Robotic arm system and object avoidance methods

• US 10,213,923 B2
• Filed: 09/09/2016
• Issued: 02/26/2019
• Est. Priority Date: 09/09/2015
• Status: Active Grant

• Current Assignee: Carbon Robotics, Inc.
• Original Assignee: Carbon Robotics, Inc.
• Inventors: Corkum, Daniel, Myers, Rosanna
• Primary Examiner(s): Sample, Jonathan L
• Application Number:
  US15/260,451
• Publication Number:
  US 20170066130A1
• Time in Patent Office: 900 Days
• Field of Search: 700245-264
• CPC Class Codes: B23K 2101/18 Sheet panels
• CPC Class Codes: B23K 26/0884 in at least in three axial directions, e.g. manipulators, robots
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B25J 9/1651 acceleration, rate control
• CPC Class Codes: B25J 9/1664 characterised by motion, path, trajectory planning
• CPC Class Codes: B25J 9/1676 Avoiding collision or forbidden zones
• CPC Class Codes: G05B 2219/37284 Capacitive 3-D proximity sensor
• CPC Class Codes: G05B 2219/37418 By capacitive means
• CPC Class Codes: G05B 2219/40454 Max velocity, acceleration limit for workpiece and arm jerk rate as constraints
• CPC Class Codes: G05B 2219/40519 Motion, trajectory planning

Abstract

One variation of a method for controlling a robotic arm includes: moving the robotic arm through a trajectory; at a first time in which the robotic arm occupies a first position along the trajectory, measuring a first capacitance of a first sense circuit comprising a first electrode extending over a first arm segment of the robotic arm; at a second time in which the robotic arm occupies a second position along the trajectory, measuring a second capacitance of the first sense circuit; calculating a first rate of change in capacitance of the first sense circuit based on a difference between the first capacitance and the second capacitance; in response to the first rate of change in capacitance of the first sense circuit exceeding a threshold rate of change, issuing a proximity alarm; and reducing a speed of the robotic arm moving through the trajectory in response to the proximity alarm.

Claims

1. A method for controlling a robotic arm, the method comprising:

moving the robotic arm through a trajectory;

at a first time in which the robotic arm occupies a first position along the trajectory, measuring a first capacitance of a first sense circuit comprising a first electrode extending over a first arm segment of the robotic arm;

at a second time in which the robotic arm occupies a second position along the trajectory, the second time succeeding the first time, measuring a second capacitance of the first sense circuit;

calculating a first rate of change in capacitance of the first sense circuit based on a difference between the first capacitance and the second capacitance;

transforming the first rate of change in capacitance of the first sense circuit into a speed of the first electrode relative to an external object;

in response to the first rate of change in capacitance of the first sense circuit exceeding a threshold rate of change and in response to the speed of the first electrode relative to an external object approximating a speed of the robotic arm from the first position to the second position, issuing a proximity alarm for motion toward a static object; and

reducing a current speed of the robotic arm moving through the trajectory to a fraction of a maximum speed of the robotic arm while the proximity alarm for motion toward a static object is current.

2. The method of claim 1, wherein measuring the first capacitance of the first sense circuit comprises measuring a resonant frequency of the first sense circuit at the first time;

wherein measuring the second capacitance of the first sense circuit comprises measuring a resonant frequency of the second sense circuit at the second time; and

wherein calculating the first rate of change comprises calculating a first rate of change in resonant frequency of the first sense circuit based on a difference between the first resonant frequency and the second resonant frequency.

3. The method of claim 1:

further comprising calculating a second rate of change in capacitance of a second sense circuit between the first time and a second time, the second sense circuit comprising a second electrode extending over the first arm segment of the robotic arm, adjacent the first electrode, and defining a second area less than a first area defined by the first electrode;

wherein issuing the proximity alarm comprises;

in response to the first rate of change exceeding the threshold rate of change and the threshold rate of change exceeding the second rate of change, issuing a first proximity alarm for proximity of an external object within a first proximity range of the robotic arm, the first proximity range corresponding to a first sensible range of the first electrode; and

in response to the first rate of change and the second rate of change exceeding the threshold rate of change, issuing a second proximity alarm for proximity of an external object within a second proximity range of the robotic arm, the second proximity range corresponding to a second sensible range of the second electrode; and

wherein reducing the current speed of the robotic arm comprises;

reducing the current speed of the robotic arm to a first fraction of the maximum speed of the robotic arm in response to the first proximity alarm; and

reducing the current speed of the robotic arm to a second fraction of the maximum speed of the robotic arm in response to the second proximity alarm, the second fraction less than the first fraction.

