Robot Tool Alignment Control for Lead-Through Programming

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Solution Overview

Problem

Existing methods for aligning a tool with a specified axis during robot programming require manual activation at each target point, causing disturbances and loss of focus for the operator, which complicates the programming process.

Innovation Solution

A method and system that automatically aligns the tool with a specified axis upon detecting that the robot movement has stopped, allowing the alignment function to be activated once and maintained until the robot resumes movement, without the need for manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual activation of alignment function is used at each target point, then tool alignment accuracy is improved, but programming time and operator workload increase

Engineering Contradiction:
Improvetool alignment accuracyVSAvoidprogramming time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The alignment function is activated in advance and remains active throughout the programming process. The control unit continuously monitors robot movement status and automatically performs alignment when movement stops, eliminating the need for repeated manual activation at each target point while maintaining alignment accuracy.

Inventive Principle:
Principle #10Preliminary action

2Measurement precision

If manual activation of alignment function is used at each target point, then tool alignment accuracy is improved, but operator focus and programming flow are disrupted

Engineering Contradiction:
Improvetool alignment accuracyVSAvoidprogramming flow
Core Design Contradiction:
Measurement precisionVSEase of operation

Solution Approach 1:

The control unit automatically detects when robot movement has stopped and autonomously activates the alignment function without requiring operator intervention. This self-service mechanism maintains alignment accuracy while allowing the operator to maintain continuous focus on the programming process without repeated hand movements to the HMI/TPU.

Inventive Principle:
Principle #25Self-service

3Productivity

If automatic alignment upon movement stop is implemented, then programming efficiency is improved, but risk of unintended alignment increases

Engineering Contradiction:
Improveprogramming efficiencyVSAvoidalignment control
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The control unit continuously monitors robot movement status through feedback signals from the robot system. Alignment is automatically activated only when the feedback indicates that movement has stopped, creating a reliable conditional trigger that improves programming efficiency while preventing unintended alignment during active movement through continuous status verification.

Inventive Principle:
Principle #23Feedback

Data Source

PatentEP3411766B1A method and a system for aligning a tool during programming of an industrial robot
Publication Date: 2025.08.20 ABB (SCHWEIZ) AG
  • EP3411766B1 patent drawingFigure 1~2b
  • EP3411766B1 patent drawingFigure 3
  • EP3411766B1 patent drawingFigure 4

AI summary

The present invention relates to an industrial robot (1) comprising a movable robot arm (5) for supporting a tool (8), and a control unit (2) configured to control the movement of the robot. The control unit is provided with an alignment function for aligning the tool with at least one specified axis Xw, Yw, Zw. The control unit is configured to supervise the movement of the robot, and to automatically adjust the orientation of the tool so that the tool is aligned with the specified axis upon detecting that the movement of the robot has been stopped and the alignment function is activated. The invention also relates to a method for controlling the industrial robot, and to the use of the method for teaching a robot a path (10) including a plurality of target points (12) by lead-through programming.