Modular Robot Sensor Stack for Low-Latency End Effector Monitoring
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Solution Overview
Problem
The location of the robot controller can result in communication delays, security risks, and complexity due to the need for multiple sensors and cables, which degrade robotic performance and make it difficult to add functionality without interfering with the end effector or environment.
Innovation Solution
Interchangeable modules, including a processing module, sensor module, and communications module, are attached between the robot tool flange and end effector, allowing for additional functionality to be added with minimal modifications, reducing processing delays and simplifying communication paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed at the end effector to monitor surroundings, then measurement precision is improved, but communication delays and latency increase due to distance from controller
Solution Approach 1:
The system is divided into modular components: sensor modules at the end effector, processing modules in the intermediate stack, and controller at the base. This segmentation allows sensors to be close to the action (improving measurement precision) while processing is distributed (reducing communication delays).
Solution Approach 2:
Processing modules act as intermediaries between sensors and the main controller. These modules pre-process sensor data locally in the intermediate stack, reducing the amount of data that needs to be transmitted to the controller and minimizing communication latency.
2Adaptability or versatility
If multiple sensors are added to provide additional functionality, then adaptability is improved, but device complexity and cable routing difficulties increase
Solution Approach 1:
The intermediate stack provides universal interfaces and processing capabilities that can handle multiple sensor types and functions through a common architecture. This allows additional functionality to be added without proportionally increasing cable routing complexity, as modules can communicate through standardized interfaces in the stack.
Solution Approach 2:
Multiple sensors and processing functions are merged into integrated modules that attach to the intermediate stack. This consolidation reduces the number of separate cable connections needed, as multiple sensor inputs can be processed through shared communication pathways in the modular architecture.
3Reliability
If robot controller is located at base or remotely, then security risks are reduced by isolating sensors, but communication bandwidth requirements increase causing congestion
Solution Approach 1:
The system segments communication traffic by processing data locally in intermediate modules before transmission to the controller. This reduces the total bandwidth consumption on the main communication channel while maintaining security isolation between sensors and the controller.
Solution Approach 2:
Processing modules perform preliminary data processing and filtering before data is transmitted to the controller. This pre-processing reduces the volume of data that requires high-bandwidth transmission, decreasing communication congestion while maintaining secure isolation.
4Measurement precision
If sensors are mounted close to end effector, then measurement precision is improved, but ease of operation deteriorates due to difficulty in mounting without interference
Solution Approach 1:
The intermediate stack serves as a mediator platform that provides standardized mounting interfaces between the end effector and sensors. This allows sensors to be mounted close to the end effector for optimal measurement precision while the standardized interfaces simplify the mounting process and reduce interference issues.
Data Source
AI summary
A sensor module is provided for adding functionality to a robot. The sensor 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 sensor module includes a sensor for monitoring a condition near the end effector. An output port of the module transmits sensor data to a processor outside of the sensor module for further processing.