Robot Axis Load Monitoring for Adaptive Collision Detection
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Solution Overview
Problem
Current collision monitoring systems for robots face challenges in reliably detecting collisions due to varying environmental conditions and model-based setpoint values, leading to cumbersome threshold specification and unwarranted responses.
Innovation Solution
The system continuously monitors axis loads of a robot using sensors and adjusts threshold values based on past deviations and changes, allowing for adaptive collision detection by calculating sliding averages and gradients, and switching between operating modes based on speed to optimize sensitivity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If model-based setpoint values are used for collision monitoring, then collision detection can be performed, but the detection reliability deteriorates due to varying environmental conditions and model errors
Solution Approach 1:
The patent changes the reference parameter from fixed model-based setpoint values to dynamically adapted reference values that are adjusted based on actual measured axis loads during collision-free operation. This adaptation process modifies the reference values to account for environmental variations, model errors, and operational conditions, thereby improving detection reliability without sacrificing measurement precision
Solution Approach 2:
The system implements feedback by continuously monitoring actual axis loads during collision-free operation and using this information to adapt reference values. The feedback loop compares measured values with reference values and automatically adjusts the reference values to minimize systematic deviations, ensuring reliable collision detection under varying conditions
2Ease of operation
If fixed threshold values are specified for collision monitoring, then the system is simple to operate, but the system produces unwarranted responses due to varying operational conditions
Solution Approach 1:
The system performs self-service by automatically adapting reference values based on measured operational data without requiring manual intervention. The controller autonomously learns the actual axis loads under various collision-free conditions and adjusts reference values accordingly, eliminating the need for cumbersome manual threshold specification while preventing unwarranted responses
Solution Approach 2:
The patent transforms the static threshold specification into a dynamic adaptation process. Reference values are no longer fixed but continuously adjusted based on actual operational conditions, allowing the system to adapt to varying speeds, accelerations, payloads, and environmental factors while maintaining ease of operation
3Reliability
If adaptive threshold values are calculated based on preceding deviations, then detection reliability improves, but system complexity increases
Solution Approach 1:
The patent replaces complex mechanical threshold adjustment mechanisms with electronic calculation and software-based adaptation. The controller uses computational algorithms to calculate sliding averages and adapt reference values automatically, substituting physical adjustment complexity with software intelligence that improves reliability without requiring additional hardware
Data Source
AI summary
A method for collision monitoring of a robot includes ascertaining an actual value of an axis load of at least one axis of the robot and identifying a collision of the robot if a deviation between this actual value and a reference value of the axis load exceeds a threshold value. The threshold value is ascertained as a function of at least one preceding deviation between the actual value and the reference value and/or at least one preceding reference value and/or the reference value, is ascertained as a function of a preceding actual value.