Robot arm and method of controlling the same

This application claims the priority benefit of Korean Patent Application No. 2008-0123182, filed on Dec. 5, 2008, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.

1. Field

Embodiments relate to a robot arm and a method of controlling the same, and more particularly to a robot arm having high back-drivability to interact with a human being, which is safely stopped, and a method of controlling the robot arm.

2. Description of the Related Art

In general, machines, which conduct motions similar to those of a human being using an electrical or magnetic action, refer to robots. Initial robots were industrial robots, such as manipulators or transfer robots, for work automation and unmanned operation in a production field, which perform dangerous work, simple repetitive work, or work requiring large force in place of a human being. Recently, humanoid robots, which have a joint system similar to that of a human being, live together with the human being in human working and living spaces, and provide various services, have been vigorously researched and developed.

Such a humanoid robot includes robot arms having high back-drivability to interact with a human being in daily life, and each of the robot arms is formed in a single rod shape or has a plurality of joints. The back-drivability denotes a degree of the movement of the robot arm, when external force is applied to the robot arm under the condition that current is not applied to a joint motor (generally, an actuator) and thus no torque is generated.

Therefore, under the condition that power is cut off, the robot arm having high back-drivability is easily moved using external force, a torque applied to a joint of the robot arm is easily measured through motor current due to small kinematical friction of the joint, and the stiffness of the robot arm is adjusted through an impedance control such that the robot arm achieves flexibility and thus is capable of performing an interaction with a human being (for example, a hug with the human being).

However, in case that power supplied to the robot arm having high back-drivability is cut off in an emergency, in which the operation of the robot arm is stopped, the robot arm (particularly, the tip of the robot arm) is dropped down by gravity due to the small friction of the joint. Thus, in case that power supplied to the robot arm is cut off, when the robot arm is located at a low position, no trouble is caused, but when the robot arm is located at a high position, the robot arm is excessively moved.

An aspect of exemplary embodiments provide a robot arm having high back-drivability to interact with a human being, which is safely stopped through a gravity compensation control in case that the operation of the robot arm is converted into a safety mode due to the occurrence of an emergency, in which the operation of the robot arm is stopped, and a method of controlling the robot arm.

In accordance with an aspect of exemplary embodiments, there is provided a method of controlling a robot arm, which performs an operation by the driving of motors respectively provided in joints, including determining whether or not the robot arm is in a safety mode, in which the operation of the robot arm is stopped; calculating a compensation torque of gravity applied to the robot arm, when it is determined that the robot arm is in the safety mode; and performing a gravity compensation control of the robot arm according to the calculated compensation torque of gravity.

The determination of whether or not the robot arm is in the safety mode may include measuring currents outputted from the motors during the operation of the robot arm, and comparing the measured currents with a control reference value; and determining whether or not the robot arm is in the safety mode, in which the operation of the robot arm is stopped, by checking degrees of torques generated from the joints according to a result of the comparison.

The determination of whether or not the robot arm is in the safety mode may include sensing speeds of the joints during the operation of the robot arm, and comparing the sensed speeds with a control reference value; and determining whether or not the robot arm is in the safety mode, in which the operation of the robot arm is stopped, according to a result of the comparison.

The compensation torque of gravity may be calculated using a center of gravity of the robot arm, a weight of the robot arm, and angles of the joints.

In an aspect of exemplary embodiments, as the angles of the joints become smaller, the value of the compensation torque of gravity becomes larger.

When the joints are perpendicular to a horizontal plane, the compensation torque of gravity may be close to zero.

The compensation torque of gravity may be a torque to maintain the current position of the robot arm such that the robot arm cannot fall due to gravity.

The gravity compensation control may be performed such that the compensation torque of gravity is outputted to the motors to maintain the current position of the robot arm.

The method may further include determining whether or not a user moves to a safe position through the gravity compensation control of the robot arm; and terminating the operation of the robot arm, when the user moves to the safe position.

