Robot System Dual Threshold Force Warning and Stop Mechanism
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Solution Overview
Problem
Existing robot systems lack effective mechanisms to prevent excessive external forces from being applied to robots during operation, which can lead to interruptions and reduced work efficiency, especially in cooperative and direct-teaching scenarios where human interaction is involved.
Innovation Solution
A robot system equipped with a force detecting unit that monitors external forces and triggers a warning through vibration when the force exceeds a first threshold and stops the robot when it exceeds a second threshold, allowing the operator to adjust the force before an excessive load is applied, while also providing directional awareness through varying warnings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a force sensor is used to detect external force magnitude and stop the robot when exceeding a threshold, then robot protection is improved, but work efficiency deteriorates due to frequent interruptions
Solution Approach 1:
The protection mechanism is segmented into two distinct force thresholds: a first threshold that triggers warnings and a second threshold that stops the robot. This segmentation allows the system to differentiate between normal operational forces and dangerous forces, reducing unnecessary interruptions while maintaining protection.
Solution Approach 2:
The system performs preliminary action by issuing warnings when the external force reaches the first threshold, before actually stopping the robot at the second threshold. This preliminary warning allows operators to adjust forces proactively, preventing excessive forces from being applied in the first place and maintaining continuous operation.
2Productivity
If a single high threshold is used to stop the robot, then work continuity is improved, but robot damage risk increases from excessive force
Solution Approach 1:
The first threshold serves as a preliminary warning mechanism that alerts operators to excessive force application before it reaches dangerous levels. This allows corrective action to be taken while the robot is still operating, preventing damage while maintaining work continuity.
Solution Approach 2:
The system provides continuous feedback through warnings when the first threshold is exceeded, allowing operators to monitor and adjust their force application in real-time. This feedback loop enables operators to understand when they are applying too much force and correct their behavior, preventing robot damage.
3Reliability
If force detection and stopping mechanisms are added, then robot protection is improved, but device complexity increases
Solution Approach 1:
The system uses parameter changes by implementing two distinct force thresholds instead of a single threshold. This simple parameter modification allows the system to provide both warning and stopping functions without adding complex hardware, merely by changing the control logic parameters.
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 solution enhances work efficiency by preventing interruptions and ensuring operators can manage external forces effectively, even in noisy environments, by providing timely warnings and ensuring the robot is stopped before excessive forces are applied, thus maintaining continuous operation.
Implementation Method 1
a force detecting unit that is provided in the robot and that detects the magnitude and the direction of an external force acting on the robot
Implementation Method 2
a warning part that vibrates the robot when an external force having a magnitude equal to or greater than a first predetermined threshold is detected
Data Source
AI summary
A robot system includes: a robot that is movable according to an external force applied thereto by a worker; a force detecting unit that is provided in the robot and that detects the magnitude of an external force acting on the robot; a warning part that vibrates the robot when an external force having a magnitude equal to or greater than a first predetermined threshold is detected by the force detecting unit; and a stop part that stops the robot when an external force having a magnitude equal to or greater than a second predetermined threshold that is greater than the first predetermined threshold is detected by the force detecting unit.