Robot Tool Posture Control Using Multi-Point Distance Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tool posture control systems struggle to accurately adjust the posture of tools relative to complex or uneven target objects, often due to limitations in distance measurement and control precision, which can lead to inefficiencies and inaccuracies in tasks like screw insertion and tightening.
Innovation Solution
A tool posture control apparatus comprising a tool support device, sensors for measuring distances to multiple reference positions around the tool, and a control device that adjusts the tool's posture based on calculated target values derived from three-dimensional shape data of the target object, ensuring precise alignment and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional distance measurement methods are used, then the measurement process is simple, but the measurement precision is insufficient for complex or uneven target objects
Solution Approach 1:
The measurement system is segmented into multiple distance measurement sensors positioned at different locations around the tool. Each sensor measures distances to specific measurement reference positions, and the control device integrates these multiple measurements to calculate precise tool posture and target object surface characteristics, achieving high measurement precision through distributed sensing.
Solution Approach 2:
The system transitions from single-point distance measurement to multi-point spatial measurement by arranging sensors around the tool at different angular positions. This dimensional expansion allows the system to capture surface geometry information and calculate tool posture in three-dimensional space, significantly improving measurement precision for complex surfaces.
2Manufacturing precision
If the tool posture control system uses multiple sensors and complex calculations, then the posture adjustment precision improves, but the control system complexity increases
Solution Approach 1:
The control device implements a feedback control system that continuously compares the actual tool posture (calculated from sensor measurements) with the target posture (derived from three-dimensional shape data). The system automatically adjusts the tool support device to minimize the difference between actual and target posture, achieving high precision through iterative correction while managing control complexity through automated algorithms.
Solution Approach 2:
The system replaces manual or simple mechanical positioning with an automated control system that uses sensor data and three-dimensional shape data to calculate and execute precise posture adjustments. This substitution of mechanical intuition with computational control enables high precision posture adjustment while the control device manages the complexity through integrated processing.
3Manufacturing precision
If the sensor measures distances at multiple reference positions, then the posture control accuracy improves, but the measurement time increases
Solution Approach 1:
The system performs preliminary action by pre-calculating the target posture values from three-dimensional shape data before the actual measurement and control process. This allows the control device to have reference values ready for comparison, enabling faster real-time posture adjustments without requiring complex calculations during the measurement phase, thus reducing measurement time while maintaining accuracy.
Data Source
AI summary
A tool posture control apparatus includes a robot which supports a tool for performing a predetermined task on a target object, the robot capable of changing posture of the tool; a sensor supported by the robot; and a control device which changes the posture of the tool by controlling the robot, where the sensor measures a distance between the target object and a respective at a plurality of measurement reference positions around the tool, and the control device performs posture control process of controlling the robot in such a way that a measured-distance difference that is a difference between the distances measured by the sensor comes close to a target value.