In accordance with an aspect of exemplary embodiments, there is provided a robot arm including joints; motors to respectively drive the joints; and a control unit to determine whether or not the robot arm is in a safety mode, in which the operation of the robot arm is stopped, while the operation of the robot arm is performed by the driving of the motors, calculate a compensation torque of gravity applied to the joints, when it is determined that the robot arm is in the safety mode, and perform a gravity compensation control according to the calculated compensation torque of gravity.

The joints may be at least one joint.

The robot arm may have high back-drivability such that the robot arm can be moved by external force due to the small friction of the at least one joint.

The robot arm may further include a sensing unit to measure currents of the motors during the operation of the robot arm, and the control unit may compare the measured currents with a control reference value, and determine whether or not the robot arm is in the safety mode, in which the operation of the robot arm is stopped, by checking degrees of torques generated from the joints according to a result of the comparison.

The robot arm may further include a sensing unit to sense speeds of the joints during the operation of the robot arm, and the control unit may compare the sensed speeds with a control reference value, and determine whether or not the robot arm is in the safety mode, in which the operation of the robot arm is stopped, according to a result of the comparison.

The control unit may calculate the compensation torque of gravity using a center of gravity of the robot arm, a weight of the robot arm, and angles of the joints.

When the angles of the joints are small, the control unit may output a large value of the compensation torque of gravity to the motors to maintain the current position of the robot arm such that the robot arm cannot fall due to gravity.

When the joints are perpendicular to a horizontal plane, the control unit may output a value of the compensation torque of gravity being close to zero to the motors to maintain the current position of the robot arm such that the robot arm cannot fall due to gravity.

These and/or other aspects of exemplary embodiments will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view illustrating the schematic configuration of a robot in accordance with an exemplary embodiment;

FIG. 2 is a view illustrating structures of main joints of the robot of FIG. 1 ;

FIG. 3 is a control block diagram to safely stop the robot arm having high back-drivability in accordance with an exemplary embodiment;

FIG. 4 is a view illustrating a method of calculating a torque to perform a gravity compensation control in accordance with an exemplary embodiment; and

FIG. 5 is a flow chart illustrating a method of safely stopping the robot arm having high back-drivability in accordance with an exemplary embodiment.

Reference will now be made in detail to exemplary embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. Exemplary embodiments are described below by referring to the figures.

FIG. 1 is a perspective view illustrating the schematic configuration of a robot in accordance with an exemplary embodiment.

In FIG. 1 , a robot 100 in accordance with an exemplary embodiment is a biped walking robot, which walks upright with two legs 110 R and 110 L in the same way as a human being, and includes a torso 120 , two arms 130 R and 130 L and a head 140 provided at the upper portion of the torso 120 , and feet 111 R and 111 L and hands 131 R and 131 L respectively provided at tips of the two legs 110 R and 110 L and the two arms 130 R and 130 L.

Here, R represents the right side of the robot 100 , and L represents the left side of the robot 100 .

FIG. 2 is a view illustrating structures of main joints of the robot 100 of FIG. 1 .

In FIG. 2 , the two legs 110 R and 110 L respectively include ankle joints 112 R and 112 L, knee joints 113 R and 113 L, and hip joints 114 R and 114 L such that parts of the robot 100 corresponding to ankles, knees, and hips are rotatable, and the hip joints 114 R and 114 L are located at both sides of the lower portion of the torso 120 connected with the two legs 110 R and 110 L.

The ankle joints 112 R and 112 L of the respective legs 110 R and 110 L are movable in the directions of the X-axis (roll axis) and the Y-axis (pitch axis), the knee joints 113 R and 113 L of the respective legs 110 R and 110 L are movable in the direction of the Y-axis (pitch axis), and the hip joints 114 R and 114 L of the respective legs 110 R and 110 L are movable in the directions of the X-axis (roll axis), the Y-axis (pitch axis), and the Z-axis (yaw axis).

Further, the two legs 110 R and 110 L respectively include thigh links 115 R and 115 L connecting the hip joints 114 R and 114 L and the knee joints 113 R and 113 L, and calf links 116 R and 116 L connecting the knee joints 113 R and 113 L and the ankle joints 112 R and 112 L, and thus have a designated degree of freedom according to the movements of the respective joints 112 R, 112 L, 113 R, 113 L, 114 R, and 114 L.

