Systems and methods for tactile fur sensing

• US 9,797,792 B2
• Filed: 03/13/2015
• Issued: 10/24/2017
• Est. Priority Date: 03/13/2015
• Status: Active Grant

• Current Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Moore, Douglas A.
• Primary Examiner(s): Fuller, Rodney
• Application Number:
  US14/658,045
• Publication Number:
  US 20160265994A1
• Time in Patent Office: 956 Days
• Field of Search: 73726
• CPC Class Codes: B25J 13/084 Tactile sensors in general G01L5/16, G01L5/22
• CPC Class Codes: G01L 1/205 using distributed sensing elements
• CPC Class Codes: G01L 5/228 using tactile array force sensors
• CPC Class Codes: Y10S 901/09 Closed loop, sensor feedback controls arm movement
• CPC Class Codes: Y10S 901/46 Sensing device

Abstract

A tactile fur sensing system and a method of operating thereof allow early detection of an impending contact with an object. A plurality of filaments or threads are positioned on a zone or area of a surface of robotic device in a cost-effective manner. One or more sensors are configured to detect electrical resistance and/or displacement of the plurality of filaments or threads. A processor determines that there is contact with an object based on the detected electrical resistance and/or displacement. The detection of electrical resistance can be based on adjustable baseline values and/or adjustable threshold values. A plurality of nubs may alternatively or in addition be positioned on a surface area. Each nub has an outer cast or protection layer defining a cavity therein. At least a portion of a sensor for detecting resistance and/or displacement is positioned within the cavity of the nub.

Claims

1. A robotic sensing system, comprising:

a first plurality of filaments or threads each having a length of at least 7 millimeters, and positioned on a first zone or area of a surface;

a first sensor connected to the first plurality of filaments or threads, and configured to detect first sensor data corresponding to at least one of a first electrical resistance value or a first displacement of the first plurality of filaments or threads; and

a processor communicatively coupled to first sensor, and configured to determine a first contact between the first plurality of elements or threads and a first object based on the first sensor data, prior to contact between the first object and the first zone or area of the surface.

2. The robotic sensing system of claim 1, further comprising:

a second plurality of filaments or threads positioned on a second zone or area of the surface; and

a second sensor connected to the second plurality of filaments or threads, and configured to detect second sensor data corresponding to at least one of a second electrical resistance value or a second displacement of the second plurality of filaments or threads,

wherein the processor is further communicatively coupled to the second sensor and further configured to determine a second contact between the second plurality of elements or threads and the first object or a second object based on the at least one of the second electrical resistance value or the second displacement, prior to contact between the first object or the second object and the second zone or area of the surface.

3. The robotic sensing system of claim 2, wherein

the first zone or area has a first portion and a second portion,

the second zone or area has a first portion and a second portion,

the first portion of the first zone or area overlaps with the first portion of the second zone or area, and

the second portion of the first zone or area does not overlap with any portion of the second zone or area.

4. The robotic sensing system of claim 2, wherein the first zone or area does not overlap with the second zone or area.

5. The robotic sensing system of claim 2, wherein the processor is further configured to determine, based on the first sensor data and the second sensor data, areas of contact between one or more objects and the surface before the one or more objects contact the surface.

6. The robotic sensing system of claim 1, wherein

the first sensor is a switch-based sensor that includes a switch that is open either when there is no contact between the first plurality of filaments or threads and an object, or when there is contact between the first plurality of filaments or threads and the object that is less than a force or pressure threshold,

the switch is closed when there is contact between the first plurality of filaments or threads and the object that is greater than or equal to the force or pressure threshold,

the first sensor data has a binary value, corresponding to either the switch being closed or open, and

the processor is configured to determine that the first contact is established when or after the switch is closed.

7. The robotic sensing system of claim 1, further comprising a memory configured to store one or more electrical resistance threshold values, wherein

the first sensor is a resistance-based sensor that detects the first electrical resistance value, and

the processor is configured to determine that the first contact is established prior to contact of the first object with the first zone or area of the surface, based on the first electrical resistance value and the one or more electrical resistance threshold values.

