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There are products that are produced more than 200,000 units every year. What do you think it is?

It is an "industrial robot". When you think of industrial robots, do you think of arm-type robots or automatic transfer machines?

Total shipments (units): 233,386 (statistical data from the Japan Robot Association)

This time, we will introduce the sensors installed in such industrial robots.

What is an industrial robot?

Industrial robots are defined by ISO as "automated, programmable manipulators with three or more degrees of freedom". (Wikipedia)

Although there are industrial robots that move independently, they are often used with teaching machines.
A teaching machine is a device that teaches robots how to move. The easiest thing to imagine is, do you have an image of a robot that paints cars in a factory?
Until now, the work that was done by craftsmen is taught by the craftsmen themselves using a teaching machine. It's like recording. The robot makes the same movements as if it were playing the movements it was taught, reproducing the craftsmanship.

In this way, industrial robots work tirelessly at production sites.

Classification of sensors by data output type

Industrial robots are equipped with various sensors. There are many types of sensors, but sensor products are mainly classified into three data output types.

  • A type that outputs an analog signal that is conditioned by an internal amplifier.
  • Digital output type that converts the output of the sensor into digital data using the internal ADC and simplifies connection with microcomputers such as SPI and I2C
  • A type that converts complex and large-scale data into an optimal signal output inside the device, such as an object detection sensor.


Each has advantages and disadvantages, so it is important to select the optimum output and utilize the sensor data.

Important points in designing industrial robots

Important points in designing industrial robots are temperature and noise characteristics.

In particular, for types that output analog signals, the path from the output from the sensor to the input to AD conversion,

  • How can noise be suppressed?
  • Can temperature factors be ruled out?


becomes an important design point.

In addition, slight distortions and deflections caused by reflow and aging during mounting require software correction.

Investigating the depth of the sensor in advance, which cannot be understood only on the data sheet, is also a shortcut to design. "If you hurry, turn around."

Sensors required for industrial robots

There are so many different types of sensors, do you ever not know which one to choose?
First, we will introduce three types of sensors used in industrial robots: "essential sensors," "convenient sensors," and "future necessary sensors."

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Essential sensor

Every industrial robot must have sensors. Maybe it's too obvious and you don't think of it as a sensor. "Voltage", "Current", "Temperature" and "Acceleration". I will explain each.

voltage sensor

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As for "voltage," I think there are machines that are supplied with a regulator, and there are things that use AC as is, but voltage is essential to operate machines. You can think of the regulator as a sensor as well.

Voltage fluctuations are a major factor leading to failures and malfunctions. Supplying a stable voltage is too commonplace, and it may not be recognized as a sensor.

current sensor

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"Current" may flow overcurrent or fall below the assumed current if the circuit is broken.
In particular, industrial robots often work in a noisy environment, and it is desirable to avoid noise-induced breakdowns as much as possible.

In such cases, using a current sensor changes the current that flows through the circuit during normal operation and during failure, allowing for quick detection of abnormalities. It is possible to detect anomalies not only in the vicinity of power supplies but also in the drive current circuits of motors and actuators.

temperature sensor

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"Temperature" measures the temperature of the machine and its surroundings.
Parts that are constantly in motion, such as motors and actuators, generate heat. In the case of industrial robot equipment, it is used for abnormal heat generation of the motor and temperature measurement of the CPU that controls the robot. In order to use the machine for a long time, it is very important to monitor the calorific value.

A temperature sensor is deep, and a general temperature sensor uses an ADC to sense the resistance value that changes with temperature depending on the material of the sensor part.

Recently, due to improvements in MEMS technology, temperature sensing using temperature sensors inside devices has increased. Since no external sensor material is required, the temperature that can be measured is often limited.

It may also be necessary to measure ambient temperature outside the machine. Construction machines often work outdoors, and if the outside temperature is too low, the machine cannot operate efficiently. Measuring the environmental temperature will be useful for future product development.

Acceleration sensor

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"Acceleration" sensors have exploded in popularity since they were installed in game consoles.

Recently, it has come to be mounted on a small evaluation board, and it has become easy to obtain. There are various types of acceleration sensors, from crystal oscillation types to MEMS products. The MEMS type is available at low cost and has come to be used in various applications.

The usage is a sensor to measure how much tilt has occurred from the offset position. It has become an essential sensor for industrial robots. It is also possible to detect positional information and weak vibrations that occur when a machine malfunctions. Signal analysis of abnormal vibrations leads to predictive maintenance.

