Robot Joint Torque Sensor Monitoring With 3D Deterioration Display
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Solution Overview
Problem
Conventional torque sensors in robotic articulated arms suffer from manufacturing errors and degradation over time, leading to offset values that require periodic measurement and replacement, increasing user workload and making it difficult to identify deteriorated sensors at specific joints.
Innovation Solution
A robot control device that includes a display system showing 3D graphics of the robot, with warning icons in color indicating deteriorated torque sensors at specific joints, and changing colors based on the degree of deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque sensors are periodically measured and monitored, then the reliability of torque detection is improved, but the user workload and time consumption increase
Solution Approach 1:
The system performs self-diagnosis by automatically calculating torque offset values and determining sensor deterioration status without requiring user intervention. The control device autonomously monitors each torque sensor, calculates offset values based on gravitational torque models, and generates deterioration determination results, thereby eliminating the need for periodic manual measurement while maintaining high reliability
Solution Approach 2:
The system implements continuous feedback monitoring by periodically calculating torque offset values and comparing them against predetermined thresholds. The control device receives torque sensor outputs, processes them through gravitational torque calculations, and provides real-time feedback on sensor status through the display device, enabling proactive maintenance without increasing user workload
2Reliability
If torque offset monitoring is implemented across all joints, then the reliability of torque detection is improved, but the device complexity increases
Solution Approach 1:
The system divides the articulated arm into multiple independent joint segments, each with its own torque sensor and corresponding gravitational torque model. The control device processes each joint separately by calculating offset values for individual segments based on their specific gravitational characteristics, enabling comprehensive monitoring without requiring a complex centralized processing approach
Solution Approach 2:
The system monitors sensor deterioration by tracking changes in torque offset parameters over time. By calculating offset values based on gravitational torque models and comparing them against predetermined thresholds, the system detects deterioration through parameter variation rather than requiring complex diagnostic procedures, thus maintaining simplicity while improving reliability
3Ease of operation
If color-coded warning icons are displayed for each torque sensor, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The system uses color-coded warning icons (red, yellow, green) to represent different levels of torque sensor deterioration. Each color corresponds to a specific deterioration level determined by comparing calculated offset values against predetermined thresholds, enabling operators to quickly assess sensor status at a glance without requiring complex interpretation of numerical data
Solution Approach 2:
The display device creates a visual representation (copy) of the physical robot structure with overlaid warning icons indicating sensor status. This graphical interface mirrors the articulated arm configuration and places color-coded indicators at corresponding joint locations, providing an intuitive visual map that simplifies operator understanding without adding physical complexity to the robot itself
Data Source
AI summary
The objective of the present invention is to allow a user to recognize, at a glance, the degree to which deterioration is occurring to a specific torque sensor from among torque sensors provided for an articulated arm of a robot. In the control device for a robot provided with sensors each of which detects an external force torque about a joint, the objective is achieved by providing a display device which displays, together with 3D graphics of a robot body, a warning icon in color at a mounted location of a deteriorated torque sensor, and changes the color according to the degree of deterioration.