Industrial Robot Manual Programming Speed Control
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Solution Overview
Problem
Industrial robots face a high risk of collision with objects during manual programming, leading to potential damage due to the inability to control forces and speeds effectively, especially when guided near workpieces, as existing force controllers and sensors are inadequate in managing the kinetic energy and elastic deformation of the robot arm.
Innovation Solution
The method involves using distance measuring devices such as ultrasonic, inductive, capacitive, or laser sensors to determine the distance between the robot and the object, and controlling the robot's drives to limit its speed based on this distance, ensuring it can only be moved at a maximum speed that prevents collision, with the option to brake or stop movement when close proximity is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the robot is guided manually near a workpiece or on the surface of the workpiece to program the robot, then the programming precision and accuracy are improved, but the robot may damage the workpiece during programming due to collision or applying relatively large force
Solution Approach 1:
The patent applies preliminary action by pre-defining a safe zone around the workpiece before programming begins. Distance measuring devices continuously monitor the robot's position relative to this predetermined safe zone, and the control system automatically limits the robot's speed or stops movement before the robot can collide with the workpiece, preventing damage before it occurs
Solution Approach 2:
The patent introduces an intermediary control system that acts as a mediator between the manual guidance input and the robot's actual movement. This intermediary system processes distance measurements from sensors and dynamically adjusts the robot's speed or position commands, allowing precise programming near the workpiece while preventing harmful contact through automated intervention
2Productivity
If the robot moves at high speed during manual programming, then the productivity and programming efficiency are improved, but the risk of collision and damage to the workpiece increases
Solution Approach 1:
The patent applies dynamics by making the robot's speed dynamic rather than fixed. The control system continuously adjusts the maximum allowable speed based on real-time distance measurements from the safe zone boundaries. When the robot is far from the workpiece, it can move at higher speeds for efficiency; when approaching the safe zone boundary, the speed is automatically reduced, maintaining both productivity and safety
Solution Approach 2:
The patent implements feedback through continuous monitoring of the robot's position using distance measuring devices. The control system receives real-time feedback about the robot's distance from the workpiece and automatically adjusts the robot's speed or movement commands accordingly, creating a closed-loop control system that maintains safe operation while optimizing programming efficiency
3Reliability
If force-controlled systems are used to prevent collision during manual programming, then the safety and workpiece protection are improved, but the system complexity and cost increase due to inadequate existing force controllers
Solution Approach 1:
The patent replaces complex mechanical force control systems with a simpler sensor-based position control system. Instead of using force torque sensors to detect and respond to contact forces, the system uses distance measuring devices to monitor position relative to a safe zone and prevents collision through proactive speed limitation and position control, eliminating the need for complex force sensing and control hardware
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the risk of collision by allowing the robot to move safely along the surface of objects and prevents damage by controlling speed and force, enabling precise programming without accidental contact.
Implementation Method 1
distance measuring devices such as ultrasonic, inductive, capacitive, or laser sensors
Implementation Method 2
distance measuring devices such as ultrasonic, inductive, capacitive, or laser sensors
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an industrial robot (R) and to a method for programming an industrial robot (R). The industrial robot (R) has drives (11-16) and is moved manually in particular along a space curve. A distance (a) between the industrial robot (R) and an object (W) is determined, and the drives (11-16) of the industrial robot (R) are controlled such that the industrial robot (R) can be moved manually only at a maximum speed, which is dependent on the distance (a) determined from the object (W).