Approach 1:
The patent introduces an intermediary device (motion control device with sensors) that mediates between the operator and the robot. The device establishes a virtual coupling through sensor detection rather than direct mechanical contact, allowing the operator to control the robot intuitively while maintaining safe distance and eliminating mechanical coupling risks
Solution Approach 2:
The patent replaces the mechanical coupling system with an optical/electronic sensing system. Instead of using physical handles mechanically coupled to the robot, the system uses imaging sensors and distance-sensitive sensors to detect the motion control device's position and establish a virtual coupling, eliminating the need for mechanical connections while maintaining control precision
2Measurement precision
If mechanical coupling devices are used to control robot movements, then control accuracy is improved, but device complexity increases due to mechanical connections and support structures
Solution Approach 1:
The patent replaces complex mechanical coupling devices with a sensor-based virtual coupling system. The motion control device uses imaging sensors and distance-sensitive sensors to detect its position relative to reference marks on the robot, eliminating the need for mechanical handles, articulations, and support structures while maintaining or improving control accuracy
Solution Approach 2:
The patent creates a virtual copy of the mechanical coupling relationship through sensor detection and computational processing. Instead of physically coupling the control device to the robot, the system detects the motion control device's position and calculates the corresponding robot position, creating a virtual representation of the coupling relationship that simplifies the physical system
3Ease of operation
If handheld control devices with mechanical coupling are used, then ease of operation is improved, but reliability deteriorates due to potential mechanical failures and frequent re-coupling requirements
Solution Approach 1:
The patent replaces the mechanical coupling system with an optical sensing system that has no moving parts or mechanical connections to fail. The sensor-based virtual coupling eliminates wear, loosening, and mechanical failure modes while requiring no re-coupling operations, thereby improving both ease of operation and system reliability simultaneously
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 solution enables simple, intuitive, and safe programming and execution of robot movements, reducing the risk of errors and injuries by allowing operators to control industrial robots from a safe distance and simplifying the selection and adjustment of machine parts, while improving ergonomics and control accuracy.
Implementation Method 1
At least one imaging sensor (16) is provided, which can be moved to a relative spatial position selected by the operator... The imaging sensor (16) is moved into a relative spatial position selected by the operator... a coupling condition (25) is defined using image-based data from the relative position between the movement specification means (3) and the reference mark (19)
Implementation Method 2
At least one distance-sensitive sensor (17) is provided... The distance-sensitive sensor (17) is moved into a relative spatial position selected by the operator... a coupling condition (25) is defined using distance-based data from the relative position between the movement specification means (3) and the reference mark (19)
Data Source
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AI summary
The invention relates to a method for controlling the movements of articulated arms (21, 22, 23) of an industrial robot (2) using a movement setting means (3), wherein the movement setting means (3) is held by an operator in a predefined position relative to a reference mark (19, 19', 19") and the reference mark (19) is detected by the movement setting means and optionally read (16), and the distance (17) thereof to the reference mark is measured. The position and the alignment of the movement setting means (3) is detected by internal sensors (9), e.g. inertial/acceleration sensors, or by external sensors (30, 31, 32), e.g. 3D camera. Upon satisfying the coupling condition (25), the industrial robot or individual articulated arms thereof are coupled virtually to the movement setting means and follow its movements, as if a fixed or rigid or flexible mechanical coupling had been established with respect to the industrial robot. In addition, a haptic feedback to the operator can be provided by a mechanical coupling of the movement setting means to an articulated arm of the industrial robot.