Torque sensor

This application is a continuation of International Application No. PCT/JP2017/042906, filed on Nov. 29, 2017, which claims priority to and the benefit of Japanese Patent Application No. 2017-023885, filed Feb. 13, 2017. The disclosures of the above applications are incorporated herein by reference.

The present disclosure relates to a torque sensor provided to, for example, a joint of a robot arm.

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

For example, in a production line, a plurality of robot arms is provided and these robot arms cooperate to assemble the products. Each joint of these robot arms is provided with a torque sensor (see, for example, Patent Literature 1 (JP 2013-096735 A), Patent Literature 2 (JP 2015-049209 A), and Patent Literature 3 (JP 5640905 B)).

Heretofore, it has been difficult for a torque sensor attached to a robot arm to detect an abnormality of the torque sensor itself or abnormality of the arm. For this reason, even in a case where in, for example, a collaborative robot in which a plurality of robot arms cooperate with each other, an abnormality of the torque sensor itself or abnormality of the arm occurs due to some cause, it has been difficult to avoid a collision between robot arms. Accordingly, a torque sensor having a so-called fail-safe function which makes it possible to detect in advance an abnormality of the torque sensor itself is desired.

Embodiments of the present invention provide a torque sensor capable of detecting an abnormality of the torque sensor itself and having a fail-safe function.

The torque sensor of the present embodiments comprises a first structure to be coupled to an object to be measured; a second structure; a first bridge circuit including a plurality of first strain sensors configured to detect force to be transmitted between the first structure and the second structure; a second bridge circuit including a plurality of second strain sensors configured to detect force to be transmitted between the first structure and the second structure; and a controller configured to output a signal indicating an abnormality when a difference between a first output voltage of the first bridge circuit and a second output voltage of the second bridge circuit is greater than a first threshold voltage.

Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.

FIG. 1 is a block diagram showing an example of a torque sensor according to a first embodiment.

FIG. 2 is a flowchart shown for explaining an operation of FIG. 1 .

FIG. 3 is a flowchart shown for explaining an operation subsequent to FIG. 2 .

FIG. 4 is a block diagram showing an example of a torque sensor according to a second embodiment.

FIG. 5 is a block diagram showing an example of a torque sensor according to a third embodiment.

Hereinafter, embodiments will be described with reference to the accompanying drawings. In the drawings, the same parts are denoted by the same reference numerals.

First Embodiment

In FIG. 1 , a torque sensor 10 comprises, for example, a first structure 11 , second structure 12 , a plurality of third structures 13 serving as beam parts, first bridge circuit B 1 , and second bridge circuit B 2 .

The first structure 11 and second structure 12 have, for example, annular shapes and, the second structure 12 and first structure 11 constitute concentric circles. A plurality of third structures 13 a , 13 b , 13 c , and 13 d couples the first structure 11 and second structure 12 to each other. In the first embodiment, the third structures 13 a , 13 b , 13 c , and 13 d function as, for example, strain-inducing parts.

The first structure 11 is attached to, for example, one of joints of a robot arm (not shown), the one of joints being an object to be measured. More specifically, the first structure 11 is attached to, for example, a speed reducer (not shown) and, the speed reducer is coupled to a motor (not shown). The second structure 12 is attached to, for example, the other of the joints of the robot arm (not shown).

The third structures 13 a , 13 b , 13 c , and 13 d transmit force (torque) between the first structure 11 and the second structure 12 .

The first structure 11 , second structure 12 , and third structures 13 a , 13 b , 13 c , and 13 d are constituted of, for example, a metal. However, if a mechanical strength sufficient for the torque to be applied can be obtained, it is also possible to form the first structure 11 , second structure 12 , and third structures 13 a , 13 b , 13 c , and 13 d of a material other than the metal.

Of the third structures 13 a , 13 b , 13 c , and 13 d , the third structures 13 a and 13 c which are arranged at positions 180° apart from each other are provided with the first bridge circuit B 1 and second bridge circuit B 2 .

The first bridge circuit B 1 is constituted of first to fourth strain sensors (strain gages) G 1 to G 4 , and second bridge circuit B 2 is constituted of fifth to eighth strain sensors G 5 to G 8 .

The first strain sensor G 1 and second strain sensor G 2 of the first bridge circuit B 1 , and fifth strain sensor G 5 and sixth strain sensor G 6 of the second bridge circuit B 2 are provided on the third structure 13 a and, third strain sensor G 3 and fourth strain sensor G 4 of the first bridge circuit B 1 , and seventh strain sensor G 7 and eighth strain sensor G 8 of the second bridge circuit B 2 are provided on the third structure 13 c.

