Robot Screw-Fastening Control With Operator Cooperation Cues
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Solution Overview
Problem
Robots performing screw-fastening tasks face limitations when components rotate relative to each other, are stacked, or have obstacles in their path, leading to incomplete or failed fastening operations.
Innovation Solution
A robot control system that determines whether it can perform screw-fastening tasks independently and outputs cooperation messages to operators when necessary, including instructions to stabilize rotating components, maintain stacked configurations, or remove obstacles, ensuring successful fastening by leveraging a camera for obstacle detection and a nut runner for precise path calculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot performs screw-fastening tasks automatically, then productivity is improved, but the robot cannot handle complex cases such as rotating components, stacked components, or obstacles
Solution Approach 1:
The system introduces an intermediary decision-making layer (robot control unit) that evaluates task complexity and coordinates between automated robot execution and human operator intervention. The control unit determines whether to execute automatically or request cooperation based on detected conditions, serving as a mediator between full automation and human assistance.
Solution Approach 2:
The system dynamically adjusts the level of automation based on real-time conditions. Instead of fixed automatic or manual operation, the robot control unit flexibly switches between autonomous execution and cooperative mode depending on whether the current task involves rotating components, stacked components, or obstacles, optimizing both productivity and adaptability.
2Extent of automation
If the robot attempts to screw-fasten components that rotate relative to each other, then automation is maintained, but the fastening operation fails
Solution Approach 1:
The system implements feedback mechanisms where the robot control unit monitors execution conditions during screw-fastening operations. When rotation or other anomalies are detected, the system provides feedback to switch from autonomous mode to cooperative mode, ensuring reliable fastening by involving human operators for complex cases.
Solution Approach 2:
The system takes preliminary anti-action by proactively identifying conditions that would lead to failure (rotating components, stacked components, obstacles) before attempting fastening. The robot control unit evaluates these conditions in advance and prevents automatic execution when failure risks are detected, switching to cooperative mode instead.
3Manufacturing precision
If the robot handles stacked components requiring precise positioning, then manufacturing precision is maintained, but the robot cannot maintain the stacked state without human assistance
Solution Approach 1:
The system applies preliminary action by having the robot control unit identify stacked component configurations before fastening begins. The system prepares appropriate cooperative messages in advance, instructing operators on how to maintain the stacked state during fastening, ensuring both precision and operational ease.
Data Source
AI summary
A robot control system includes a robot that screw-fastens a sub-component placed in a main-component to the main-component, a robot control unit that controls the robot, and a display as an output unit through which the robot control unit outputs a message to an operator. The robot control unit determines whether or not the robot can screw-fasten the sub-component to the main-component by itself. Then, when the robot control unit determines that the robot cannot screw-fasten the sub-component to the main-component by itself, the robot control unit outputs a cooperation message to an operator through the display.