The two arms 130 R and 130 L respectively include shoulder joints 132 R and 132 L, elbow joints 133 R and 133 L, and wrist joints 134 R and 134 L such that parts of the robot 100 corresponding to shoulders, elbows, and wrists are rotatable, and the shoulder joints 132 R and 132 L are located at both sides of the upper portion of the torso 120 .

The shoulder joints 132 R and 132 L of the respective arms 130 R and 130 L are movable in the directions of the X-axis (roll axis), the Y-axis (pitch axis), and Z-axis (yaw axis), the elbow joints 133 R and 133 L of the respective arms 130 R and 130 L are movable in the direction of the Y-axis (pitch axis), and the wrist joints 134 R and 134 L of the respective arms 130 R and 130 L are movable in the directions of the X-axis (roll axis), the Y-axis (pitch axis), and the Z-axis (yaw axis).

Further, the two arms 130 R and 130 L respectively include upper arm links 135 R and 135 L connecting the shoulder joints 132 R and 132 L and the elbow joints 133 R and 133 L, and lower arm links 136 R and 136 L connecting the elbow joints 133 R and 133 L and the wrist joints 134 R and 134 L, and thus have a designated degree of freedom according to the movements of the respective joints 132 R, 132 L, 133 R, 133 L, 134 R, and 134 L. The robot arms 130 R and 130 L with the above kinematical structure has high back-drivability due to the small friction of the joints 132 R, 132 L, 133 R, 133 L, 134 R, and 134 L.

The torso 120 connected with the two legs 110 R and 110 L includes a waist joint 121 such that a part of the robot 100 corresponding to a waist is rotatable, and the head 140 connected to the torso 120 includes a neck joint 141 such that a part of the robot 100 corresponding to a neck is rotatable.

Each of the joints 112 R, 112 L, 113 R, 113 L, 114 R, 114 L, 132 R, 132 L, 133 R, 133 L, 134 R, 134 L, 121 , and 141 includes a motor 158 (for example, an electric motor, such as an actuator), as shown in FIG. 3 , to drive the corresponding joint.

FIG. 3 is a control block diagram to safely stop the robot arm having high back-drivability in accordance with an exemplary embodiment. The robot arm includes a safety mode sensing unit 150 , a control unit 154 , a driving unit 156 , an input unit 160 , and a power cutoff unit 162 .

The safety mode sensing unit 150 senses whether or not an emergency, in which the operation of the robot arm 130 R or 130 L having high back-drivability to interact with a human being is stopped, occurs during the interaction of the robot arm 130 R or 130 L with the human being (for example, a hug with the human being). The safety mode sensing unit 150 includes a current sensor 151 to sense currents flowing in the motors 158 provided in the respective joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L of the robot arm 130 R or 130 L, and an encoder 152 to sense speeds of the respective joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L of the robot arm 130 R or 130 L.

The control unit 154 checks whether or not any excessive torque is generated by comparing the currents sensed by the current sensor 151 of the safety mode sensing unit 150 with a predetermined control reference value, or checks whether or not any abnormal speed is generated by comparing the speeds sensed by the encoder 152 of the safety mode sensing unit 150 with a predetermined control reference value, and thus determines whether or not an emergency, in which the operation of the robot arm 130 R or 130 L is stopped, occurs. Then, in case that the emergency occurs and the operation of the robot arm 130 R or 130 L needs to be converted into the safety mode, the control unit 154 safely stops the robot arm 130 R or 130 L through a gravity compensation control.

Further, the control unit 154 monitors whether or not a user safely escapes from the robot arm 130 R or 130 L through the gravity compensation control of the robot arm 130 R or 130 L, and terminates the operation of the robot arm 130 R or 130 L, in case that the user moves to a safe position.

The driving unit 156 , in case that the operation of the robot arm 130 R or 130 L is converted into the safety mode, drives the motors 158 provided in the respective joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L of the robot arm 130 R or 130 L such that torques of the respective joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L of the robot arm 130 R or 130 L are controlled according to a torque control signal outputted from the control unit 154 .