Each of the first to eighth strain sensors G 1 to G 8 is constituted of, for example, a thin-film resistive element provided on, for example, a metallic plate (not shown) through an insulating film. However, the configuration of each of the first to eighth strain sensors G 1 to G 8 is not limited to this.

The metallic plate of each of the first to eighth strain sensors G 1 to G 8 is fixed to the surface of the third structure 13 a or third structure 13 c by means of, for example, adhesive bonding, screwing, welding or the like.

Further, although the first strain sensor G 1 , second strain sensor G 2 , fifth strain sensor G 5 and sixth strain sensor G 6 are provided on the third structure 13 a , and third strain sensor G 3 , fourth strain sensor G 4 , seventh strain sensor G 7 , and eighth strain sensor G 8 are provided on the third structure 13 c , the arrangement of the strain sensors is not limited to this.

For example, the metallic plate provided in each of the first to eighth strain sensors G 1 to G 8 may also be used as a strain body. In this case, the metallic plates of the first strain sensor G 1 , second strain sensor G 2 , fifth strain sensor G 5 , and sixth strain sensor G 6 may be provided between the first structure 11 and second structure 12 at positions other than the third structures 13 a , 13 b , 13 c , and 13 d , and metallic plates of the third strain sensor G 3 , fourth strain sensor G 4 , seventh strain sensor G 7 , and eighth strain sensor G 8 may be provided between the first structure 11 and second structure 12 . The metallic plate of each strain sensor may be fixed to the first structure 11 or second structure 12 by means of, for example, adhesive bonding, screwing, welding or the like.

In the first bridge circuit B 1 , the first strain sensor G 1 and third strain sensor G 3 are connected in series, and second strain sensor G 2 and fourth strain sensor G 4 are also connected in series. The first strain sensor G 1 and third strain sensor G 3 connected in series are connected in parallel with the second strain sensor G 2 and fourth strain sensor G 4 connected in series.

A power-supply voltage Vo, for example, 5 V is supplied to a connection node between the second strain sensor G 2 and fourth strain sensor G 4 , and connection node between the first strain sensor G 1 and third strain sensor G 3 is grounded.

In the second bridge circuit B 2 , the fifth strain sensor G 5 and seventh strain sensor G 7 are connected in series, and sixth strain sensor G 6 and eighth strain sensor G 8 are also connected in series. The fifth strain sensor G 5 and seventh strain sensor G 7 connected in series are connected in parallel with the sixth strain sensor G 6 and eighth strain sensor G 8 connected in series.

A power-supply voltage Vo, for example, 5 V is supplied to a connection node between the sixth strain sensor G 6 and eighth strain sensor G 8 , and connection node between the fifth strain sensor G 5 and seventh strain sensor G 7 is grounded.

In the first bridge circuit B 1 , a connection node between the first strain sensor G 1 and second strain sensor G 2 is connected to a first input terminal of a first voltage detecting circuit 15 , and connection node between the third strain sensor G 3 and fourth strain sensor G 4 is connected to a second input terminal of the first voltage detecting circuit 15 .

In the second bridge circuit B 2 , a connection node between the fifth strain sensor G 5 and sixth strain sensor G 6 is connected to a first input terminal of a second voltage detecting circuit 16 , and connection node between the seventh strain sensor G 7 and eighth strain sensor G 8 is connected to a second input terminal of the second voltage detecting circuit 16 .

The first voltage detecting circuit 15 detects an output voltage of the first bridge circuit B 1 , and second voltage detecting circuit 16 detects an output voltage of the second bridge circuit B 2 . Each of the first voltage detecting circuit 15 and second voltage detecting circuit 16 is constituted of, for example, voltage-dividing resistors and operational amplifier. However, the configuration of each of the first and second voltage detecting circuits 15 and 16 is not limited to this.

The principle of operation of the first voltage detecting circuit 15 is as follows.

For example, when torque (in the clockwise direction or counterclockwise direction of the first structure 11 and second structure 12 ) is applied to the torque sensor 10 , in the first bridge circuit B 1 , an output voltage Vout+ is output from the connection point between the first strain sensor G 1 and second strain sensor G 2 , and output voltage Vout− is output from the connection point between the third strain sensor G 3 and fourth strain sensor G 4 . From the output voltage Vout+ and output voltage Vout−, an output voltage Vout 1 of the first bridge circuit B 1 indicated by a formula (1) is obtained.

where

R1 is the resistance value of the first strain sensor G 1 ,

R2 is the resistance value of the second strain sensor G 2 ,

R3 is the resistance value of the third strain sensor G 3 ,

R4 is the resistance value of the fourth strain sensor G 4 , and

R1=R2=R3=R4=R is obtained in a state where no torque is applied to the torque sensor 10 .