8. The robotic sensing system of claim 1, wherein

the first plurality of filaments or threads form a fur texture, each of the first plurality of filaments or threads having a first angle as compared with the surface, and

at least one filament or thread of the first plurality of filaments or threads that contacts the first object has a second angle as compared with the surface as a result of the first contact, the second angle being substantially different than the first angle.

9. The robotic sensing system of claim 1, wherein the first sensor is the only sensor that is connected to the first plurality of filaments or threads, and is configured to detect contact between an object and the first plurality of filaments or threads.

10. The robotic sensing system of claim 1, wherein the surface corresponds to an outer surface of a robotic part or device, and the first plurality of filaments or threads corresponds to a woven conductive yarn positioned on the surface of the robotic part or device.

11. The robotic sensing system of claim 1, wherein the first plurality of filaments or threads includes at least 8 filaments or threads positioned on a millimeter square of the first zone or area of the surface.

12. The robotic sensing system of claim 1, wherein the first plurality of filaments or threads are made of a conductive material.

13. A robotic sensing system, comprising:

a plurality of nubs positioned on a surface area and configured to be flexible in order to be displaced upon contact, each nub including;

an outer cast or protection layer having a length of at least 7 millimeters, and defining a cavity therein, and

a sensor configured to detect a displacement of the nub, with at least one part of the sensor positioned in the cavity of the outer cast or protection layer, the outer cast or protective layer configured to prevent contact between the at least one part of the sensor and an object outside the cavity; and

a processor communicatively coupled to the sensor, and configured to determine a first contact between the plurality of nubs and a first object prior to contact between the first object and the first zone or area of the surface based on the detected displacement.

14. The robotic sensing system of claim 13, wherein the sensor is a pressure-based sensor configured to generate a signal when a pressure or force applied to the outer cast or protection layer exceeds a pressure or force threshold.

15. The robotic sensing system of claim 13, wherein

the at least one part of the sensor includes a first electrical contact and a second electrical contact,

the first electrical contact is configured to contact the second electrical contact when sufficient pressure or force is applied to the outer cast or protection layer by an object, and

the sensor is configured to generate a signal when the first electrical contact contacts the second electrical contact.

16. The robotic sensing system of claim 13, wherein the outer cast is made of urethane and is molded.

17. A method for detecting an impending contact with an object using a plurality of filaments or threads positioned on a zone or area of a surface of a robotic device, the method comprising:

storing, in a memory, a baseline value corresponding to at least one of a baseline resistance value or a rate or amount of change in a resistance value, when the plurality of filaments or threads are in a first position without contact with any object;

detecting, using a sensor connected to the plurality of filaments or threads, the resistance value corresponding to the plurality of filaments or threads;

determining, using a processor communicatively coupled to the sensor and the memory, a first contact between the plurality of filaments or threads and a first object based on the detected resistance value and the stored baseline value;

determining, by the processor, that the plurality of filaments or threads are in a steady state position, that is different than the first position, without contact with the object;

resetting, using the processor, the stored baseline value when or after the plurality of filaments or threads are in the steady state position; and

determining, using the processor, a second contact between the plurality of filaments or threads and the first object or a second object based on the detected resistance value and the reset baseline value.

18. The method of claim 17, further comprising:

storing one or more resistance threshold values for distinguishing between a contact with the object and a contact with a part of the robotic device, the one or more resistance threshold values being based on at least one of an electrical resistance value or a rate or amount of change in the electrical resistance value,

wherein the step of determining, using the processor, the first contact is further based on the stored one or more resistance threshold values.

19. The method of claim 17, wherein the step of resetting, using the processor, the stored baseline value is performed when or after the processor determines that the plurality of filaments or threads are in the steady state and without any contact with the object.

20. The method of claim 17, wherein each of the plurality of filaments or threads has a length of at least 7 millimeters.