Industrial Robot Programming With Reachability-Guided Tool Tracking
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Solution Overview
Problem
Existing lead-through programming methods for industrial robots are cumbersome due to the need to mount tools on heavy robotic arms, and are often inaccessible in industrial settings, complicating programming and reducing efficiency.
Innovation Solution
A method and system that allows tool models to be moved by users without attachment to the robotic arm, using a posture tracker to capture data, convert it to robot coordinates, and generate executable codes, with real-time alarms guiding the user to avoid unreachable postures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lead-through programming is used where the tool is mounted on the robot and moved by the user, then the robot path can be programmed conveniently, but the tool and robotic arm become very heavy and difficult to move
Solution Approach 1:
The system separates the programming function from the execution function. The programming device (virtual robot) is segmented from the actual robotic arm, allowing the user to operate a lightweight programming interface while the heavy robotic arm remains stationary and performs the actual work. This segmentation resolves the contradiction by making the programming interface lightweight while maintaining the capability to program the heavy robot.
Solution Approach 2:
A virtual robot model serves as an intermediary between the user and the actual robotic arm. The user interacts with the virtual model which is much lighter and easier to manipulate, while the system automatically translates these interactions into commands for the heavy physical robot. This intermediary resolves the weight contradiction by providing a lightweight interface that controls the heavy executor.
2Ease of operation
If lead-through programming is used with the tool mounted on the robot, then the robot path can be recorded, but the user cannot access the robot due to safety reasons in industrial fields
Solution Approach 1:
The virtual robot model acts as an intermediary that allows the user to program the robot from a safe distance. The user interacts with the virtual representation rather than the physical robot, eliminating the need to access the hazardous industrial area while still enabling full programming capability. This resolves the contradiction by providing programming access without physical exposure to safety hazards.
Solution Approach 2:
The system creates a virtual copy of the robot and its workspace that the user can interact with safely. This digital twin allows all programming operations to be performed on the copy without requiring the user to be physically present in the dangerous industrial environment. The copy preserves all necessary programming functionality while eliminating safety risks.
3Productivity
If the tool model is moved by the user without being attached to the robotic arm, then programming efficiency is improved, but the user may move beyond the reach for the robot
Solution Approach 1:
The system provides real-time feedback to the user during programming by monitoring whether the programmed positions are within the robot's reachable workspace. The feedback mechanism alerts the user when attempting to program positions beyond reach, allowing correction while maintaining the efficiency benefits of free movement. This resolves the contradiction by enabling efficient unrestricted programming while ensuring reliability through continuous reachability verification.
Solution Approach 2:
The system performs preliminary verification of reachability before finalizing the programmed path. By checking whether programmed positions are within the robot's workspace boundaries in advance, the system prevents invalid programs from being executed. This preliminary action ensures reliability while allowing the user the freedom to program efficiently without physical constraints.
Data Source
AI summary
A method includes acquiring posture data of a tool model moved by a user around a workpiece to be processed, the tool model being held by the user without being held by the robot. The method includes determining reachability of the posture data by the robot and generating, based on reachable posture data, executable code which is to be executed by the robot to process the workpiece via a real tool held by the robot.