On the other hand, when force other than torque, for example, thrust force (force to be applied to the first structure 11 and second structure 12 shown in FIG. 1 in the horizontal direction (X direction) or in the vertical direction (Y direction)) is applied to the torque sensor 10 , changes in the resistance values of the first strain sensor G 1 , second strain sensor G 2 , third strain sensor G 3 , and fourth strain sensor G 4 (R1=R−ΔR, R2=R+ΔR, R3=R−ΔR, R4=R+ΔR, where ΔR is a value of a change in the resistance value) cancel each other, and the output voltage Vout 1 of the first bridge circuit B 1 becomes 0 V.

The principle of operation of the second voltage detecting circuit 16 corresponding to the second bridge circuit B 2 is identical to the first voltage detecting circuit 15 . An output voltage Vout 2 of the second voltage detecting circuit 16 is also obtained in the same manner as the first voltage detecting circuit 15 .

The output voltage Vout 1 of the first voltage detecting circuit 15 is supplied to an analog-to-digital (A/D) converter circuit 17 , and is converted into a digital signal and, output voltage Vout 2 of the second voltage detecting circuit 16 is supplied to an A/D converter circuit 18 , and is converted into a digital signal. Output signals of the A/D converter circuit 17 and A/D converter circuit 18 (hereinafter referred to also as output signals of the first bridge circuit B 1 and second bridge circuit B 2 ) are supplied to, for example, a controller 19 periodically. The controller 19 supplies one or both of the output signals of the A/D converter circuit 17 and A/D converter circuit 18 to an external device as an output signal or output signals of the torque sensor 10 or detects an abnormality of the torque sensor 10 to be described later.

Further, the controller 19 is provided with a storage part 20 capable of storing therein the output signals of the A/D converter circuit 17 and A/D converter circuit 18 for, for example, a fixed period. The output signals of the A/D converter circuit 17 and A/D converter circuit 18 stored in the storage part 20 are updated, for example, every fixed periods.

Furthermore, to the controller 19 , for example, a display device 21 is connected. The display device 21 displays a detection output signal of the torque sensor 10 and signal or the like indicating that an abnormality of the torque sensor 10 has been detected.

Operation

FIG. 2 and FIG. 3 are flowcharts for explaining the operation of the controller 19 .

In normal times, in the torque sensor 10 , both the first bridge circuit B 1 and second bridge circuit B 2 simultaneously operate, and the output voltages of the first bridge circuit B 1 and second bridge circuit B 2 are compared with each other. That is, the controller 19 obtains an absolute value of a difference between the output voltage Vout 1 of the first bridge circuit B 1 supplied thereto from the first voltage detecting circuit 15 through the A/D converter circuit 17 and output voltage Vout 2 of the second bridge circuit B 2 supplied thereto from the second voltage detecting circuit 16 through the A/D converter circuit 18 , and compares the absolute value of the difference with a first threshold voltage (S 1 ). It should be noted that the absolute value is not indispensable, and it is sufficient if the difference between both the output voltages can be obtained.

When the absolute value of the difference is less than the first threshold voltage as a result of the above comparison (S 1 , NO), it is determined that both the first bridge circuit B 1 and second bridge circuit B 2 normally operate. The controller 19 determines whether or not a predetermined operation of the torque sensor 10 has been completed on the basis the output voltage of, for example, one of the first bridge circuit B 1 and second bridge circuit B 2 (S 2 ). The predetermined operation implies, as described previously, an operation of, for example, supplying the output signal of the torque sensor 10 to the external device, detecting an abnormality of the torque sensor 10 or the like. When the predetermined operation has not been completed yet as a result of this determination (S 2 , NO), the control is moved to S 1 . Further, when the predetermined operation has already been completed (S 2 , YES), the control is terminated.

On the other hand, when it is determined in S 1 that the absolute value of the difference is greater than the first threshold voltage (S 1 , YES), the control is moved to an abnormality processing routine S 3 . That is, that the absolute value of the difference is greater than the first threshold voltage implies that an abnormality has occurred in one of the first bridge circuit B 1 and second bridge circuit B 2 . Accordingly, in the abnormality processing routine S 3 , it is determined in which of the first bridge circuit B 1 and second bridge circuit B 2 the abnormality has occurred.

