Robot-on-Mover Motion Control for Synchronized Cart Trajectories
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Solution Overview
Problem
Existing motion control systems for independent cart systems struggle to coordinate the motion of robots mounted on movers with the vehicles, lacking efficient integration and synchronization of robot and mover movements.
Innovation Solution
A motion controller system that receives a robot motion command, converts it into separate commands for each axis of the robot and the mover, ensuring synchronized motion trajectories for the robot and mover, utilizing position feedback systems and electromagnetic fields to propel the movers along the track.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a robot is mounted on a mover in an independent cart system, then the system gains enhanced flexibility and positioning accuracy, but the coordination and synchronization between robot motion and mover motion becomes complex and difficult to control
Solution Approach 1:
The patent combines the robot control system and mover control system into a unified coordination framework. The motion controller receives robot motion commands and simultaneously generates both robot axis commands and mover motion commands, merging previously separate control functions into one integrated system that coordinates both components seamlessly.
Solution Approach 2:
The motion controller serves multiple functions: it processes robot motion commands, generates robot axis commands for each robotic axis, generates mover motion commands for the independent cart system, and coordinates all these functions simultaneously. This multi-functional approach reduces the need for separate specialized controllers.
2Manufacturing precision
If the motion of the robot and mover are coordinated through a unified control system, then positioning accuracy is improved, but the computational load and control system complexity increase
Solution Approach 1:
The system implements feedback mechanisms where the motion controller continuously receives position information from both the robot axes and the mover, and adjusts commands in real-time to maintain accurate positioning. This closed-loop control enables high positioning accuracy while managing the complexity through systematic feedback processing.
Solution Approach 2:
The motion controller performs preliminary computation of coordinated motion trajectories before execution. By pre-calculating the necessary robot and mover commands based on the desired robot motion trajectory, the system reduces real-time computational burden while maintaining positioning accuracy.
3Device complexity
If separate control systems are used for the robot and mover, then system simplicity is maintained, but motion synchronization and coordination efficiency deteriorate
Solution Approach 1:
The patent merges separate robot and mover control systems into a unified motion controller that generates coordinated commands for both. This integration eliminates the delays and coordination issues that would arise from separate systems, thereby improving productivity and motion synchronization efficiency.
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 precise and coordinated motion of robots and movers, enhancing flexibility and positioning accuracy in manufacturing and packaging processes, improving operational efficiency and accuracy.
Implementation Method 1
Successive activation of the coils establishes a moving electromagnetic field that interacts with the movers and causes the mover to travel along the track
Data Source
AI summary
Motion is coordinated between a robot and a mover in an independent cart system. Positions for a mover along a track for the independent cart system and for each axis of motion of the robot mounted on the mover are received at the motion controller. The axis position corresponds to either an angular position of the motor or a mechanical position of a corresponding axis on which the motor is mounted. The motion controller receives a robot motion command corresponding to a desired operation of the robot and generates a mover motion command for the mover and an axis motion command for each axis of the robot. The mover motion command and the axis motion commands are generated as a function of the robot motion command, the position of the mover along the track, and the position of the motor or of the axis for each axis of the robot.