Sensor Fusion Conflict Resolution for Robotic Workpiece Tracking
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Solution Overview
Problem
In automotive assembly, movement irregularities and vibrations during the final trim and assembly stage hinder accurate robot motion control due to continuous motion of vehicles on assembly lines, affecting repeatability and precision in sensor data convergence.
Innovation Solution
A method using sensor fusion to predict workpiece locations, identify the most accurate sensor, and adjust predictions with weighted values to guide robotic movements, incorporating both natural and artificial tracking features for enhanced reliability and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional teach and repeat position based robot motion control is used, then the system is simple to operate, but the positioning accuracy deteriorates due to movement irregularities and vibrations
Solution Approach 1:
The patent implements feedback mechanisms where sensors continuously monitor the actual positions of the vehicle and workpiece, and this information is fed back to the control system to adjust robot motion in real-time, compensating for movement irregularities and vibrations
Solution Approach 2:
The patent introduces sensors as intermediary devices that detect positions and provide data to the control system, acting as a mediator between the moving vehicle and the robot control to enable accurate positioning despite vibrations and motion irregularities
2Reliability
If multiple sensors are used for tracking, then the reliability of position detection improves, but sensor conflicts and data convergence issues worsen
Solution Approach 1:
The patent merges data from multiple sensors by combining their position information through mathematical operations, weighting factors, or fusion algorithms to produce a single reliable position estimate that compensates for individual sensor limitations and conflicts
Solution Approach 2:
The patent changes parameters such as weighting factors assigned to different sensors based on their reliability, adjusts detection thresholds, or modifies data fusion algorithms dynamically to resolve sensor conflicts and optimize position detection under varying conditions
Data Source
AI summary
A system and method that automatically resolves conflicts among sensor information in a sensor fusion robot system. Such methods can accommodate converging ambiguous and divergent sensor information in a manner that can allow continued, and relatively accurate, robotic operations. The processes can include handling sensor conflict via sensor prioritization, including, but not limited, prioritization based on the particular stage or segment of the assembly operation when the conflict occurs, overriding sensor data that exceeds a threshold value, and/or prioritization based on evaluations of recent sensor performance, predictions, system configuration, and/or historical information. The processes can include responding to sensor conflicts through comparisons of the accuracy of workpiece location predictions from different sensors during different assembly stages in connection with arriving at a determination of which sensor(s) is providing accurate and reliable predictions.