Robot Controller Switching for Stable Manual Guidance
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Solution Overview
Problem
Existing robot control systems are prone to unexpected reactions when switching to manual operating mode due to errors in modeling robot-guided loads, leading to reduced positioning accuracy and potential dropping of the robot, as they fail to accurately detect external forces and torques.
Innovation Solution
A method for switching a robot controller to manual operating mode that uses detected joint forces and torques to trigger an error reaction if they exceed predetermined threshold values, thereby reducing unexpected reactions and warning the operator, by employing force or torque sensors and software to control the robot's drives and specify target joint forces and torques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the robot uses a simplified model of robot-guided load, then the control system complexity is reduced, but the positioning accuracy deteriorates and unexpected reactions occur when switching to manual guidance mode
Solution Approach 1:
The control system performs preliminary detection of joint forces and torques before switching to manual guidance mode. By evaluating the detected forces against expected values from the simplified model, the system proactively identifies model errors that would cause positioning inaccuracies or unexpected reactions, allowing corrective action before the mode switch occurs.
Solution Approach 2:
The system continuously monitors joint forces and torques during operation and compares detected values with model-predicted values. This feedback mechanism enables the system to detect discrepancies between the simplified model and actual robot-guided load, triggering warnings or corrections to maintain positioning accuracy while using the simpler model.
2Ease of operation
If the robot operates in manual guidance mode with simplified load modeling, then the ease of operation is improved, but the reliability deteriorates due to unexpected reactions from undetected model errors
Solution Approach 1:
Before enabling manual guidance mode, the system performs a preliminary check by detecting joint forces and torques and comparing them with model predictions. This advance detection identifies potential model errors that would cause unreliable behavior during manual operation, preventing the system from entering an unsafe state while maintaining ease of operation when conditions are safe.
Solution Approach 2:
The continuous monitoring and comparison of detected joint forces with model predictions provides real-time feedback on model accuracy. This feedback ensures reliable operation by alerting operators to model errors that could cause unexpected reactions, maintaining trust in the system's behavior during manual guidance.
3Device complexity
If the robot does not detect external forces accurately, then the device complexity is reduced, but the stability deteriorates when switching to manual guidance mode due to unrecognized load weights
Solution Approach 1:
The system performs preliminary detection and evaluation of joint forces and torques before mode switching. By comparing detected forces with model predictions, it identifies unrecognized load weights that would cause instability during manual guidance, allowing corrective action before the transition occurs.
Solution Approach 2:
The system uses feedback from joint force detection to continuously assess model accuracy. This feedback mechanism identifies discrepancies between the simplified model and actual loads, enabling the system to maintain stability by alerting operators to unrecognized weights that would affect robot behavior during manual operation.
Data Source
Figure 1~2
AI summary
In an inventive method for switching a control (1) of a robot (2) into a hand-guided operating mode (H) for moving the robot by manually applying forces and/or torques to the robot, an error reaction (R) is triggered as a result of the switching and depending on detected and/or target joint forces and/or torques and/or a pose of the robot (S40).