FIG. 3 shows an example of the abnormality processing routine S 3 .

First, the controller 19 obtains an absolute value of a difference between the output voltage Vout 1 of the first bridge circuit B 1 and last output voltage Vout 11 of the first bridge circuit B 1 stored in the storage part 20 , and determines whether or not this absolute value is greater than a second threshold voltage (S 31 ). The second threshold voltage may be equal to the first threshold voltage or may be less than or equal to the first threshold voltage.

When the absolute value of the difference is greater than the second threshold voltage as a result of this determination (S 31 , YES), it is determined that the first bridge circuit B 1 is abnormal, and power supply to, for example, the first bridge circuit B 1 is stopped. Concomitantly with this, a signal indicating an abnormality is supplied to the display device 21 , and it is displayed on the display device 21 that the first bridge circuit B 1 is abnormal (S 32 ). After this, the control is moved to, for example, S 2 , and the predetermined operation is executed by using the normal second bridge circuit B 2 .

On the other hand, when the absolute value is less than or equal to the second threshold voltage, it is determined that the first bridge circuit B 1 is normal (S 31 , NO), the controller 19 obtains an absolute value of a difference between the output voltage Vout 2 of the second bridge circuit B 2 and last output voltage Vout 21 of the second bridge circuit B 2 stored in the storage part 20 , and determines whether or not this absolute value of the difference is greater than the second threshold voltage (S 33 ).

As a result of this determination, when the absolute value of the difference is greater than the second threshold voltage (S 33 , YES), it is determined that the second bridge circuit B 2 is abnormal, and power supply to, for example, the second bridge circuit B 2 is stopped. Concomitantly with this, a signal indicating an abnormality is supplied to the display device 21 , and it is displayed on the display device 21 that the second bridge circuit B 2 is abnormal (S 34 ). After this, the control is moved to, for example, S 2 , and the predetermined operation is executed by using the normal first bridge circuit B 1 .

Further, when it is determined in S 33 that the absolute value of the difference is less than or equal to the second threshold voltage (S 33 , NO), it is determined that an abnormality has not been detected in neither of the first bridge circuit B 1 and second bridge circuit B 2 in the determination of this time. When such a result is brought about, it is conceivable as a cause that an abnormality or the like may have occurred in something other than the torque sensor 10 . Accordingly, when it is determined in S 33 that the absolute value is less than or equal to the second threshold voltage (S 33 , NO), it is displayed on the display device 21 , for example, that an abnormality has occurred (S 35 ). After this, the control is moved to S 2 .

As described above, when an abnormality is detected in one of the first bridge circuit B 1 and second bridge circuit B 2 in the abnormality processing routine S 3 , one of the first bridge circuit B 1 and second bridge circuit, the one being the bridge circuit in which the abnormality is detected is stopped, and the operation of the torque sensor 10 is continued by using the other of the first bridge circuit B 1 and second bridge circuit B 2 , the other being the normal bridge circuit.

However, the abnormality processing routine is not limited to this and, when an abnormality is detected in S 1 , both the first bridge circuit B 1 and second bridge circuit B 2 may immediately be stopped, and it may be displayed on the display device 21 that an abnormality has occurred in the torque sensor 10 .

According to the first embodiment described above, the torque sensor 10 is provided with the first bridge circuit B 1 and second bridge circuit B 2 and, when the difference (absolute value thereof) between the output voltage of the first bridge circuit B 1 and output voltage of the second bridge circuit B 2 is greater than the first threshold voltage, it is determined that an abnormality has occurred in one of the first bridge circuit B 1 and second bridge circuit B 2 . Accordingly, it is possible to detect an abnormality of the torque sensor 10 before both the first bridge circuit B 1 and second bridge circuit B 2 go out of order. Therefore, the torque sensor 10 has a fail-safe function, and it is possible to prevent beforehand a robot arm equipped with the torque sensor 10 from causing a collision or the like.

Further, when an abnormality has occurred in the first bridge circuit B 1 or in the second bridge circuit B 2 , it is possible to identify and stop the bridge circuit in which the abnormality has occurred, and continue the operation by using the normal bridge circuit. Accordingly, it is possible to make the torque sensor 10 continue to operate by using the normal bridge circuit, and carry out control or the like to stop the robot arm after moving the robot arm to, for example, a safe position.

