Soft body robot for physical interaction with humans

• US 9,802,314 B2
• Filed: 02/19/2016
• Issued: 10/31/2017
• Est. Priority Date: 10/01/2015
• Status: Active Grant

• Current Assignee: Disney Enterprises Incorporated (The Walt Disney Company)
• Original Assignee: Disney Enterprises Incorporated (The Walt Disney Company)
• Inventors: Yamane, Katsu, Kim, Joohyung, Alspach, Alexander Nicholas
• Primary Examiner(s): MANCHO, RONNIE M
• Application Number:
  US15/047,820
• Publication Number:
  US 20170095925A1
• Time in Patent Office: 620 Days
• Field of Search: 700245, 700260
• CPC Class Codes: B25J 9/1633 compliant, force, torque control, e.g. combined with position control
• CPC Class Codes: B25J 9/1676 Avoiding collision or forbidden zones
• CPC Class Codes: G05B 2219/37399 Pressure
• CPC Class Codes: G05B 2219/39319 Force control, force as reference, active compliance
• CPC Class Codes: G05B 2219/39325 External force control, additional loop comparing forces corrects position
• CPC Class Codes: G05B 2219/40199 Soft material covers links, arms for shock and pain attenuation
• CPC Class Codes: G05B 2219/40201 Detect contact, collision with human
• CPC Class Codes: G05B 2219/40202 Human robot coexistence
• CPC Class Codes: G05B 2219/40253 Soft arm robot, light, rubber, very compliant

Abstract

A robot designed for reducing collision impacts during human interaction. The robot includes a robot controller including a joint control module. The robot includes a link including a rigid support element and a soft body segment coupled to the rigid support element, and the body segment includes a deformable outer sidewall enclosing an interior space. The robot includes a pressure sensor sensing pressure in the interior space of the link. A joint is coupled to the rigid support element to rotate or position the link. During operations, the robot controller operates the joint based on the pressure sensed by the pressure sensor. The robot controller modifies operation of the joint from a first operating state with a servo moving or positioning the joint to a second operating state with the servo operating to allow the joint to be moved or positioned in response to outside forces applied to the link.

Claims

1. A robot for human interaction, comprising:

a robot controller including a joint control module;

a link comprising a rigid support element and a body segment coupled to the rigid support element, wherein the body segment includes an outer sidewall enclosing an interior space;

a pressure sensor sensing pressure in the interior space of the link; and

a joint coupled to the rigid support element,

wherein the robot controller operates the joint based on the pressure sensed by the pressure sensor,

wherein the interior space is filled with a fluid,

wherein the pressure is a pressure of the fluid in the interior space, and

wherein the robot controller operates the joint based on the pressure when the pressure exceeds a predefined threshold pressure value or when a change greater than a predefined pressure change is identified by the controller.

2. The robot of claim 1, wherein the robot controller modifies operation of the joint, when the pressure exceeds a predefined threshold pressure value or when a change greater than a predefined pressure change is identified by the controller, from a first operating state with a servo moving or positioning the joint to a second operating state with the servo operating to allow the joint to be moved or positioned in response to outside forces applied to the link.

3. The robot of claim 1, wherein the joint is upstream of the link in the robot.

4. The robot of claim 1, wherein the outer sidewall is flexible whereby the interior space has a first volume in a pre-contact state and a second volume less than the first volume in a second state in which a contact force is applied to the outer sidewall.

5. The robot of claim 4, wherein the link further includes a deformation control member extending from the rigid support element to be positioned within the interior space to limit a magnitude of deformation of the outer sidewall.

6. The robot of claim 1, wherein the link is fabricated as a single unit using a three dimensional (3D) printer.

7. The robot of claim 6, wherein the single unit includes a threaded cap and an O-ring-like component that seals the interior space when the threaded cap is tightened during assembly of the robot.

8. A robot for human interaction, comprising:

a robot controller including a joint control module;

a link comprising a rigid support element and a body segment coupled to the rigid support element, wherein the body segment includes an outer sidewall enclosing an interior space;

a pressure sensor sensing pressure in the interior space of the link; and

a joint coupled to the rigid support element,

wherein the robot controller operates the joint based on the pressure sensed by the pressure sensor,

wherein the link is fabricated as a single unit, and

wherein the rigid support element includes a connector for the pressure sensor providing a passageway to the interior space.

9. A robot for human interaction, comprising:

a robot controller including a joint control module;

a link comprising a rigid support element and a body segment coupled to the rigid support element, wherein the body segment includes an outer sidewall enclosing an interior space;

a pressure sensor sensing pressure in the interior space of the link; and

a joint coupled to the rigid support element,

wherein the robot controller operates the joint based on the pressure sensed by the pressure sensor, and

wherein the joint includes one of a thrust bearing and a friction bearing fabricated as a single unit.

10. The robot of claim 9, wherein the thrust bearing is configured as a double direction thrust bearing and includes a lower roller cage assembly arranged in an arc and containing a number of rollers, the number of rollers being less than a number of rollers included in a corresponding upper roller cage assembly arranged in a full circle.

11. A robot, comprising:

a plurality of body segments; and

a set of servo-driven joints interconnecting the body segments,

wherein one or more of the body segments includes a fluid-filled void enclosed by a sidewall,

wherein the sidewall comprises a membrane of a flexible material, and

wherein each of the body segments further comprises a rigid support element coupled to an edge of the sidewall and coupled to one of the servo-driven joints; and

a pressure sensor in communication with the fluid-filled void of each of the body segments operating to sense a pressure in each of the body segments,

a controller comparing the pressure in each of the body segments with a predefined threshold value or measuring a change in pressure in the body segments based on the pressure and based on the comparing or the measuring, modifying operations of at least one of the servo-driven joints.

12. The robot of claim 11, wherein the modifying of the operations of the at least one of the servo-driven joints comprises powering off a servo or allowing a servo to freewheel.

13. The robot of claim 12, wherein the at least one of the servo-driven joints is a parent joint for one of the body segments having a pressure exceeding the predefined threshold value or having a change in pressure exceeding a predefined maximum pressure change value.

14. The robot of claim 11, wherein the body segments are printed using a 3D printer and the flexible material is a rubber, a plastic, or a rubber-like material.

15. The robot of claim 14, wherein the robot is configured to have a predefined body shape and wherein the body segments are selected to each have an outer shape defined by one of a plurality of primitive modules.

16. The robot of claim 15, wherein the outer shapes of the primitive modules are selected from the group consisting of a donut shape, a cylinder, and a cylinder with a round end.

17. A method of controlling operation of a robot, comprising:

first transmitting a control signal to operate a joint upstream of a link in a first operating state, wherein the link includes a rigid support element coupled to the joint and a cavity enclosed by a sidewall affixed to the rigid support element;

measuring a pressure of a fluid in the cavity;

based on the measured pressure, determining when a contact force is being applied to the sidewall; and

when the contact force is determined, second transmitting a control signal to operate the joint upstream of the link in a second operating state differing from the first operating state, wherein the second operating state comprises powering off an actuator or servo in the joint.

18. The method of claim 17, further comprising measuring a second pressure in of the fluid in the cavity, determining when the contact force is removed from the sidewall, and, where the contact force is determined removed, third transmitting a control signal to operate the joint upstream of the link in a third operating state differing from the second operating state.

19. The method of claim 17, wherein the robot is a humanoid robot and the link comprises a forearm link, an upper arm link, a torso link, a back link, or a chest link.