There are many types of acceleration sensors, and when selecting a device, temperature characteristics and noise performance are of course important, but accuracy, power consumption, and response performance are also important. Depending on the type of industrial robot, selecting an analog output acceleration sensor is also an option.

convenient sensor

Sensors these days come in a wide variety of shapes, costs, and performance. Although not necessarily essential, we will introduce sensors that can be used as IoT sensor data if installed.

Sensors that know "movement and position"

Industrial robots are powered by servo motors, DC motors, and actuators. However, there are few things that just turn around, and it is necessary to monitor how much it moves.

Automatic transfer machines and the like may also need to know whether they have moved as specified. I need to know how many times the arm robot's servo motor is rotating. Furthermore, there may be detailed angle specifications such as "27.23 degrees in the X direction and 31.85 degrees in the Y direction".

Accelerometers and gyro sensors are effective in such cases. Here, a sensor that can detect movement and position is essential, so we will introduce it.

gyro sensor

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The gyro sensor can calculate the current speed from the angular velocity of the rotation angle, and the distance traveled from the speed and time.

Distance can also be calculated using GPS signals, but in indoor areas where GPS cannot reach, acceleration and gyro sensors can be used as a substitute for GPS. Again, if the accuracy is poor, the position may shift.

If you are considering replacing GPS, selecting an IMU (inertial unit) eliminates the need for troublesome adjustments, and there are many products that have been calibrated at the time of shipment.

Sensor that "knows the specified position"

A sensor called "ToF (Time of Flight)" has recently been attracting attention as a sensor that can detect a specified position.

ToF sensor

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A ToF sensor is a sensor that recognizes height and distance by reflecting light.
Conventionally, we used ultrasonic sensors, pressure sensors, and air pressure sensors to implement this, but this is a mechanism that measures the time it takes for light to be reflected and received.

Since it does not depend on objects that reflect light, it is attracting attention as a type of sensor that can accurately measure depth and distance, and is expected to be used as a position sensor in the future.

"Judge by image" image sensor

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There are many types of image sensors, but the number of pixels is one option.

If the angle of view is large, the image data will not be cut off, but image processing will require CPU power accordingly. If the number of pixels is small, it can be processed with relatively light CPU power.

Also important is the dynamic range of the image sensor. If the dynamic range is narrow, it may be difficult to detect the difference between the object and the background, as well as minor defects. A wide dynamic range is likely to result in a clean image, which can simplify further processing.

"External environment" sensor

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The external environment has many uses. Of course, the typical temperature sensor is different depending on what the industrial robot is working on.

  • pressure sensor
  • Strain gauge (weight sensor)
  • illuminance sensor
  • gas sensor
  • Infrared sensor
  • Temperature sensor for high temperature


These sensors differ depending on the usage environment of the industrial robot, but depending on the application, it is necessary to select a high-precision sensor.

Sensors required in the future

Here, we introduce the sensors expected in the future.
Currently, even if the budget is still over the specs, or the functions that are not so necessary, they may be useful for the users who actually use them. I would like to introduce two such sensors.

gesture sensor

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A gesture sensor is one of the optical sensors and is a sensor used at a short distance. As a mechanism, it is possible to determine the distance and position from the reflection of the blocked light.

As an example of application, it is assumed to be used in factories where direct contact with equipment is not possible or in environments with strict hygiene control.

voice recognition sensor

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Voice-based operation may still be one of these technologies, but voice-based systems can be expected to be fully utilized as a new operation system if the CPU that controls them becomes inexpensive.

In that sense, it can be said that speech recognition is a promising field as a voice sensor.

Summary

Now that we have introduced the sensors required for industrial robots, what do you think?
Sensors are one of the electronic devices that is difficult to choose, as there are many prices and types.

Even if it seems easy to use, I often hear that it doesn't provide the accuracy I expected.
First of all, it is important to obtain an evaluation board, etc., and thoroughly verify whether the values and accuracy you expect can be secured, including temperature characteristics and noise performance, including hardware and software.

Evaluation boards range from a single sensor to those equipped with multiple sensors. Please search for the most suitable evaluation board from Macnica Online Service.


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APS Laboratory [Head] Yasuo Urabe

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[Head] Yasuo Urabe

1995 Engaged in the development of in-house products at a semiconductor trading company
2001 Engaged in a wide range of tasks as FAE for Ethernet products at SMSC (now Microchip)
2010 Joined Altera (currently Intel) and engaged in FPGA FAE
2011 In embedded system RTOS (eForce), OS sales and consulting as sales technology
Since 2015, he is currently the head of the APS Laboratory.
We provide a wide variety of contents such as hardware, software, digital, analog, communication, and power supply in an easy-to-understand manner from an engineer's perspective.

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Contributed articles on Mbed and Cortex-M cores, focusing on Ethernet, for CQ Publishing