Patent ID: 12257710

DETAILED DESCRIPTION

FIG.1is a schematic configuration view of a robot hand1. The robot hand1includes a control device10, an encoder20, a motor30, a drive gear40, a driven gear50, and claws60. The control device10controls the operation of the entire robot hand1. The motor30is a drive source for opening and closing the claws60, and is, for example, a stepping motor or a brushless DC motor. The encoder20is provided at a proximal end of a rotation shaft32of the motor30, and detects a rotational position of the motor30(a rotational angle of the rotation shaft32of the motor30). The encoder20may be of an optical type or a magnetic type. The drive gear40is provided at a distal end of the rotation shaft32of the motor30and meshes with the driven gear50. The rotational force of the motor30is transmitted from the drive gear40to the driven gear50via the rotation shaft32. The driven gear50has a substantially semicircular shape, and teeth are formed on an arc-shaped outer peripheral surface. The meshing mechanism between the drive gear40and the driven gear50is, for example, a worm gear, but may be a screw gear or other gears. A proximal end portion of the claw60is fixed to the driven gear50. Although only two pairs of the driven gear50and the claw60are illustrated inFIG.1, three or more pairs of the driven gear50and the claw60may be provided.

When the motor30rotates in the forward direction, the driven gear50swings in one direction corresponding to the meshing with the drive gear40, and the distal end portions of the claws60approach each other. When the motor30rotates in the reverse direction, the driven gear50swings in the opposite direction which is opposite to the above-described one direction, and the tip portions of the claws60are separated from each other. When the distal end portions of the claws60approach each other, it is possible to grip a workpiece that is a gripping target. The workpiece is released by separating the distal end portions of the claws60from each other. In this manner, the claws60are opened and closed by switching the rotation of the motor30between the forward rotation and the reverse rotation.

FIG.2is a block view illustrating a schematic configuration of the control device10. The robot hand1is used by being fixed to a distal end of a robot arm. In addition, the control device10controls the driving of the motor30in response to a command from a robot controller100that controls the entire operation of the robot hand1and a robot arm. The control device10includes a control unit11and a driver circuit13. The control unit11is mainly configured by a microcomputer or the like, and includes a CPU, a ROM, a RAM, an I/O, a bus line connecting these components, and the like, none of which are illustrated. Each process in the control unit11may be a software process in which a program stored in advance in a tangible memory (that is, a readable temporary tangible recording medium) such as a ROM is executed by a CPU, or may be a hardware process by a dedicated electronic circuit using a field programmable gate array (FPGA) or the like.

The control unit11calculates the position and the movement amount of the claws60based on the detection signal from the encoder20. As described above, since the opening and closing of the claws60is performed by transmitting the rotational force from the drive gear40to the driven gear50by the rotation of the motor30, the state of the opening and closing of the claws60is grasped by the rotational angle of the rotation shaft32obtained by the detection signal from the encoder20. When the motor30is a stepping motor, the driver circuit13includes a switching element that controls energization of a coil of each phase, and controls driving of the motor30by switching energization of a winding of each phase of the motor30. In the driver circuit13, in addition to using the function of a general-purpose IC for controlling the motor30, a shunt resistor is provided and its potential difference is A/D converted. Accordingly, the control unit11grasps the current of the coil of each phase of the motor30. Similarly, in the driver circuit13, by using a function of a general-purpose IC for controlling the motor30, it is possible to set an effective value of energization of each phase of the coil of the motor30by modulation such as PWM. Further, the control unit11is capable of estimating the torque T of the motor30based on the current of the coil of each phase and the detection signal from the encoder20. As described above, the control unit11is capable of controlling the current of the coil of each phase of the motor30. Therefore, the control unit11is capable of arbitrarily setting the torque T by setting the current of the coil of each phase of the motor30with reference to the detection signal from the encoder20. In this way, the control unit11is capable of controlling the driving of the motor30by issuing a command to the driver circuit13based on the detection signal from the encoder20, and is capable of finally controlling the opening and closing of the claws60.

Next, the gripping control performed by the control unit11of the control device10will be described.FIG.3is a flowchart illustrating an example of the gripping control. The control unit11first executes a limiting process for limiting the torque T of the motor30(step S10), then executes an increasing process for increasing the torque T of the motor30(step S20), and then executes a maintaining process for maintaining the torque T of the motor30(step S30). The restriction process will be described below.

FIG.4is a flowchart illustrating an example of the restriction process. The control unit11obtains a target position Pt of the claws60, a moving speed S of the claws60, and the torque limit value Tr of the motor30based on a command from the robot controller100(step S11). Next, the control unit11controls the motor30so that the claws60moves from the current position toward the target position Pt at the moving speed S (step S13) while limiting the current applied to the motor30by outputting a command to the driver circuit13so that the torque T of the motor30becomes constant at the torque limit value Tr or less (step S12). As a result, the claws60moves so as to be closed when the torque T of the motor30is relatively weak torque equal to or less than the torque limit value Tr.

