Robotic Arm Posture Inspection via Marker Tracking and Encoder Comparison
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Solution Overview
Problem
Conventional robotic arm control technologies lack effective monitoring capabilities, leading to potential navigation errors due to undetected abnormalities such as marker falling, robot mechanism malfunctions, motor issues, or external force-induced failures, which can result in erroneous position determination and abnormal movement.
Innovation Solution
A machine posture inspection method and system that utilizes a 3D image capturing device and motor encoders to capture and analyze the posture of a machine device, comparing the obtained posture with encoder signals to detect abnormalities and issue warnings, ensuring system safety by stopping the machine if anomalies are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional control technology using 3D camera and coordinate transformation is used, then the robotic arm can achieve continuous navigation control, but the monitoring ability is finite and cannot detect abnormalities such as marker falling, mechanism malfunction, or motor failure
Solution Approach 1:
The patent introduces an intermediary inspection system comprising an image capturing device and processing device that acts as a mediator between the robotic arm control system and the external environment. This intermediary system captures images of markers on the robotic arm, calculates actual posture through coordinate transformation, and compares it with commanded posture to detect abnormalities such as marker falling, mechanism malfunction, or motor failure, thereby enhancing reliability without interfering with the primary control function
Solution Approach 2:
The patent replaces traditional mechanical monitoring methods with an optical-based inspection system. Instead of using mechanical sensors or switches to detect abnormalities, the system uses 3D image capturing devices to visually track markers on the robotic arm, process images computationally to determine actual posture, and detect deviations from commanded posture, thereby substituting mechanical detection with optical and computational methods
2Device complexity
If the robotic arm operates without comprehensive monitoring, then the system complexity is reduced, but position determination errors and abnormal movements cannot be detected
Solution Approach 1:
The patent creates a virtual copy of the robotic arm's physical state through image capturing and processing. The system captures images of physical markers on the robotic arm, calculates actual posture coordinates through coordinate transformation, and creates a digital representation of the arm's position and orientation. This virtual copy is then compared with the commanded posture to detect deviations, thereby enhancing measurement precision while maintaining relatively simple hardware
3Ease of operation
If no abnormality detection mechanism is implemented, then the system operates smoothly without additional safety protocols, but undetected abnormalities can lead to unsafe operations
Solution Approach 1:
The patent implements a feedback mechanism where the inspection system continuously monitors the robotic arm's actual posture by capturing images, calculating positions through coordinate transformation, and comparing them with commanded posture. When deviations indicating abnormalities (such as marker falling, mechanism malfunction, or motor failure) are detected, the system provides feedback by triggering alarms or stopping operation, thereby ensuring safety while maintaining ease of operation through automated monitoring
Data Source
AI summary
A machine posture inspection method and a machine posture inspection system are provided. The method includes: configuring an image capturing device to capture a current image of a region where a machine device is located, and configuring a processing device to: identify a reference marker in the current image and a first marker connected to the machine device; and calculate and obtain a current posture of the machine device according to the reference marker and the first marker; configure a motor encoder to measure an encoder signal associated with a motor; and determining whether or not the machine device is abnormal according to the current posture and the encoder signal.