The input unit 160 allows the user to directly input instructions to safely terminate the operation of the robot arm 130 R or 130 L and transmit the instructions to the control unit 154 , after the user moves to the safe position through the gravity compensation control of the robot arm 130 R or 130 L.

Although an exemplary embodiment has described that the user directly inputs the instructions to safely terminate the operation of the robot arm 130 R or 130 L, whether or not the user moves to the safe position (for example, the initial position) through the gravity compensation control may be monitored through various sensors (a three-dimensional measuring unit, an FIT sensor, etc.) installed on the robot 100 , and a result of monitoring may be transmitted to the control unit 154 .

The power cutoff unit 162 receives a power control signal of the control unit 154 according to user's instructions, and cuts off power supplied to the robot arm 130 R or 130 L or converts the operation of the robot arm 130 R or 130 L into a standby mode, after the user moves to the safe position through the gravity compensation control of the robot arm 130 R or 130 L.

Hereinafter, an operation of the above-described robot arm and effects of a method of controlling the robot arm will be described.

In the robot arm 130 R or 130 L having high back-drivability in accordance with an exemplary embodiment, torques applied to the joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L are easily measured through currents of the motors 158 due to small kinematical friction of the joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L, and the stiffness of the robot arm 130 R or 130 L is adjusted through an impedance control such that the robot arm 130 R or 130 L achieves flexibility and thus is capable of performing an interaction with a human being (for example, a hug with the human being).

However, the robot arm 130 R or 130 L having high back-drivability fall down by the effect of gravity, when power supplied to the robot arm 130 R or 130 L is cut off due to the occurrence of an emergency, in which the operation of the robot arm 130 R or 130 L is stopped. In an exemplary embodiment, a user can easily move the robot arm 130 R or 130 L through a gravity compensation control, before the power supplied to the robot arm 130 R or 130 L is cut off due to the occurrence of the emergency, and thus safely escape from the robot arm 130 R or 130 L or move the robot arm 130 R or 130 L to a position, which does not collide with surroundings. This operation of the robot arm 130 R or 130 L will be described with reference to FIG. 5 .

FIG. 5 is a flow chart illustrating a method of safely stopping the robot arm having high back-drivability in accordance with an exemplary embodiment.

In FIG. 5 , the control unit 154 of the robot arm 130 R or 130 L having high back-drivability calculates torques required to perform an interaction with a human being (for example, a hug with the human being) and outputs the calculated torques to the motors 158 of the joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L, and then the operation of the robot arm 130 R or 130 L is performed (operation 200 ). During this operation, a gravity compensation control value is calculated or is not used, if necessary.

Thereafter, the control unit 154 determines whether or not an emergency, in which the operation of the robot arm 130 R or 130 L is stopped, occurs during the operation of the robot arm 130 R or 130 L having high back-drivability (operation 202 ).

The determination of whether or not an emergency occurs is achieved by measuring currents flowing in the motors 158 of the respective joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L of the robot arm 130 R or 130 L through the current sensor 151 of the safety mode sensing unit 150 or sensing speeds of the respective joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L of the robot arm 130 R or 130 L through the encoder 152 of the safety mode sensing unit 150 .

Therefore, the control unit 154 checks whether or not any excessive torque is generated by comparing the currents sensed by the current sensor 151 with a predetermined control reference value, or checks whether or not any abnormal speed is generated by comparing the speeds sensed by the encoder 152 with a predetermined control reference value, and thus determines whether or not an emergency, in which the operation of robot arm 130 R or 130 L is stopped, occurs.

Although an exemplary embodiment has described that whether or not an emergency, in which the operation of robot arm 130 R or 130 L is stopped, occurs is determined by checking torques and speeds through the current sensor 151 or the encoder 152 , whether or not an emergency occurs may be determined using acceleration values according to the speeds of the respective joints 132 R or 132 L, 133 R or 133 L, and 134 R or 134 L of the robot arm 130 R or 130 L sensed by the encoder 152 , or it may be determined that an emergency occurs in case of a sudden happening caused by various reasons, such as the falling down of the robot 100 , etc.

