Robot Force Sensor Diagnosis Using Theoretical Force-Moment Comparison
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Solution Overview
Problem
The detection accuracy of force sensors in industrial robots can decrease due to various causes, making it difficult to correctly detect contact with objects or persons, and identifying the cause of decreased accuracy is challenging.
Innovation Solution
A force sensor diagnostic device is integrated into the robot control device, which calculates theoretical values of force and moment, compares them with actual measurements, and determines if the force sensor is distorted, notifying the results to facilitate corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a force sensor is disposed near an installation surface to detect contact, then contact detection capability is improved, but detection accuracy decreases due to various causes
Solution Approach 1:
The patent applies preliminary action by performing sensor diagnosis before robot operation begins. The diagnostic device calculates theoretical force and moment values based on robot configuration data, then compares these with actual sensor readings to detect installation errors or sensor malfunctions in advance, ensuring accurate contact detection during subsequent operation.
Solution Approach 2:
The patent implements feedback by continuously comparing actual force sensor measurements with theoretically calculated values during robot operation. When deviations exceed predetermined thresholds, the system generates diagnostic information to notify operators of potential sensor issues, enabling real-time monitoring and maintenance of detection accuracy.
2Ease of operation
If force sensor measurements are used directly without verification, then operation simplicity is maintained, but identification of accuracy degradation causes becomes difficult
Solution Approach 1:
The patent applies self-service by enabling the robot system to automatically diagnose its own force sensor status. The diagnostic device uses the robot's existing configuration data to calculate theoretical values and automatically compares them with sensor measurements, allowing the system to self-verify sensor accuracy without requiring external calibration equipment or complex manual procedures.
Solution Approach 2:
The patent introduces an intermediary diagnostic device that acts as a mediator between the force sensor and the control system. This device calculates theoretical values based on robot configuration and serves as a reference standard, comparing it with actual sensor readings to identify discrepancies and their causes without disrupting normal operation.
3Measurement precision
If theoretical values are calculated and compared with actual measurements to diagnose sensor distortion, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a diagnostic device that leverages existing robot configuration data and control system resources. The same hardware components used for robot control are utilized for diagnostic calculations, and the theoretical value computation uses general-purpose physics calculations based on existing robot parameters, avoiding the need for specialized dedicated diagnostic hardware.
Data Source
AI summary
A force sensor diagnostic device that diagnoses a force sensor provided in a robot, the force sensor disposed near an installation surface on which the robot is installed and detecting a force and a moment applied to the robot from an outside. The device includes a calculation unit that calculates a theoretical value of the force and a theoretical value of the moment detected by the force sensor, a determination unit that determines whether the force sensor is distorted by comparing an actually measured value of the force and an actually measured value of the moment detected by the force sensor with the theoretical values of the force and the moment, and a notification unit that notifies a determination result from the determination unit.