Robot Controller Replacement Using Stored Calibration Parameters
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Solution Overview
Problem
Existing robot systems face challenges in easily replacing and connecting robot controllers or auxiliary components due to individual differences in motor and encoder variations, leading to complex procedures and potential operational failures.
Innovation Solution
A robot system with a target robot featuring a first memory unit for device-specific data and an auxiliary component, and a robot controller with a second memory unit that stores and updates individual identification data and difference parameters, allowing for appropriate control and preventing mismatches during replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual difference parameters are measured and stored in the robot controller for each manipulator, then control accuracy is improved, but replacement of the robot controller or manipulator becomes difficult
Solution Approach 1:
The patent segments the storage of individual difference parameters by creating separate storage locations: the robot controller stores parameters for currently connected manipulators, while the manipulator itself stores parameters for previously connected manipulators. This segmentation allows the robot controller to be replaced without losing access to individual difference parameters, as they are distributed across multiple storage locations.
Solution Approach 2:
The manipulator acts as an intermediary storage device for individual difference parameters. When a robot controller is replaced, the new controller can retrieve parameters from the manipulator's storage, which retains them as a backup. This intermediary role of the manipulator enables smooth transitions between controllers without losing critical calibration data.
2Ease of repair
If robot controller replacement is allowed, then system maintainability is improved, but control accuracy may deteriorate due to loss of individual difference parameters
Solution Approach 1:
The system performs preliminary actions by automatically detecting controller replacement and proactively retrieving individual difference parameters from the manipulator's storage before normal operation resumes. This preliminary retrieval ensures that control accuracy is restored immediately upon replacement, eliminating the need for manual re-calibration and maintaining precision throughout the repair process.
Solution Approach 2:
The patent implements feedback mechanisms where the robot controller continuously monitors connection status and individual difference parameter integrity. When replacement is detected, the system feedback loop triggers automatic parameter retrieval and verification, ensuring that control accuracy is maintained through continuous monitoring and automatic correction of any parameter loss.
3Device complexity
If individual difference parameters are stored only in the robot controller, then data management is simplified, but reliability decreases when controller failure or replacement occurs
Solution Approach 1:
The patent applies local quality by placing individual difference parameter storage in two different locations with different functions: the robot controller stores parameters for active manipulation, while the manipulator stores parameters as a backup for previously connected controllers. This distributed storage approach with differentiated roles improves reliability without significantly increasing overall system complexity.
Solution Approach 2:
The system implements discarding and recovering by allowing old individual difference parameters to be retained in the manipulator's storage even after being superseded by new parameters. When controllers are replaced, the system can recover these previously discarded parameters from the manipulator's storage, ensuring continuous availability of critical calibration data and improving system reliability.
Data Source
AI summary
A robot system may include a robot controller; and a target robot. The target robot may include a first memory to store device specific data including individual identification data; and an individual difference parameter unique to the target robot. The robot controller may include a second memory structured to store the individual identification data and the individual difference parameter of the target robot connected to the robot controller; and a controller to control the target robot on the basis of model configuration information the individual difference parameter stored in the second memory. The controller may check the individual identification data read from the first memory unit against the individual identification data stored in the second memory unit and, in accordance with a checking result, update the individual difference parameter stored in the second memory unit with the individual difference parameter read from the first memory unit.