Second Embodiment

In the first embodiment, both the first bridge circuit B 1 and second bridge circuit B 2 are provided on the third structures 13 a and 13 c . That is, the first bridge circuit B 1 and second bridge circuit B 2 are arranged in parallel with each other.

Conversely, in a second embodiment, a first bridge circuit B 1 and second bridge circuit B 2 are arranged in such a manner that the first bridge circuit B 1 and second bridge circuit B 2 intersect each other.

FIG. 4 shows an example of the second embodiment.

As shown in FIG. 4 , a first strain sensor G 1 and second strain sensor G 2 of the first bridge circuit B 1 are arranged on a third structure 13 a , and third strain sensor G 3 and fourth strain sensor G 4 of the first bridge circuit B 1 are arranged on a third structure 13 c.

Further, a fifth strain sensor G 5 and sixth strain sensor G 6 of the second bridge circuit B 2 are arranged on a third structure 13 b , and seventh strain sensor G 7 and eighth strain sensor G 8 of the second bridge circuit B 2 are arranged on a third structure 13 d.

In the second embodiment, the circuit configuration and operation are the same as the first embodiment.

It is possible to obtain, by the second embodiment too, an advantage identical to the first embodiment.

Moreover, according to the second embodiment, the first bridge circuit B 1 and second bridge circuit B 2 are arranged in such a manner that the first bridge circuit B 1 and second bridge circuit B 2 intersect each other, the first to fourth strain sensors G 1 to G 4 of the first bridge circuit B 1 are arranged on the third structures 13 a and 13 c , and fifth to eighth strain sensors G 5 to G 8 of the second bridge circuit B 2 are arranged on the third structures 13 b and 13 d other than the third structures 13 a and 13 c . Accordingly, it is possible to reduce the probability that both the first bridge circuit B 1 and second bridge circuit B 2 simultaneously go out of order.

Third Embodiment

In the first and second embodiments, the abnormality of the first bridge circuit B 1 or second bridge circuit B 2 is detected on the basis of a digital signal. However, detection of the abnormality is not limited to this, and it is also possible to detect an abnormality of the first bridge circuit B 1 or second bridge circuit B 2 on the basis of an analog signal.

FIG. 5 shows an example of a third embodiment.

In the third embodiment, although the arrangement of the first bridge circuit B 1 and second bridge circuit B 2 is done in the same manner as the first embodiment, i.e., the first bridge circuit B 1 and second bridge circuit B 2 are arranged in parallel with each other, the first bridge circuit B 1 and second bridge circuit B 2 may be arranged in the same manner as the second embodiment, i.e., the first bridge circuit B 1 and second bridge circuit B 2 may be arranged in such a manner that the first bridge circuit B 1 and second bridge circuit B 2 intersect each other.

Output voltages Vout+ and Vout− of the first bridge circuit B 1 are supplied to a first voltage detecting circuit 15 , and output voltages Vout+ and Vout− of the second bridge circuit B 2 are supplied to a second voltage detecting circuit 16 . An output voltage Vout 1 of the first voltage detecting circuit 15 and output voltage Vout 2 of the second voltage detecting circuit 16 are supplied to a subtracting circuit 22 . The subtracting circuit 22 outputs a voltage of a difference between the output voltage Vout 1 of the first voltage detecting circuit 15 and output voltage Vout 2 of the second voltage detecting circuit 16 . An output voltage of the subtracting circuit 22 and first threshold voltage 24 are supplied to a comparison circuit 23 . The comparison circuit 23 compares the output voltage of the subtracting circuit 22 and first threshold voltage 24 with each other. A comparison result of the comparison circuit 23 is supplied to a controller 19 . When the comparison result of the comparison circuit 23 indicates an abnormality, the controller 19 stops power supply to, for example, the first bridge circuit B 1 and second bridge circuit B 2 , and stops, for example, the operation of the robot arm. Alternatively, as in the case of the first embodiment, the controller 19 may also be configured to detect one of the first bridge circuit B 1 and second bridge circuit B 2 , the one being the bridge circuit having an abnormality.

It is possible to obtain, by the third embodiment too, an advantage identical to the second embodiment. Moreover, by carrying out processing on the basis of an analog signal, it is possible to enhance the processing speed.

In addition, the present invention is not limited to the above embodiments as it is, and at the implementation stage, the constituent elements can be modified and embodied without departing from the scope of the invention. In addition, various inventions can be formed by appropriate combinations of a plurality of constituent elements disclosed in the above embodiments. For example, some components may be deleted from all the components shown in the embodiment. Furthermore, components in different embodiments may be combined as appropriate.