Human-Cooperative Robot Force Feedback for Overload Prevention
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Solution Overview
Problem
Human-cooperative robot systems lack effective mechanisms to differentiate between appropriate and excessive external forces applied by workers, leading to potential damage when inexperienced operators misunderstand robot responses to force thresholds.
Innovation Solution
A control device equipped with sensors that detect external forces and initiate a retreating operation or warning, such as vibrating the robot, when forces exceed certain thresholds, preventing excessive loads without requiring additional alarm devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the robot stops operation when external force reaches the first threshold, then robot safety is improved, but inexperienced operators may misunderstand the robot's response and apply excessive force causing damage
Solution Approach 1:
The system implements a two-stage feedback mechanism: first threshold triggers stopping operation, second threshold triggers warning signal. This layered feedback helps operators understand the robot's force response characteristics, preventing excessive force application while maintaining safety.
Solution Approach 2:
A warning signal acts as an intermediary between the first threshold (stopping) and potential damage. When force reaches the second threshold, the warning signal alerts operators before actual damage occurs, serving as a protective mediator.
2Loss of information
If additional alarm devices are added to warn operators of excessive force, then operator awareness is improved, but system complexity and cost increase
Solution Approach 1:
The robot's existing control system performs multiple functions: normal operation control, force detection, stopping operation at first threshold, and issuing warnings at second threshold. This multi-functionality eliminates the need for separate alarm devices, reducing system complexity while maintaining operator awareness.
3Loss of information
If the robot performs retreating operation at a lower third threshold, then operator communication is improved, but operation continuity is reduced
Solution Approach 1:
The force response is segmented into three distinct stages: retreating operation (third threshold), stopping operation (first threshold), and warning signal (second threshold). This segmentation provides clear force usage feedback to operators while allowing operation continuity in the first stage, balancing communication and productivity.
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
Ensures safe operation by clearly communicating excessive force application to workers, preventing robot damage and allowing experienced operators to recognize and correct force usage, while simplifying system configuration.
Implementation Method 1
the robot is provided with a sensor that detect an external force applied to the robot
Implementation Method 2
the warning may be issued by causing the robot to operate in a vibrating manner
Data Source
AI summary
An aspect of the present invention prevents a robot from being subjected to an excessive load even when operated by an inexperienced user. Provided is a human-cooperative robot system including a robot and a control device that controls the robot. The robot is provided with a sensor that detect an external force applied to the robot. The control device stops the operation of the robot when the detected external force is equal to or greater than a first threshold, and issues a warning when the detected external force is equal to or greater than a second threshold exceeding the first threshold.