Robot Load Profile Control for External Force Detection
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Solution Overview
Problem
Collaborative robots face challenges in ensuring safety without the need for costly safety fences, as existing methods rely on detecting external forces which can be unreliable due to environmental changes, leading to unnecessary robot stoppages.
Innovation Solution
A robot system with a control device that records and updates a reference load profile based on detected forces, allowing for real-time determination of external forces without altering the robot's environment, ensuring safe operation without safety fences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the robot stops when an external force is detected by a sensor to ensure safety, then safety is improved, but productivity deteriorates due to unnecessary stoppages when load fluctuates
Solution Approach 1:
The system changes the parameter of reference load values by storing multiple reference load profiles corresponding to different operation commands. The determination unit selects and compares against the appropriate reference profile based on the current operation command, allowing the external force determination threshold to adapt dynamically to different operational contexts, thereby reducing false detections while maintaining safety
Solution Approach 2:
The system implements feedback by storing the detected load values as new reference load profiles when operation commands are executed without external forces. This creates a self-learning mechanism where the reference profiles are continuously updated and refined based on actual operational data, improving the accuracy of external force detection over time while maintaining productivity
2Measurement precision
If the magnitude of force detected by a sensor is stored in association with operation commands in a state in which no external force acts on the robot, then external force detection accuracy is improved, but device complexity increases due to environment/setting configuration
Solution Approach 1:
The system applies self-service by automatically storing the detected load values as new reference load profiles when operation commands are executed without external forces. This self-learning mechanism eliminates the need for manual environment/setting configuration, as the system automatically adapts to its operational context and refines its detection accuracy over time without user intervention
Solution Approach 2:
The system performs preliminary action by pre-storing reference load profiles for each operation command before actual operation begins. This allows the determination unit to quickly compare real-time sensor data against pre-established references, improving detection speed and accuracy while simplifying the operational setup process
3Reliability
If safety fences are installed to ensure safety in the case of a normal robot, then safety is improved, but cost and installation time increase
Solution Approach 1:
The system replaces the mechanical safety fence with an intelligent software-based detection mechanism. By using the sensor to detect external forces and comparing them against dynamically stored reference load profiles, the system achieves safety through intelligent control algorithms rather than physical barriers, eliminating installation time and cost while maintaining protective functionality
Data Source
AI summary
To record the load exerted on a robot according to changes over time without changing the environment and configuration under which the robot is used. A robot system including a robot, a robot control device that controls the robot, and a sensor that is able to detect information about a force exerted on the robot, the robot control device including a record processing unit that stores a first reference load profile in a storage unit, and a determination unit that determines at least the presence or absence of an external force exerted on the robot according to the first reference load profile and the load exerted on the robot detected by the sensor, and the record processing unit storing the load in the storage unit as a second reference load profile depending on the state of the external force.