Robot Working Precision Prediction via Torque Monitoring
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Solution Overview
Problem
Current industrial procedures lack the ability to determine and control the overall working precision of robots in machining operations, as they fail to account for both robot-derived and process-related errors, leading to suboptimal precision and increased testing costs.
Innovation Solution
A method that predicts, controls, and determines the overall working precision of a robot by simulating its movement to estimate deviations due to dynamic response and external stresses, calculating predictive torque profiles, and monitoring actual torques in real-time to generate corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If robots are used in machining operations with high precision requirements, then the working precision and repeatability improve, but the cost increases due to the need for extensive testing in the process planning phase
Solution Approach 1:
The patent performs preliminary prediction of robot working precision and torque requirements during the process planning phase using simulation and calculation methods. This allows the precision and torque characteristics to be determined in advance before actual machining operations begin, eliminating the need for extensive testing during implementation
Solution Approach 2:
The patent replaces physical testing and experimental methods with computational simulation and calculation methods. By using dynamic simulation to predict robot behavior, torque profiles, and working precision, the system substitutes mechanical trial-and-error with virtual modeling and analysis
2Measurement precision
If experimental methods are used to establish force profiles for robot control, then the control accuracy improves for specific operations, but the adaptability deteriorates when processing different products
Solution Approach 1:
The patent creates a universal prediction and control system that can handle different machining operations and products through simulation and calculation. The method uses generalizable models for robot dynamics, torque prediction, and precision analysis that adapt to various scenarios without requiring product-specific experimental calibration
Solution Approach 2:
The patent uses simulation to create virtual models and digital twins of the robot system, machining operations, and process conditions. These virtual copies allow for prediction and optimization of torque profiles and working precision across different products without physical testing, enabling the control system to adapt to new products through simulation rather than experimentation
3Manufacturing precision
If the robot torque monitoring is performed in real-time with predictive profiles, then the working precision is maintained, but the system complexity increases
Solution Approach 1:
The patent implements real-time monitoring of actual robot torques during machining operations and compares them against pre-calculated predictive torque profiles. This feedback mechanism allows the system to detect deviations, identify potential issues, and maintain working precision within acceptable tolerances through continuous verification
Solution Approach 2:
The patent performs preliminary calculation of torque profiles during the offline planning phase, establishing expected torque characteristics before actual machining begins. This pre-computation allows real-time monitoring to focus on simple comparison and deviation detection rather than complex real-time calculation, reducing online system complexity
Data Source
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AI summary
A method comprising: processing a simulated movement of a robot in at least one processing operation to determine deviations of the robot due to a dynamic response of the robot and external stresses on the robot; estimating an overall working precision on a robot end-effector, at each of one or more path coordinates of the end-effector, taking into account effects of the robot dynamic response and process response of at least one processing operation; performing a predictive calculation of torques in robot joints under robot idle and working conditions, according to a predetermined process force model and/or with information from a process force and torque profile, resulting in predictive torque profiles; performing a calculation of a ratio between robot deviations and at least one deviation of a measured torque from a nominal torque at each joint of the robot; monitoring the measured torques at the joints of the robot, preferably in real time, based on the predictive torque profiles; and generating an alarm action and/or a corrective action based on the monitoring of the measured torques.