Workcell Motion Profile Matching for Legacy Robot Digital Twins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing robotics systems lack the capability to automatically generate virtual representations, making it difficult to optimize and improve their performance efficiently, especially for legacy systems without documentation.
Innovation Solution
The described techniques enable the generation of a virtual representation of a physical operating environment by creating virtual equivalents of physical robots and sensors, which can be calibrated and configured to perform tasks similarly to their physical counterparts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual pre-programming is used to schedule robotic movements, then the robot can perform tasks with predefined instructions, but accumulated errors occur and task failure rate increases
Solution Approach 1:
The patent creates a virtual copy (digital twin) of the physical robot and its operating environment. This virtual representation allows for error-free simulation and optimization of robotic movements before executing them in the physical system, eliminating accumulated errors while maintaining productivity.
2Productivity
If virtual representations are used to optimize robotic systems, then efficiency and performance improvement are enhanced, but the complexity of system setup and calibration increases
Solution Approach 1:
The system automatically generates the virtual representation by capturing sensor data and robot states during normal operation. The virtual model self-calibrates by matching observed physical robot behavior with simulated behavior, eliminating the need for manual setup and reducing complexity while maintaining optimization benefits.
3Loss of information
If conventional techniques are used to obtain virtual representations, then documentation and manual configuration are required, but legacy systems without documentation cannot be represented
Solution Approach 1:
The patent replaces manual documentation processes with automated sensor-based observation. Sensors capture robot positions, states, and environmental data during operation, automatically building a virtual representation without requiring any documentation. This substitutes the mechanical process of manual documentation with an automated sensing and modeling system, enabling legacy systems to be represented without any documentation.
4Ease of manufacture
If trial and error methods are used to modify physical robotics systems, then direct optimization is possible, but time consumption and cost increase significantly
Solution Approach 1:
The patent performs optimization in the virtual environment before applying changes to the physical system. All trial and error iterations occur in the digital twin, allowing multiple configurations to be tested virtually. Once the optimal configuration is found in simulation, it is transferred to the physical robot, eliminating time-consuming physical trial and error while maintaining ease of modification.
Data Source
AI summary
Methods, systems, and apparatus, including computer programs encoded on computer storage media, for measuring and reporting calibration accuracy of robots and sensors assigned to perform a task in an operating environment. One of the methods includes obtaining sensor data of one or more physical robots performing a process in an operating environment; generating, from the sensor data for a first robot of the one or more physical robots, a motion profile representing how the first robot moves while performing the process; obtaining data representing a plurality of candidate virtual robot components, each having a respective virtual motion profile and is a candidate to be included in a virtual representation of the operating environment; performing a motion profile matching process to determine a first virtual robot component from the plurality of candidate virtual robot components that matches the first robot; and adding the first virtual robot component to the virtual representation.