Next, the control unit11determines whether or not all of the claws60have come into contact with the workpiece in a state in which the torque T of the motor30is limited (step S14). Specifically, it is determined whether or not the rate of change in the rotational position of the motor30(the amount of change per unit time in the rotational angle of the rotation shaft32) has become equal to or less than a threshold value α. The threshold value α is set to a value smaller than a change speed of the rotational position of the motor30corresponding to the moving speed S described above. That is, it is determined whether or not the moving speed S has decreased to a moving speed corresponding to the threshold value α. The change speed of the rotational position is calculated by the encoder20based on the rotation amount of the motor30within a predetermined time. When the change speed of the rotational position of the motor30is higher than the threshold value α, it is determined that all the claws60are not yet in contact with the workpiece. When the change speed of the rotational position of the motor30decreases to the threshold value α or less, it is determined that all the claws60have come into contact with the workpiece. In the case of No in step S14, the process of step S13is executed again. In the case of Yes in step S14, the limiting process ends, and then the increasing process described above is executed.

The increasing process will be described.FIG.5is a flowchart illustrating an example of the increasing process. The control unit11obtains a torque upper limit value Tmax and a movement amount upper limit value ΔPmax (step S21). The torque upper limit value Tmax and the movement amount upper limit value ΔPmax may be stored in in advance in the ROM described above may be used, or numerical values transferred from the robot controller100may be stored in the RAM described above and used. The torque upper limit value Tmax is a value greater than the torque limit value Tr. Next, the control unit11temporarily stores in the memory a contact start position P1determined in the limiting process that all the claws60have come into contact with the workpiece (step S22). Next, the control unit11increases the torque T by one step (step S23). Specifically, the control setting is changed so that the torque increases in accordance with the control characteristic of a motor employed as the motor30. For example, an absolute value of the current of the coil of each phase of the motor30is increased, or the duty ratio of the PWM control is increased. Here, “increase by one step” means discretely increasing the torque T of the motor30. The “increase by one step” means that the torque T fluctuates before and after the increase, and large energy is transmitted from the motor30to the drive gear40with respect to the friction loss in the meshing mechanism of the drive gear40and the driven gear50described above. In the meshing mechanism, when the meshing speed decreases, there is a possibility that the meshing stops due to a friction loss. Specifically, since the friction that has been acting so far changes from dynamic friction to static friction, and the static friction is larger than the dynamic friction, the meshing mechanism might fall into a so-called stuck state. In order for the meshing mechanism to start to move again, a torque impact is applied to the meshing mechanism by an increase in the torque T in discrete values, so it is possible to make a transition from static friction to dynamic friction.

Next, the control unit11determines whether or not the torque T is equal to or greater than the torque upper limit value Tmax (step S24). In the case of Yes in step S24, the increasing process ends, and a maintaining process of maintaining the current torque T of the motor30at the torque upper limit value Tmax is executed (step S30).

In the case of No in step S24, the control unit11temporarily stores a current position P2of the claws60in the memory (step S25). Next, the control unit11calculates a movement amount ΔP of the claws60which is a difference between the contact start position P1and the current position P2(step S26). Next, the control unit11determines whether or not the calculated movement amount ΔP is equal to or greater than the movement amount upper limit value ΔPmax (step S27). In the case of No in step S27, the process of step S23is executed again. In this case, the torque T is further increased by one step in step S23. As a result, as long as No is determined in steps S27and S24, the torque T increases at a constant rate of increase. In the case of Yes in step S27, the increasing process ends, and a maintaining process of maintaining the current torque T of the motor30is executed (step S30).

Next, a transition between the position P of the claws60and the torque T of the motor30when the workpiece is gripped will be described.FIG.6is a timing chart illustrating changes in the position P and the torque T of the motor30when a soft workpiece is gripped. At time T0, the torque T is maintained substantially constant at a torque T0equal to or less than the torque limit value Tr, and the position P of the claws60gradually moves from an initial position P0. At time t1, the position P of the claws60reaches the contact start position P1at which all the claws60come into contact with the workpiece. Since the position P of the claws60do not move and it is determined that all the claws60are in contact with the workpiece at time t2, the torque T increases and the positions P of the claws60start to move. When the movement amount Δ P, which is the difference between the current position P2and the contact start position P1, reaches the movement amount upper limit value ΔPmax at time t3, the torque T is maintained at the torque T1at that time. In this way, it is possible to grip a soft workpiece with a weak gripping force that does not damage the workpiece.

