Robotic Welding Manipulator Control With 6DOF Input Masking
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Solution Overview
Problem
Conventional robotic welding systems face challenges in precision and intuitiveness due to the complexity of using teach pendants and free drive modes, which can lead to unintended movements and collisions, especially in collaborative robot environments where human proximity is common.
Innovation Solution
The implementation of a 6DOF motion sensor and a three-position switch on the robotic manipulator, allowing operators to mask specific input dimensions, such as rotational or translational movements, to prevent unintended actions and enhance precision by limiting the types of movement controlled by the device, thereby improving the ease of configuring and controlling robotic welding procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If teach pendants and free drive modes are used for controlling robotic manipulators, then programming capability is provided, but precision and intuitiveness deteriorate due to complexity and unintended movements
Solution Approach 1:
The patent segments the control input by separating translational and rotational degree of freedom masking. The three-position switch allows independent control of translational masking (position 1) and rotational masking (position 2), dividing the complex 6DOF control into manageable, intuitive segments that reduce operator cognitive load while maintaining precision.
2Reliability
If all input dimensions are allowed for robotic manipulator control, then flexibility is maintained, but unintended movements and collisions increase
Solution Approach 1:
The patent implements dynamic masking where the robot control system adapts the active degree of freedom based on the current operational context. The three-position switch enables real-time switching between different masking states (translational mask, rotational mask, or no mask), allowing the system to dynamically adjust flexibility versus safety based on task requirements.
3Manufacturing precision
If precision adjustment is enabled through masking inputs, then manufacturing precision improves, but device complexity increases due to additional control mechanisms
Solution Approach 1:
The patent introduces a three-position switch as an intermediary device that simplifies access to complex masking functions. This single switch acts as a mediator between the operator and the sophisticated 6DOF control system, providing intuitive mechanical positions that correspond to specific masking states without requiring complex software interfaces or multiple controls.
Data Source
AI summary
Disclosed example robotic welding systems include: a robotic manipulator configured to manipulate a welding torch; a first input device attached to the robotic manipulator and configured to receive rotational and translational inputs; a second input device attached to the robotic manipulator and configured to receive a masking input; and a robot control system, comprising: a processor; and a machine readable storage medium comprising machine readable instructions which, when executed by the processor, cause the processor to: in response to activation of the masking input via the second input device, masking at least a portion of the inputs received via the first input device; and in response to inputs to the first input device, move the robotic manipulator according to the inputs and based on whether the inputs are masked.