4. The method of claim 1, further comprising:

at a third time, detecting first contact between an object and a first region of the first arm segment adjacent the first electrode based on a second rate of change in capacitance of the first sense circuit exceeding a second threshold rate of change, the second threshold exceeding the first threshold;

at approximately the third time, detecting a second contact between an object and a second region of the first arm segment adjacent a second electrode coupled to a second sense circuit based on a third rate of change in capacitance of the second sense circuit exceeding the second threshold rate of change, the second region of the first arm segment opposite the first region of the first arm segment;

interpreting the first contact and the second contact as a manual control gesture to control a first actuatable axis coupled to the first arm segment; and

unlocking the first actuatable axis in response to the manual control gesture.

5. The method of claim 4, further comprising:

at approximately a fourth time, detecting a third contact between an object and a third region of the first arm segment adjacent a third electrode coupled to a third sense circuit based on a fourth rate of change in capacitance of the third sense circuit exceeding the second threshold rate of change, the third region of the first arm segment interposed between the first region and the second region of the first arm segment; and

interpreting the first contact, the second contact, and the third contact as a second manual control gesture to control the first actuatable axis and a second actuatable axis coupled to a second arm segment supporting the first arm segment; and

unlocking the first actuatable axis and the second actuatable axis in response to the second manual control gesture.

6. A system comprising:

a base;

a first arm segment;

a second arm segment interposed between the base and the first arm segment, coupled to the first arm segment via a first actuatable axis, and coupled to the base via a second actuatable axis;

an end effector coupled to an end of the first arm segment opposite the first actuatable axis;

a first electrode arranged across a region of the first arm segment and electrically coupled to a first sense circuit;

a controller configured to measure a first capacitance of the first sense circuit at a first time and to measure a second capacitance of the first sense circuit at a second time during actuation of the first actuatable axis and the second actuatable axis, the second time succeeding the first time;

a processor configured to;

actuate the first actuatable axis and the second actuatable axis to move the end effector from a first position in physical space at the first time to a second position in physical space at the second time;

calculate a first rate of change in capacitance of the first sense circuit between the first time and the second time;

issue a proximity alarm at the second time in response to the first rate of change in capacitance of the first sense circuit exceeding a threshold rate of change; and

reduce a maximum actuation speed of the first actuatable axis and the second actuatable axis in response to the proximity alarm.

7. The system of claim 6, wherein the controller is configured to measure capacitance of the first sense circuit by sensing a resonant frequency of the first sense circuit.

8. The system of claim 6:

wherein the first electrode is arranged across a dorsal side of the first arm segment; and

wherein the processor is configured to;

issue the proximity alarm for motion in a first direction normal to the dorsal side of the first arm segment in response to the first rate of change in capacitance of the first sense circuit exceeding the threshold rate of change; and

reduce the maximum actuation speed of the first actuatable axis in a direction that moves the first arm segment in the first direction in response to the proximity alarm.

9. The system of claim 6:

further comprising a second electrode arranged across a lateral side of the first arm segment and coupled to a second sense circuit; and

wherein the processor is configured to;

issue a second proximity alarm for motion in a second direction normal to the lateral side of the first arm segment in response to a rate of change in capacitance of the second sense circuit exceeding the threshold rate of change; and

reduce the maximum actuation speed of the second actuatable axis in a direction that moves the first arm segment in the second direction in response to the second proximity alarm.

10. The system of claim 6:

further comprising;

a second electrode arranged on a first side of the first arm segment between the end effector and the first electrode and electrically coupled to a second sense circuit; and

a third electrode arranged on a second side of the first arm segment opposite the second electrode and electrically coupled to a third sense circuit;

wherein the controller is configured to measure capacitances of the second sense circuit and the third sense circuit; and

wherein the processor is further configured to unlock the first actuatable axis for manual manipulation in response to a first change in capacitance of the second sense circuit indicating contact between an external object and the first side of the first arm segment at a third time and in response to a second change in capacitance of the third sense circuit indicating contact between an external object and the second side of the first arm segment at approximately the third time.

11. The system of claim 6, further comprising a third arm segment interposed between the second arm segment and the base, coupled to the second actuatable axis on a first end, and coupled to the base at a second end opposite the first end via a third actuatable axis.

12. The system of claim 6:

wherein the first arm segment comprises;

a rigid beam extending from the first actuatable axis; and

a cover arranged over and extending along the rigid beam; and

wherein the first electrode comprises a conductive material arranged across the cover and is electrically coupled to the first sense circuit arranged within the first arm segment.

13. The system of claim 12, wherein the first arm segment further comprises a ground electrode arranged on the cover under the first electrode;

and wherein the controller drives the ground electrode to a reference electric ground potential.

