Robot Control Method for Transverse Mechanical Load Prevention
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Solution Overview
Problem
Existing robot control methods fail to account for mechanical loads transverse to the pivoting plane, leading to potential mechanical overload during robot movement, as they only consider rigid axes and torques parallel to the joint pivot axis, neglecting tilting moments and forces at right angles to the pivot axis.
Innovation Solution
A control method that pre-calculates mechanical loads along the robot's path, including transverse loads, to anticipate and mitigate mechanical overload by adapting drive motor control, such as braking or modifying the path, to ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional robot control methods are used that only consider torques parallel to the joint pivot axis, then the control system remains simple, but mechanical overload occurs due to unaccounted transverse loads
Solution Approach 1:
The control method pre-calculates mechanical loads including transverse components before executing robot movements. By computing tilting moments and transverse forces in advance based on the dynamic robot model and planned trajectory, the system identifies potential overload conditions beforehand and adjusts control parameters proactively, preventing mechanical overload before it occurs.
Solution Approach 2:
The control system continuously monitors actual robot state and compares it with the dynamic model predictions. It uses feedback from position sensors and load cells to update the mechanical load calculations in real-time, adjusting drive motor control dynamically to maintain safety margins and prevent overload conditions.
2Productivity
If the robot moves at high speed along the predefined path, then productivity increases, but mechanical overload risk increases due to unaccounted transverse forces
Solution Approach 1:
The control method dynamically adjusts robot movement parameters based on real-time mechanical load calculations. When transverse loads approach critical thresholds, the system automatically modifies speed profiles, acceleration rates, or trajectory parameters to maintain safe operating conditions, enabling optimal productivity without compromising mechanical safety.
3Device complexity
If rigid robot axes are assumed as in traditional control, then the control algorithm remains simple, but actual mechanical loads including tilting moments are not accounted for
Solution Approach 1:
The control method extends the traditional rigid-axis model by incorporating additional mechanical parameters including moment of inertia, centrifugal forces, Coriolis forces, and tilting moments. The dynamic robot model uses these expanded parameters to calculate comprehensive mechanical loads, providing accurate load predictions that account for transverse forces while maintaining computational efficiency through optimized algorithms.
Data Source
AI summary
The invention relates to a control method for a robot (1) having a plurality of movable robot axes (2, 4, 6), in particular for a painting robot (1) or a manipulating robot, comprising the following steps: (a) predetermining a robot path by means of a plurality of path points through which a reference point of the robot (1) is intended to travel; (b) controlling drive motors of the individual robot axes (2, 4, 6) according to the predetermined robot path, such that the reference point of the robot (1) travels through the predetermined robot path; (c) precalculating the mechanical loading (My1, Mx1, Fx1, Fy1, Fz1, Fx2, Fy2, Fz2, Mx2, My2, Mz2) that occurs within at least one of the robot axes (2, 4, 6) between two joints when travelling through the robot path ahead; and also (d) adjusting the control of the drive motors of the robot axes (2, 4, 6) on the basis of the precalculated mechanical loading (My1, Mx1, Fx1, Fy1, Fz1, Fx2, Fy2, Fz2, Mx2, My2, Mz2), such that a mechanical overload is avoided.