Robot Arm Transport Abnormality Detection Using Force Feedback
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Solution Overview
Problem
Existing transfer systems using robot arms for item transfer face challenges in accurately detecting and responding to abnormalities during the transport process, such as incorrect identification, failure to grip, or damage to items, which can lead to inefficiencies and potential damage.
Innovation Solution
The proposed transfer system incorporates a control apparatus that includes sensors and image capturing devices to detect and analyze the characteristics of packages, a drive control unit to manage the robot arm's movements, and an abnormality detecting unit that compares actual data with registered data to identify any discrepancies, allowing for real-time adjustments or stoppages as necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robot arm transfer system operates without advanced abnormality detection, then device complexity is reduced, but reliability of transfer operation deteriorates due to undetected abnormalities
Solution Approach 1:
The system performs preliminary actions by registering normal transfer data beforehand and comparing actual transfer data against these pre-established standards. The abnormality detecting unit proactively identifies potential issues before they cause failures by continuously monitoring and comparing parameters during operation, enabling preventive rather than reactive management.
Solution Approach 2:
The system implements feedback mechanisms where the abnormality detecting unit continuously monitors transfer operations, compares actual data with registered normal data, and provides feedback signals when deviations are detected. This closed-loop feedback enables real-time adjustment and correction of transfer operations to maintain reliability.
2Measurement precision
If multiple sensors and detection devices are added to improve abnormality detection accuracy, then measurement precision improves, but device complexity increases
Solution Approach 1:
The abnormality detecting unit serves multiple functions: it detects abnormalities, identifies their locations, determines causes, and triggers stoppage decisions. By consolidating these diverse detection and analysis functions into a single multi-functional unit, the system achieves high measurement precision without proportionally increasing device complexity.
Solution Approach 2:
The system uses an intermediary approach by introducing a control apparatus that mediates between the robot arm's mechanical operations and the detection systems. This control apparatus integrates data from multiple sensors and applies intelligent analysis algorithms, acting as an intermediary that processes complex sensor data without requiring direct complex interconnections between all detection components.
3Reliability
If real-time abnormality detection and stoppage capability are implemented, then reliability improves, but loss of time increases due to transfer interruptions
Solution Approach 1:
The system applies local quality by enabling selective stoppage of only the specific transfer operation or robotic arm component where an abnormality is detected, rather than halting the entire transfer system. This localized response maintains overall system productivity while ensuring safety at the problem location.
Solution Approach 2:
The system implements dynamic decision-making where the control apparatus continuously evaluates abnormality severity and determines stoppage necessity in real-time. The stoppage decision is not static but dynamically adjusted based on the type, severity, and location of detected abnormalities, allowing the system to maintain transfers when safe and interrupt only when necessary.
Data Source
AI summary
A control apparatus includes a force sensation information acquiring unit for acquiring force sensation information representing a magnitude of at least one of a force and a torque at a distal end of a manipulator while a target item is being transported; a mass information acquiring unit for acquiring mass information representing a mass of the item; a plan information acquiring unit for acquiring plan information representing content of a plan of a trajectory; a force sensation estimating unit for estimating a magnitude of at least one of a force and a torque to be detected at the distal end of the manipulator; and a first detecting unit for detecting an abnormality, based on the magnitude of at least one of the force and the torque represented by the force sensation information and the magnitude of at least one of the force and the torque estimated by the estimating unit.