14. The system of claim 6:

further comprising;

a first ground electrode arranged on the first arm segment adjacent the first electrode and coupled to the first sense circuit;

a second electrode arranged across a region of the second arm segment and electrically coupled to a second sense circuit; and

a second ground electrode arranged on the first arm segment adjacent the first electrode and coupled to the first sense circuit;

wherein the controller is configured to sequentially drive the first electrode and the second electrode to measure a capacitance between the first electrode and the first ground electrode and to measure a capacitance between the second electrode and the second ground electrode, respectively.

15. The system of claim 6, wherein the end effector comprises a motorized gripper transiently coupled to the end of the second arm opposite the second actuatable axis.

16. A method for controlling a robotic arm, the method comprising:

moving the robotic arm through a trajectory;

at a first time in which the robotic arm occupies a first position along the trajectory, measuring a first capacitance of a first sense circuit comprising a first electrode extending over a first arm segment of the robotic arm;

at a second time in which the robotic arm occupies a second position along the trajectory, the second time succeeding the first time, measuring a second capacitance of the first sense circuit;

calculating a first rate of change in capacitance of the first sense circuit based on a difference between the first capacitance and the second capacitance;

transforming the first rate of change in capacitance of the first sense circuit into a speed of the first electrode relative to an external object;

in response to the speed of the first electrode relative to an external object exceeding a speed of the robotic arm from the first position to the second position, issuing a proximity alarm for motion of a dynamic object toward the robotic arm; and

ceasing motion of the robotic arm while the proximity alarm for motion of a dynamic object toward the robotic arm is current.

17. A method for controlling a robotic arm, the method comprising:

moving the robotic arm through a trajectory by actuating a first actuatable axis interposed between a first arm segment and a second arm segment of the robotic arm and actuating a second actuatable axis interposed between the second arm segment and a base of the robotic arm;

at a first time in which the robotic arm occupies a first position along the trajectory, measuring a first capacitance of a first sense circuit comprising a first electrode extending over a first arm segment of the robotic arm;

at a second time in which the robotic arm occupies a second position along the trajectory, the second time succeeding the first time, measuring a second capacitance of the first sense circuit;

calculating a first rate of change in capacitance of the first sense circuit based on a difference between the first capacitance and the second capacitance;

calculating a second rate of change in capacitance of a second sense circuit between the first time and a second time, the second sense circuit comprising a third electrode extending over the second arm segment;

in response to one of the first rate of change in capacitance and the second rate of change in capacitance exceeding a threshold rate of change, issuing a proximity alarm; and

in response to the proximity alarm, setting a reduced maximum speed of rotation of the first actuatable axis and the second actuatable axis in response to the proximity alarm.

18. The method of claim 17, further comprising, at an initial time preceding the first time:

moving the robotic arm through a capacitance mapping route;

recording a set of absolute capacitance values of the first sense circuit at discrete waypoints along the capacitance mapping route;

transforming the set of absolute capacitance values into relative capacitance value changes between the discrete waypoints along the capacitance mapping route;

aggregating the relative capacitance value changes into a baseline capacitance map of a physical space occupied by the robotic arm; and

calculating the threshold rate of change between the first position and the second position from the baseline capacitance map and a speed of the robotic arm between the first position and the second position.

19. The method of claim 18:

wherein moving the robotic arm through a trajectory comprises moving the robotic arm through the trajectory approximating the capacitance mapping route;

wherein recording the set of absolute capacitance values of the first sense circuit comprises recording the set of absolute capacitance values of the first sense circuit at a set of discrete waypoints along the capacitance mapping route, the set of discrete waypoints comprising the first position and the second position; and

wherein issuing the proximity alarm comprises detecting a change in the physical space, occupied by the robotic arm, between the initial time and the second time in response to the first rate of change in capacitance of the first sense circuit exceeding the threshold rate of change and issuing the proximity alarm based on the change in the physical space.

20. A system comprising:

a base;

a first arm segment;

a second arm segment interposed between the base and the first arm segment, coupled to the first arm segment via a first actuatable axis, and coupled to the base via a second actuatable axis;

an end effector coupled to an end of the first arm segment opposite the first actuatable axis;

a first electrode arranged across a region of the first arm segment and electrically coupled to a first sense circuit;

a second electrode arranged on a first side of the first arm segment between the end effector and the first electrode and electrically coupled to a second sense circuit; and

a third electrode arranged on a second side of the first arm segment opposite the second electrode and electrically coupled to a third sense circuit;

a controller configured to measure capacitance of the first sense circuit, the second sense circuit, and the third sense circuit during actuation of the first actuatable axis and the second actuatable axis; and

a processor configured to unlock the first actuatable axis for manual manipulation in response to a first change in capacitance of the second sense circuit indicating contact between an external object and the first side of the first arm segment at a third time and in response to a second change in capacitance of the third sense circuit indicating contact between an external object and the second side of the first arm segment at approximately the third time.