FIG.7is a timing chart illustrating changes in the position P of the claws60and the torque T of the motor30when a hard workpiece is gripped. Similarly to the case illustrated inFIG.6, after times t0, t1, and t2are reached, the torque T increases, but the current position P2does not move from the contact start position P1. For this reason, the torque T further increases, becomes equal to or greater than the torque upper limit value Tmax at time t3, and the torque T is maintained at the upper limit value Tmax. In this way, it is possible to grip a hard workpiece with a gripping force that is strong enough to prevent the hard workpiece from falling.

The above described limiting process (step S10) will be supplemented. The main point of the limiting process is to detect the position of the workpiece. In other words, the limiting process is a control of the claws60for searching for the presence of a workpiece. The torque T is set to a relatively weak value so as not to damage the workpiece in order to detect the position of the workpiece. On the other hand, when the torque T is weak (low value), the rotational speed of the motor30becomes slow depending on the type or control method of the driver circuit13to be employed or the type of the motor30to be employed, and it might take time to detect the position of the workpiece. In order to avoid such inconvenience, it is also possible to select to operate the motor30in a high-speed rotation and low-torque control region during the limiting process and to operate the motor30in a low-speed rotation and high-torque control region during the increasing process and the maintaining process. For example, in a case where an inner rotation type brushless DC motor is adopted as the motor30, this is realized by changing the excitation of the poles by switching the connection of the stator winding. When the motor30is provided with a transmission (not illustrated) capable of changing a gear ratio and a ratio between the rotational speed of the motor30and the rotational speed of the drive gear40, it is also possible to rotate the motor30in a high-speed and low-torque state with a low reduction ratio during the limiting process, and to rotate the motor30in a low-speed and high-torque state with a high reduction ratio during the increasing process and the maintaining process.

As described above, it is not needed to change the setting of the gripping force for each of an unspecified number of types of workpieces, to prepare in advance to obtain the deformation ratio of the workpiece, and to provide a pressure sensor for measuring the gripping force based on the rotational position of the motor30detected by the encoder20. Therefore, it is possible to grip the workpiece with an appropriate gripping force according to the hardness of the workpiece by a simple method.

With the above-described embodiment, a robot to which the robot hand of the present embodiment is applied has the following advantages. First, one robot hand is capable of dynamically coping with an unspecified variety of workpieces. For this reason, it is possible to reduce man-hours for teaching and setup change when constructing a mass-production line. Further, the torque T and the movement amount ΔP is capable of being obtained, after the gripping force of each workpiece is determined by the increasing process. Therefore, for example, in a production line in which workpieces of the same type are continuously fed, the robot hand according to the present embodiment is capable of being used as a measuring instrument while gripping the workpiece. As a result, the torque T and the movement amount ΔP after the determination of the gripping force are regarded as physical properties of each workpiece, the quality of the workpiece is statistically determined, and a non-standard workpiece is discriminated. As a similar application, in a production line in which a plurality of types of workpieces are continuously fed, it is also possible to classify each workpiece based on the torque T or the movement amount ΔP after the determination of the gripping force.

In addition to the torque T and the movement amount ΔP obtained at the time of determining the gripping force of each workpiece in the increasing process as described above, the position P1of the claw when it is determined in the limiting process that all the claws come into contact with the workpiece in the limiting process, a required time (t2to t3) until the movement amount ΔP becomes equal to or greater than the movement amount upper limit value ΔPmax, and the like also represent the physical properties of each workpiece. The plurality of physical quantities representing the physical properties of each workpiece are defined as gripping parameters. By using these gripping parameters, the robot hand according to the present embodiment is capable of being widely used. In the case of the above-described production line in which workpieces of the same type are continuously fed, it is possible to accurately detect defective workpieces by setting a threshold value that defines a range of non-defective workpieces in order to determine whether the workpieces are non-defective or defective, and by comparing a gripping parameter obtained by gripping each workpiece with the threshold value. Further, a plurality of non-defective workpieces to be a reference for quality determination are prepared in advance, and the workpieces of the non-defective group are continuously gripped to obtain a gripping parameter, and statistical process is executed to generate a threshold for defining a range of non-defective workpieces. Accordingly, it is possible to detect a defective product by comparing the gripping parameter of each workpiece with the threshold value at the time of subsequent operation of the production line. In addition, since it is not needed for a production line process designer to handle the gripping parameter as a specific numerical value, it is possible to reduce input errors and working man-hours, and to save labor.

The above-described obtainment of the gripping parameter, generation of the threshold value, and comparison between the gripping parameter and the threshold value may be performed by the control unit11, or may be collectively performed with another robot hand by exchanging needed information with the external robot controller100or the like.

While the exemplary embodiments of the present disclosure have been illustrated in detail, the present disclosure is not limited to the above-mentioned embodiments, and other embodiments, variations and variations may be made without departing from the scope of the present disclosure.