Robot Tool Control for Precise Tracking of Moving Objects
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Solution Overview
Problem
Conventional robot systems face challenges in precisely matching the movement of a tool with an object being conveyed, especially when the object's movement cycle is shorter than the robot's control cycle, leading to imprecise positioning and potential damage.
Innovation Solution
A robot system with a sensor that detects the object's position and a tool control cycle shorter than the robot's control cycle, allowing the tool to be precisely positioned and moved in sync with the object, even when the object's movement is irregular, using a tool moving device controlled by a tool controller with a shorter cycle than the robot's.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the robot's control cycle is used to control the tool, then the system structure is simple, but the positioning precision deteriorates when the object's movement cycle is shorter than the robot's control cycle
Solution Approach 1:
The control system is segmented into two independent controllers: a robot controller for overall coordination and a tool controller for precise tool positioning. The tool controller operates with a shorter control cycle specifically for tool positioning tasks, while the robot controller maintains the original longer cycle for robot arm movement. This segmentation allows each controller to optimize its performance for its specific function without increasing overall system complexity.
Solution Approach 2:
The tool controller acts as an intermediary between the robot controller and the tool moving device. It receives positioning information from the robot controller and translates it into precise tool movements with a shorter control cycle. This intermediary layer enables high-precision tool positioning without requiring the entire robot system to operate at the faster cycle rate.
2Manufacturing precision
If the robot control cycle is shortened to match the object's movement cycle, then the positioning precision improves, but the processing speed deteriorates
Solution Approach 1:
The control functions are segmented by time scale: the robot controller operates at a longer cycle rate suitable for robot arm movement and overall process coordination, while the tool controller operates at a shorter cycle rate specifically for tool positioning. This allows the system to achieve high positioning precision for the tool without forcing the entire system to operate at the faster rate, thereby maintaining processing speed.
Solution Approach 2:
The control system dynamically adapts different control cycles to different operational requirements. The tool controller uses a shorter control cycle when precise positioning is needed, while the robot controller maintains its original longer cycle for non-critical movements. This dynamic approach ensures high precision where needed without sacrificing overall processing speed.
3Manufacturing precision
If the robot control cycle is shortened to match the object's movement cycle, then the positioning precision improves, but the robot and tool may be damaged due to irregular object movement
Solution Approach 1:
The tool controller incorporates damping and smoothing algorithms that anticipate and compensate for irregularities in object movement before they cause damage. By operating with a shorter control cycle, the system can detect and respond to sudden movements or position changes in the object, applying corrective forces that prevent damage to the robot and tool while maintaining positioning precision.
Solution Approach 2:
The tool controller continuously receives feedback from sensors about the object's position and movement characteristics. This real-time feedback allows the controller to adjust tool positioning dynamically, responding to irregular object movements by making fine corrections that maintain precision while avoiding forces that could cause damage. The feedback loop operates at the shorter tool control cycle rate, providing responsive protection.
Data Source
AI summary
This robot system includes a sensor which obtains data for detecting at least a position of an object which is being moved, a robot at which a tool is attached, and which performs a predetermined operation for the object by means of the tool, and a controller which controls a tool moving device which moves the tool with respect to the robot, the tool, or an arm member which is located at a distal end side of an arm of the robot with a tool control cycle which is shorter than a control cycle of the robot.