Hybrid Robot Force-Position Control for Stable Manual Guidance
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Solution Overview
Problem
Existing industrial robot control systems fail to achieve a balance between rigidity, transparency, and stability when partially guided manually, leading to issues like bounces when encountering rigid environmental elements.
Innovation Solution
A control system for industrial robots that includes a multi-axis robot arm with electric actuators, sensors, a central unit, and an auxiliary unit, utilizing a data bus for communication, and a multi-axis force sensor to measure external forces, calculating articular force setpoints, and implementing an articular conversion matrix to improve control precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the robot control system uses traditional control methods to achieve satisfactory rigidity and transparency, then the robot can be easily moved and maintain structural stability, but the robot exhibits insufficient stability and bounces when contacting rigid environmental elements
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting control parameters (gain values, filtering frequencies) based on the robot's operational state and external forces detected. The control system modifies stiffness and damping parameters in real-time to prevent bounces while maintaining rigidity during manual guidance, resolving the contradiction between structural strength and stability.
2Stability of the object's composition
If the robot control system increases stability to prevent bounces, then the robot becomes more stable when contacting rigid elements, but the robot loses transparency and becomes harder to move manually
Solution Approach 1:
The patent implements dynamics by making the control system adaptive and state-dependent. The controller dynamically adjusts its characteristics based on detected external forces, robot velocity, and operational mode, allowing the system to be soft and transparent during manual guidance while becoming stiff and stable when preventing bounces during autonomous operation or contact with rigid elements.
Solution Approach 2:
The control system changes parameters dynamically based on operational conditions. Gain values, filtering frequencies, and impedance parameters are adjusted in real-time to maintain transparency during manual operation while ensuring stability during autonomous operation or contact with rigid environmental elements.
3Device complexity
If the robot control system uses simplified control architecture, then the system is easier to implement and maintain, but the control precision and ability to achieve all three criteria simultaneously is insufficient
Solution Approach 1:
The patent applies segmentation by dividing the control system into distinct functional modules: force sensing module, articular conversion matrix calculation module, auxiliary unit for real-time control, and main control unit. This modular architecture allows each component to be optimized independently while maintaining overall system precision and manageability.
Solution Approach 2:
The patent introduces an articular conversion matrix as an intermediary computational element that transforms force sensor data into actionable control commands. This matrix acts as a mediator between the physical force measurements and the control system's decision-making processes, enabling precise control without requiring complex direct control algorithms.
Data Source
AI summary
A process of controlling an industrial robot includes the steps of calculating, in a calculation module, a control articular force setpoint of the axis controller module; calculating, in an articular converter, the articular conversion matrix from articular positions; providing the axis controller module with the multi-dimensional external forces exerted on the effector; calculating, in the axis controller module, the vector of the articular forces; calculating, in the axis controller module, the current loop control setpoints, taking into account the articular force vector and the articular force setpoint; and calculating, in the axis controller module, the control setpoints for the power units according to the control setpoints for the current loops.