Robot Communications Module for End-Effector Sensor Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The location of the robot controller can result in communication delays, security risks, and complexity due to the need for multiple cables or wireless pathways for sensors, which degrades robotic performance and complicates sensor mounting and data transmission.
Innovation Solution
Interchangeable modules, including a processing module, sensor module, and communications module, are introduced between the robot tool flange and end effector, allowing for additional functionality with minimal modifications, reducing processing delays and simplifying sensor data transmission and routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the robot controller is located in or near the base of the robot, then the robot controller can collect data from and send instructions to joints, end effector and sensors, but communication delays between sensors at the end effector and the robot controller decrease performance of the robot
Solution Approach 1:
The system is divided into segments: the robot controller remains in the base, while intermediate controllers are placed at strategic locations (end effector, tool flange) to handle local sensor data processing. This segmentation reduces communication delays by processing data closer to the source while maintaining the centralized controller's coordination function.
Solution Approach 2:
Intermediate controllers act as mediators between sensors at the end effector and the main robot controller. These intermediaries process and pre-transmit sensor data, reducing the communication burden and delay on the main controller while ensuring reliable data transmission.
2Adaptability or versatility
If sensors transmit large amounts of data (e.g., video data from cameras), then additional functionality is provided, but high-bandwidth transmission requirements result in latency and jitter problems that degrade overall performance of the robot
Solution Approach 1:
High-bandwidth data processing is extracted from the main robot controller and placed in intermediate controllers located near the sensors. This extraction allows the main controller to focus on coordination while intermediate handlers process large data volumes locally, reducing latency and jitter in data transmission.
Solution Approach 2:
Intermediate controllers perform preliminary processing of sensor data (filtering, preprocessing, compression) before transmitting to the main robot controller. This preliminary action reduces the bandwidth requirements and processing burden on the main controller, thereby reducing latency and jitter.
3Adaptability or versatility
If additional sensors are added to the robot to provide additional functionality, then sensor capabilities are enhanced, but the number of cables that must be run to the robot controller increases creating routing difficulties and increasing complexity of the system
Solution Approach 1:
Multiple sensor connections are merged into a single communication path through intermediate controllers. Instead of running individual cables from each sensor to the main controller, sensors connect to intermediate controllers locally, which then aggregate and transmit data through a single cable to the main robot controller, dramatically reducing cable routing complexity.
Solution Approach 2:
The intermediate controllers serve multiple functions: they act as connection points for multiple sensors, perform data processing, and manage communication with the main controller. This multi-functionality allows the system to support enhanced sensor capabilities without proportionally increasing cable routing complexity.
4Measurement precision
If sensors are mounted close to the end effector since the operations of the robot are performed by the end effector, then sensing accuracy is improved, but it can be difficult to find a location to mount the sensor at the end effector without interfering with the end effector or the surrounding environment
Solution Approach 1:
The intermediate controller is designed as a nested module that fits between the robot's tool flange and the end effector. This nesting arrangement allows sensors to be mounted close to the end effector for improved accuracy while the intermediate controller housing provides a compact, non-interfering mounting structure.
Solution Approach 2:
The intermediate controller utilizes the radial dimension by mounting on the tool flange interface, rather than requiring additional linear space. This dimensional approach allows sensors to be positioned close to the end effector without interfering with its operational space.
5Adaptability or versatility
If loading additional software applications and drivers provided by third-party developers onto the robot controller, then sensor functionality is enhanced, but unexpected and uncontrolled risks are introduced that may be unacceptable
Solution Approach 1:
The software architecture is segmented into isolated environments: the main robot controller runs trusted core software, while third-party sensor software and drivers are loaded into isolated containers or virtual environments on intermediate controllers. This segmentation allows enhanced sensor functionality while containing potential security risks within isolated environments that cannot compromise the main controller.
Data Source
AI summary
A communications module is provided for simplifying routing of communications pathways in a robot. The communications module is attached between the robot tool flange and the end effector. Additional interchangeable modules may also be provided between the tool flange and the end effector. The communications module includes multiple input ports and at least one output port. A data switch within the module combines sensor data from multiple input ports into a single output stream that is transmitted from one or more of the output ports.