Industrial Robot Manipulator Trajectory Control for Dynamic Load Limits
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Solution Overview
Problem
Existing industrial robot manipulators are limited by conservative design choices that reduce their workspace and payload capacity due to static load assumptions, failing to utilize their full potential and compromising mechanical integrity.
Innovation Solution
A method for controlling the manipulator by determining position-dependent loads and modifying trajectories to optimize performance parameters, such as speed and acceleration, based on dynamic load considerations, allowing for an extended workspace and increased payload without compromising mechanical component lifetime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If worst case constant limits are chosen for each mechanical component, then structural integrity is ensured, but workspace is significantly reduced and maximum payload is reduced
Solution Approach 1:
The patent applies dynamics by transitioning from static constant load limits to dynamic position-dependent load limits. The control system calculates varying load limits based on the manipulator's current position and configuration, allowing the workspace to be extended while maintaining structural integrity. This is achieved by determining position-dependent load values and using them to modify candidate trajectories, enabling the manipulator to operate in previously restricted areas.
Solution Approach 2:
The patent changes the parameter of load limits from constant values to position-dependent variable values. By calculating load limits as a function of manipulator position and configuration, the system optimizes the balance between structural integrity and workspace utilization. This parameter transformation allows dynamic adjustment of operational constraints based on actual mechanical conditions.
2Reliability
If worst case constant limits are chosen for each mechanical component, then structural integrity is ensured, but maximum payload is significantly reduced
Solution Approach 1:
The system dynamically adjusts payload capacity based on manipulator position and configuration. By calculating position-dependent load limits, the control system allows the manipulator to carry heavier payloads in positions where the mechanical structure can support them, while maintaining safety margins in positions where structural loads are higher. This dynamic approach maximizes payload utilization without compromising structural integrity.
Solution Approach 2:
The patent transforms the payload parameter from a fixed conservative limit to a variable position-dependent limit. The control system calculates the maximum allowable payload at each position based on the manipulator's configuration and structural capacity, enabling optimal payload utilization across the entire workspace while ensuring structural integrity is maintained at all times.
3Duration of action of stationary object
If conservative maximum values are defined for payload, speed, acceleration and position, then mechanical component lifetime is ensured, but full potential of the manipulator is not utilized
Solution Approach 1:
The patent applies dynamics by replacing static conservative limits with dynamic position-dependent load limits. The control system calculates optimal speed and acceleration profiles based on the manipulator's current position and the corresponding load limits, allowing full utilization of mechanical component capacity while ensuring lifetime requirements are met. This dynamic optimization enables the manipulator to operate at maximum potential in safe regions while maintaining protective margins in critical regions.
Solution Approach 2:
The system changes the parameters of speed and acceleration from fixed conservative values to variable values that depend on manipulator position. By calculating position-dependent load limits and adjusting operational parameters accordingly, the system maximizes productivity while ensuring mechanical component lifetime is preserved through appropriate safety margins.
Data Source
AI summary
A method of controlling a manipulator of an industrial robot having a plurality of joints, the method including providing a candidate trajectory for the manipulator; determining at least one position dependent load value representative of at least one position dependent load acting on the manipulator for the candidate trajectory; modifying the candidate trajectory based on the at least one position dependent load value to provide a modified trajectory; and executing the modified trajectory by the manipulator. A control system for controlling a manipulator of an industrial robot having a plurality of joints, and an industrial robot including a manipulator and a control system, are also provided.