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Development of a Virtual Collision Sensor for Industrial Robots.

Marina Indri1, Stefano Trapani2, Ivan Lazzero3

  • 1Dipartimento di Automatica e Informatica, Politecnico di Torino, Corso Duca degli Abruzzi 24, Torino 10129, Italy. marina.indri@polito.it.

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A novel virtual collision sensor for industrial robots uses motor current data to detect collisions without needing extra sensors or a precise robot model. This method enhances safety and avoids false alarms in robotic cells.

Keywords:
collision detectionindustrial manipulatorsvirtual sensors

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Area of Science:

  • Robotics
  • Control Systems
  • Machine Safety

Background:

  • Collision detection is critical for robotic cell safety.
  • Existing methods often require specialized sensors or detailed robot dynamic models.
  • A robust, model-independent solution is needed for industrial manipulators.

Purpose of the Study:

  • To introduce a virtual collision sensor for industrial robots.
  • To enable collision detection using only standard motor current measurements and estimated currents from the robot's internal model.
  • To develop a method that does not require knowledge of the robot's dynamic model parameters or accuracy.

Main Methods:

  • A virtual collision sensor is proposed, utilizing motor currents and estimated currents from the robot's internal dynamic model.
  • Collision detection is performed by comparing the current residue against a time-varying threshold function.
  • The threshold function incorporates model error estimates and a bias term for adjustable sensitivity.

Main Results:

  • The proposed virtual sensor effectively detects collisions using readily available data.
  • The method demonstrates robustness against variations in the robot's dynamic model.
  • Experimental results validate the sensor's performance, showing accurate and reliable collision detection.

Conclusions:

  • The developed virtual collision sensor offers a practical and effective solution for industrial robot safety.
  • It provides a reliable alternative to traditional collision detection methods, reducing reliance on external sensors or precise models.
  • The technology has been successfully implemented in industrial settings, confirming its real-world applicability.