Robot Manipulator Dynamic Workspace Limits for Heavy Loads
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Solution Overview
Problem
Robot manipulators are limited by a highest permissible mass for loads on their end effectors, restricting their operational capabilities when handling heavier masses.
Innovation Solution
A method for operating a robot manipulator that involves ascertaining a wrench or joint torque vector based on the weight and inertia of a load, determining a maximum permissible workspace and kinematic variable, and activating the robot to execute tasks within these constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the highest permissible mass for the load is defined based on the mechanical design limits, then the robot manipulator can operate safely within material tensile limits and yield points, but the operational capability is restricted to handling only loads up to this permissible mass
Solution Approach 1:
The patent applies dynamics by making the permissible mass limit variable rather than fixed. The control unit dynamically adjusts the permissible mass based on the robot's current pose, velocity, and acceleration. This allows the robot to handle heavier loads when moving slowly or in poses that generate lower torques, while maintaining safety when speeds or torques increase. The dynamic adaptation resolves the contradiction between structural safety and load handling capability.
Solution Approach 2:
The patent changes the parameter of permissible mass from a constant design limit to a variable parameter that depends on operational conditions. By calculating real-time torques based on current pose, velocity, and acceleration, the system adjusts the permissible mass threshold dynamically. This parameter change enables the robot to exceed the static design limit under controlled conditions while maintaining safety margins.
2Strength
If the robot manipulator is designed with a fixed highest permissible mass limit, then the mechanical components remain protected from excessive loads, but the robot cannot adapt to different load masses and operational scenarios
Solution Approach 1:
The system dynamically adjusts operational parameters including permissible mass, velocity, and workspace boundaries based on real-time torque calculations. This dynamic approach protects mechanical components by ensuring torques never exceed design limits, while simultaneously providing operational flexibility by allowing heavier loads when kinematic conditions are favorable.
Solution Approach 2:
The control unit continuously monitors the robot's pose, velocity, and acceleration, calculates the resulting torques, and uses this feedback to adjust the permissible mass and workspace limits. This closed-loop feedback mechanism ensures component protection while enabling adaptive operation across different load scenarios.
3Adaptability or versatility
If the robot manipulator operates with a load mass exceeding the highest permissible mass, then the load handling capability is improved, but the torque on joints and base may exceed material yield points causing damage
Solution Approach 1:
The patent changes the permissible mass from a fixed design parameter to a dynamically adjusted parameter. By recalculating the permissible mass based on current pose, velocity, and acceleration, the system enables heavy load handling when kinematic conditions allow, while preventing material stress limits from being exceeded through real-time parameter adjustment.
Solution Approach 2:
The system uses dynamic torque calculation to enable temporary operation with masses exceeding the static design limit. By continuously monitoring and adjusting operational parameters based on real-time conditions, the robot can safely handle heavier loads in specific scenarios without risking material failure.
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
Enables the operation of robot manipulators with higher mass loads by defining a safe workspace and kinematic limits, preventing damage to the robot's mechanical components.
Implementation Method 1
ascertaining a wrench or joint torque vector based on a weight force of a mass
Implementation Method 2
force induced by an inertia of the mass of a load arranged on an end effector
Data Source
AI summary
A method of operating a robot manipulator including: ascertaining a wrench or joint torque vector based on a weight force and/or based on an inertial force of a mass of a load on an end effector of the robot manipulator; ascertaining a maximum permissible workspace and/or a maximum permissible kinematic variable, in each case based on the wrench or joint torque vector such that the wrench or joint torque vector does not exceed a predetermined metric within the maximum permissible workspace; and activating the robot manipulator to execute a predetermined task in consideration of the maximum permissible kinematic variable, such that the end effector or the load on the end effector remains within the maximum permissible workspace if, at beginning of execution of the task, the end effector or the load on the end effector is located within the maximum permissible workspace.