Robot Joint Alignment Control Using Feedback and Sensor Fusion
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Solution Overview
Problem
Conventional high-accuracy assembly processes using industrial robots require multiple cycles of measuring and moving, leading to increased cycle time, commission time, and cost due to the need for accurate calibration.
Innovation Solution
A system and method that combines feedback data from the robot and sensing data from sensors to predict a target position for alignment, using data fusion techniques such as predictor, filter, sum, and subtraction modes, to reduce the number of sensing and moving cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple cycles of measuring and moving are performed to achieve high accuracy assembly, then manufacturing precision is improved, but productivity deteriorates due to increased cycle time
Solution Approach 1:
The system performs preliminary calibration to establish a mapping relationship between robot joint positions and workpiece positions before actual assembly. This pre-established model allows the robot to directly calculate target positions without requiring multiple iterative measuring and moving cycles during assembly, thus achieving high precision while maintaining productivity
Solution Approach 2:
The patent replaces the traditional mechanical iterative adjustment process with a computational approach. By using sensors to capture workpiece positions and a controller to calculate target positions based on pre-established mapping relationships, the system substitutes physical trial-and-error cycles with mathematical computation, reducing cycle time while maintaining assembly accuracy
2Manufacturing precision
If multiple cycles of measuring and moving are performed to achieve high accuracy assembly, then manufacturing precision is improved, but loss of time worsens due to increased commission time
Solution Approach 1:
The system performs preliminary calibration during the commissioning phase to establish the mapping relationship between robot joint positions and workpiece positions. This one-time preliminary action during commissioning eliminates the need for repeated measuring and adjusting cycles, thereby reducing commission time while ensuring assembly accuracy is achieved from the start
3Manufacturing precision
If multiple cycles of measuring and moving are performed to achieve high accuracy assembly, then manufacturing precision is improved, but device complexity worsens due to calibration requirements
Solution Approach 1:
The system uses the robot's own motion data and sensor measurements to automatically establish the mapping relationship between joint positions and workpiece positions. The calibration process is self-contained, using the robot's built-in sensors and controllers to perform the calibration without requiring external complex calibration equipment or manual intervention, thereby reducing device complexity while achieving high precision
Data Source
AI summary
A system and a method for controlling the robot. The method includes determining, based on feedback data received from the robot, first position information of a joint of the robot. The feedback data indicates a movement of the joint. The method also includes determining second position information of the joint based on sensing data received from a sensor. The sensing data indicates a relative movement between the joint and a second object to be aligned with the first object. The method also predicts a target position for aligning the first object with the second object.