Robot Path Correction Using Quality Feedback From Part Shape
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Solution Overview
Problem
Existing robot controllers face challenges in accurately determining and modifying the position and orientation of robots during tasks, particularly in arc welding and adhesive application, due to shifts in workpiece positions caused by jig degradation, spatter, and manufacturing errors, which affect the quality of the workpiece and are time-consuming to correct.
Innovation Solution
A controller for a robot apparatus that includes a correction amount calculating unit, an operation control unit, a shape detecting sensor, and a determination unit to calculate and correct the position or orientation of the robot based on the correlation between the correction amount and quality variables detected by sensors, allowing for real-time modification of the robot's movement path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the operator manually modifies the position or orientation of the robot based on experience, then the quality of the workpiece can be maintained, but the time required for modification increases and the process becomes dependent on operator expertise
Solution Approach 1:
The system implements feedback by detecting the actual position of the workpiece using a sensor, comparing it with the intended position, and automatically calculating correction amounts. This closed-loop feedback mechanism eliminates the need for manual operator intervention and experience-based adjustments, thereby reducing modification time while maintaining workpiece quality.
Solution Approach 2:
The robot system performs self-correction by automatically determining its own position deviations and calculating necessary corrections without external operator input. The determination unit and correction amount calculating unit enable the system to service itself, eliminating dependency on operator expertise and reducing modification time.
2Manufacturing precision
If the operator manually determines and modifies robot position or orientation, then adjustments can be made to maintain workpiece quality, but the complexity of the operation increases and requires experienced operators
Solution Approach 1:
The automatic feedback system continuously monitors workpiece position and robot orientation, comparing actual values with target values. This eliminates the need for operators to manually determine corrections, making the system easier to operate while maintaining high manufacturing precision through automated determination of position and orientation modifications.
Solution Approach 2:
The system replaces manual operator judgment and mechanical adjustment with automated sensor-based detection and computational determination. The determination unit and correction amount calculating unit substitute for operator expertise, simplifying operation while maintaining the ability to preserve workpiece quality through automatic position and orientation correction.
3Productivity
If the robot performs tasks without position correction, then the operation speed is maintained, but the quality of the workpiece deteriorates due to position shifts
Solution Approach 1:
The system performs preliminary detection of workpiece position and calculates correction amounts before the robot executes its task. This advance preparation allows the robot to move directly to corrected positions without manual intervention during operation, maintaining high productivity while ensuring workpiece quality through pre-calculated position adjustments.
Solution Approach 2:
The automatic position detection and correction calculation operate continuously alongside the robot's task execution, ensuring that quality maintenance does not interrupt productivity. The seamless integration of detection, determination, and correction functions allows continuous useful action without stopping for manual modifications.
Data Source
AI summary
A controller calculates a correction amount of a position of a robot 1 at a movement point in a first movement path, and drives the robot 1 in a second movement path obtained by correcting the first movement path. The controller includes a second camera configured to detect a shape of a part after a robot apparatus performs a task, and a variable calculating unit configured to calculate, based on an output of the second camera, a quality variable representing quality of a workpiece. When the quality variable deviates from a predetermined determination range, a determination unit of the controller determines that the position or an orientation of the robot 1 needs to be modified based on a correlation between the correction amount of the position in the first movement path and the quality variable.