As a result of the determination of the operation 202 , when it is determined that an emergency occurs, the control unit 154 performs a gravity compensation control so as to suspend the operation conducted by the robot arm 130 R or 130 L and safely stop the robot arm 130 R or 130 L (operation 204 ).

The gravity compensation control denotes a control method, in which only a torque having a degree to compensate for gravity applied to the robot arm 130 R or 130 L, i.e., to maintain the kinematical position of the current state of the robot arm 130 R or 130 L without falling of the robot arm 130 R or 130 L due to gravity, is outputted to control the robot arm 130 R or 130 L as if the robot arm 130 R or 130 L is in a weightless state. When the gravity compensation control is performed, a user can easily move the robot arm 130 R or 130 L although the user is close to the robot arm 130 R or 130 L or caught in the robot arm 130 R or 130 L and thus safely escape from the robot arm 130 R or 130 L, and it is possible to prevent the falling of the robot arm 130 R or 130 L due to gravity and thus to prevent the collision of the robot arm 130 R or 130 L with surroundings, thereby protecting devices of the robot arm 130 R or 130 L or peripheral environment around the robot arm 130 R or 130 L and securing user's safety.

Hereinafter, a method of calculating a torque to perform the gravity compensation control will be described with reference to FIG. 4 .

FIG. 4 is a view illustrating the method of calculating a torque to perform the gravity compensation control in accordance with an exemplary embodiment.

As shown in FIG. 4 , a motor 170 is installed on the ground, and a link 172 is connected to a driving shaft of the motor 170 . The link 172 has a mass, and thus a weight having a size obtained by multiplying the mass by the acceleration of gravity caused by gravity is applied to the link 172 in the direction of gravity.

The gravity compensation control is performed such the motor 170 generates a minimum torque so as not to move the link 172 when external force is not applied to the link 172 in the above state. The torque is calculated using the center of gravity (G) representing the weight of the link 172 , the weight of the link 172 , and an angle of the link 172 , which is formed by the link 172 and the ground. The smaller the angle of the link 172 , the larger torque the motor 170 generates so as not to move the link 172 . When the angle of the link 172 is 90°, i.e., the link 172 is perpendicular to the ground, the torque is close to zero.

In case that the link 172 is moved by external force, as described above, the torque is calculated by the changed angle of the link 172 . The torque is expressed by a function of the angle of the link 172 , i.e., an angle (θ) of a joint, as the following expression [1].

τ= g (θ)  Expression [1]

Here, τ represents a torque of the motor 170 , and g represents a mapping of a gravity compensation function according to the angle (θ) of the joint.

Thereafter, the control unit 154 monitors whether or not a user moves to a safe position through the gravity compensation control of the robot arm 130 R or 130 L (operation 206 ). The monitoring whether or not the user moves to the safe position may be achieved by causing the user to directly input instructions to safely terminate the operation of the robot arm 130 R or 130 L through the input unit 160 , after the user moves to the safe position, or be achieved through various sensors (a three-dimensional measuring unit, an F/T sensor, etc.) installed on the robot 100 .

When it is determined that the user moves to the safe position, the control unit 154 transmits a power control signal to the power cutoff unit 162 , and the power cutoff unit 162 cuts off power supplied to the robot arm 130 R or 130 L or converts the operation of the robot arm 130 R or 130 L into a standby mode according to the power control signal of the control unit 154 . Thereby, the operation of the robot arm 130 R or 130 L is terminated (operation 208 ).

In accordance with an exemplary embodiment, when the operation of the robot arm having high back-drivability to interact with a human being is converted into a safety mode due to the occurrence of an emergency, in which the operation of the robot arm is stopped, only a torque having a degree to compensate for gravity applied to the robot arm, i.e., only a torque to maintain the kinematical position of the current state of the robot arm without falling of the robot arm due to gravity, is outputted to control the robot arm as if the robot arm is in a weightless state, thus being capable of safely stopping the robot arm. Thereby, a user can easily move the robot arm and thus safely escape from the robot arm, and it is possible to prevent the falling of the robot arm due to gravity and thus to protect devices of the robot arm and peripheral environment around the robot arm.

Although a few exemplary embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these exemplary embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents.