Robot Coating Control With Abnormality Position Notification

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Solution Overview

Problem

Existing systems for applying viscous materials to workpieces lack effective early detection of abnormalities in the application state, which can lead to suboptimal coating quality and increased maintenance costs.

Innovation Solution

A control system comprising a discharge control circuit, a robot control circuit, an application abnormality detection circuit, an application position calculation circuit, and an abnormality notification circuit that monitors the application device and articulated robot to detect and notify abnormalities in the coating application state on a workpiece.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an application device with an articulated robot is used to apply viscous material to a workpiece, then the coating can be applied with automation and flexibility, but early detection of abnormalities in the application state is lacking

Engineering Contradiction:

Improvecoating qualityVSAvoidabnormality detection capability

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The system performs preliminary actions by calculating the expected application position of the coating based on robot position and orientation data before the actual application occurs. This allows the system to predict where coating should be applied and compare it with actual application results to detect abnormalities early, rather than waiting for visual inspection after application.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by continuously monitoring robot position and orientation, calculating expected application positions, and comparing these with actual application outcomes. When deviations are detected, the system provides feedback through abnormality notifications that include specific location information, enabling real-time quality control and immediate corrective action.

Inventive Principle:

Principle #23Feedback

2Reliability

If monitoring of the application process is enhanced to detect abnormalities early, then coating quality improves, but the system complexity increases

Engineering Contradiction:

Improvecoating qualityVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control device performs multiple functions using a single integrated system. It controls the articulated robot's movement, calculates the discharge circuit position and orientation, determines expected coating application positions, and detects abnormalities - all within one control device. This multi-functionality reduces the need for separate monitoring hardware while maintaining comprehensive quality control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses an intermediary approach by calculating virtual application position data based on robot state information rather than directly measuring physical coating properties. This computational intermediary allows abnormality detection through position analysis, avoiding the need for complex physical sensors in the coating material itself while still achieving reliable quality monitoring.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If the discharge circuit position and orientation are continuously monitored to detect application abnormalities, then measurement precision improves, but the use of energy increases

Engineering Contradiction:

Improveapplication position accuracyVSAvoidenergy consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The system replaces physical measurement mechanisms with computational calculations. Instead of using additional sensors to physically measure coating application position, the system substitutes mechanical measurement with mathematical calculations based on robot joint data and kinematic models. This substitution achieves high measurement precision while consuming minimal energy, as computational operations require far less energy than physical sensing and measurement hardware.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20220097232A1Control system, monitoring device, monitoring method, and non-transitory computer-readable storage medium storing program

Publication Date: 2022.03.31 YASKAWA DENKI KK

AI summary

A control system including a discharge control circuit configured to control an application device such that a coating is discharged from a discharge circuit; a robot control circuit configured to cause an articulated robot to change a position and an orientation of the discharge circuit such that the coating is applied to a workpiece; an application abnormality detection circuit configured to detect an abnormality in an application state of the coating on the basis of at least one of a state of the device or of the robot; an application position calculation circuit configured to calculate an application position of the coating; and an abnormality notification circuit configured to send a notification of a site of an abnormality in the application state on the workpiece on the basis of a detection result of the abnormality in the application state and a calculation result of the application position.