Robotic Process Control via Sensor Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current robotic programming methods fail to ensure consistent process results in applications with varying material properties, tool wear, or sensitive processes, as they rely on predictable relationships between movement commands and outcomes, which are not always reproducible.
Innovation Solution
A method that uses a controller and sensors to compare actual work progress with a desired objective, converting movement sequences into real-time control commands to achieve a specific processing objective, adapting parameters to compensate for deviations and optimize the process result.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional robot programming with movement commands is used, then the robot can execute tasks with predictable movements, but the process results vary due to material property changes, tool wear, and process sensitiveness
Solution Approach 1:
The patent implements feedback by measuring the actual effect achieved by movement sequences using sensors, comparing it with the planned effect, and using this information to adapt subsequent movement sequences. This closed-loop approach ensures consistent process results despite variations in material properties, tool wear, or environmental conditions.
Solution Approach 2:
The system dynamically adapts robot movement sequences based on real-time or near-real-time measurement data. Instead of executing fixed predetermined movements, the robot continuously adjusts its motion parameters (position, speed, acceleration) to achieve the desired process effect, making the system flexible and adaptive to changing conditions.
2Reliability
If progressive control with force/moment control is used to compensate for uncertainties, then some adaptation is achieved, but it is not sufficient for processes sensitively reacting to parameter changes
Solution Approach 1:
The patent replaces complex force/moment control mechanisms with a measurement-based approach. Instead of using sophisticated sensors and controllers to directly manage forces and moments, the system measures the actual process effect (e.g., material removal, coating thickness) and adjusts movements accordingly, simplifying the control system while improving reliability.
Solution Approach 2:
The patent introduces an intermediary measurement system that indirectly assesses process quality. Rather than directly controlling force and moment parameters, the system uses sensors to measure the actual effect achieved and uses this information as an intermediary to adjust movement sequences, achieving better control with simpler mechanisms.
3Manufacturing precision
If robot control focuses on precise movement execution, then movement accuracy is maintained, but the actual process effect deviates from the objective due to unpredictable relationships between actions and results
Solution Approach 1:
The patent performs preliminary simulation to predict the process effect of planned movement sequences before execution. This allows the system to pre-calculate and adjust movements to compensate for expected variations, ensuring that the actual process effect matches the objective even before considering real-time measurement feedback.
Solution Approach 2:
The system measures the actual process effect achieved by executed movements and uses this feedback to adapt subsequent movement sequences. This ensures that even if individual movements are precisely executed, the cumulative process effect remains consistent with the objective by continuously correcting for deviations.
Data Source
AI summary
A method for the automated control of a process robot with a controller performing movement and work sequences and with one or more sensors that record a work progress. A planning tool compares a recorded progress of work with an aimed-for processing objective and determines, from a difference between the processing objective and an actual value of the process that corresponds to the recorded progress of work, movement and work sequences with which the aimed-for processing objective is achieved. Then the determined movement and work sequences are converted into robot-executable control commands in real time or in-step with the process, and the process robot is controlled in such a way as to achieve the aimed-for processing objective.