Robot Controller for Curved-Path Process Restart Without Gaps
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Solution Overview
Problem
Existing robot controller techniques fail to efficiently resume continuous processing tasks when interrupted while the tool is advancing along a curved path, leading to potential collisions and manual rework due to the inability to linearly retreat, resulting in gaps or excessive processing.
Innovation Solution
A robot controller that stores the interrupted position and speed of the tool, calculates a command signal to reverse along a curved path, and resumes the task from a reversed position to avoid collisions and ensure accurate re-starting of the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tool is linearly retreated before resuming the application processing task, then gaps without processing and excessive processing are avoided, but collision with obstacles may occur when the tool advances along a curved path
Solution Approach 1:
Instead of linearly retreating the tool before resuming processing (conventional approach), the invention reverses the tool along the curved path it previously followed. This inversion of the retreat direction allows the tool to avoid obstacles while still eliminating gaps and excessive processing by retracing its path to an appropriate restart position.
Solution Approach 2:
The invention applies curvature by having the tool reverse along a curved path rather than a straight line. The tool follows the same curved trajectory it traversed during the interrupted processing, enabling it to retreat to a safe position without colliding with obstacles that would be encountered during linear retreat.
2Productivity
If the application processing task is resumed immediately after interruption, then processing continuity is maintained, but gaps without processing and excessive processing occur
Solution Approach 1:
Before resuming the application processing task, the invention performs a preliminary reverse motion along the curved path to reposition the tool. This preliminary action eliminates gaps and excessive processing by ensuring the tool starts from an appropriate position and speed, thereby maintaining both processing continuity and quality.
Solution Approach 2:
The invention uses feedback by storing the interrupted position and speed information, then using this data to calculate the appropriate reverse distance and restart parameters. This feedback mechanism ensures the tool resumes processing at the correct position and speed, preventing gaps and excessive processing while maintaining continuity.
3Loss of time
If the tool speed is not adjusted to the programmed speed before resuming processing, then processing can start immediately, but excessive processing amount per unit distance occurs
Solution Approach 1:
The invention performs preliminary acceleration of the tool along the curved path before resuming the application processing task. This preliminary action ensures the tool reaches the programmed speed in advance, preventing excessive processing amount per unit distance while minimizing the time loss through efficient speed adjustment during the reverse motion.
Solution Approach 2:
The invention changes the speed parameter dynamically by storing the interrupted speed, calculating the required acceleration, and adjusting the tool speed during the reverse motion. This parameter change ensures the tool reaches the correct speed before resuming processing, maintaining processing quality without excessive time loss.
Data Source
AI summary
The purpose of the present invention is to provide a robot controller that does not require manual correction when an applying process operation is interrupted due to occurrence of an error, and that enables automatic avoidance of occurrence of an interrupted part (gap) of the applying process and occurrence of excessive processing upon resuming the applying process operation. When an applying operation is interrupted, if the operation has stopped after further advancement of the operation site from the position of interruption, the operation site is moved back by a predetermined distance along the curved trajectory at the time of an advancing movement prior to the stopping, and the advancing movement is resumed from the moved-back position along the curved trajectory. Thus, it is possible to resume the continuous process while the operation site, at the position where the continuous process operation has been interrupted, proceeds at the same speed as when the applying operation was interrupted.