Robot Task Comparison Using Real and Virtual Control Records
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Solution Overview
Problem
In manufacturing systems, inconsistencies between real and virtual execution records of tasks by robots lead to difficulties in identifying the cause of production pace and quality inconsistencies, making it challenging to adapt to changes in production plans and environments.
Innovation Solution
A control system that includes a robot controller for real-space task execution, a virtual robot controller for virtual-space task execution, and units for collecting and comparing execution records to identify inconsistent tasks, allowing for autonomous task reordering and adaptation to changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If real robot execution is performed without virtual space simulation, then productivity is improved through direct task execution, but manufacturing precision deteriorates due to inability to detect inconsistencies between real and virtual execution records
Solution Approach 1:
The system performs preliminary simulation in virtual space before actual robot execution. The virtual robot executes tasks in advance in a virtual environment, generating expected execution records that serve as reference standards for comparing against real execution records, thereby enabling inconsistency detection before actual production
Solution Approach 2:
The system creates a virtual copy of the robot and its operating environment. The virtual robot is a digital replica that mimics the real robot's behavior and parameters, allowing execution records to be generated and compared without affecting actual production operations
2Manufacturing precision
If virtual space simulation is added to real robot control, then manufacturing precision is improved through inconsistency detection, but device complexity increases due to dual real and virtual control systems
Solution Approach 1:
The control system is designed with multi-functionality where the same control architecture serves both real and virtual spaces. The control unit can switch between controlling the real robot directly or the virtual robot in simulation, and the execution record management system handles both real and virtual records using unified processing logic, reducing overall system complexity despite the dual-environment capability
3Reliability
If execution records are collected and compared between real and virtual spaces, then reliability is improved through inconsistency identification, but loss of time increases due to additional data collection and comparison processes
Solution Approach 1:
The virtual robot executes tasks in advance in the virtual environment, generating expected execution records before real execution occurs. This preliminary generation of reference data eliminates the need for real-time data collection during actual production, reducing time loss while maintaining reliability through pre-established comparison standards
Data Source
AI summary
A control system includes: a robot controller configured to control a robot to execute a plurality of tasks included in a process for a workpiece in a real space; and circuitry configured to: control a virtual robot to execute the plurality of tasks in a virtual space; collect a real execution record from the real space during execution of each of the plurality of tasks by the robot; collect a virtual execution record from the virtual space during execution of each of the plurality of tasks by the virtual robot; and extract, from the plurality of tasks, one or more inconsistent tasks for which the real execution record and the virtual execution record are inconsistent with each other.