Granted Patent B2

US 12,397,414 · App. 17/770,733 · Granted Aug 26, 2025

Inventor: Jacob Gregers Hansen (Kolding, DK)

Assignee: Universal Robots A/S

B25J9/0081B25J9/1674B25J13/085G05B19/423G05B2219/36418G05B2219/36429G05B2219/39194G05B2219/39529G05B2219/40586

Abstract

Claims (64)

1. A robot controller for controlling a robotic arm, the robot controller for switching the robotic arm from a first mode of operation to a free-drive mode of operation, where, in the free-drive mode of operation, the robot controller is configured to:

keep the robotic arm in a posture that is static when only gravity acts on the robotic arm; and

allow a change in the posture of the robotic arm when an external force different from gravity is applied to the robotic arm;

wherein the free-drive mode of operation is activatable in response to a free-drive activation signal at the robot controller; and

wherein the robot controller, in the free-drive mode of operation, is configured to perform operations comprising:

monitoring a value of at least one parameter of at least one sensor associated with a joint of the robotic arm;

comparing the value of the at least one parameter to at least one threshold value;

keeping the robotic arm in the free-drive mode of operation for a predetermined period of time; and

causing the robotic arm to leave the free-drive mode of operation and to return to normal mode of operation when the value of the at least one parameter does not exceed the at least one threshold value during the predetermined period of time.

2. The robot controller of claim 1 , wherein the robot controller is configured to perform operations comprising:

starting a restart free-drive period of time when the value of the at least one parameter exceeds the at least one threshold value;

keeping the robotic arm in the free-drive mode of operation for the restart free-drive period of time; and

causing the robotic arm to leave the free-drive mode of operation when the value of the at least one parameter does not exceed the at least one threshold value during the restart free-drive period of time.

3. The robot controller of claim 2 , wherein the robot controller is configured to start at least one of the predetermined period of time or the restart free-drive period of time following expiration of the free-drive activation signal.

4. The robot controller of claim 2 , wherein the robot controller is configured to restart the predetermined period of time or the restart free-drive period of time based on a restart free-drive mode signal set by a user.

5. The robot controller of claim 2 , wherein the robot controller is configured to provide feedback to a user based on at least one of a remainder of the predetermined period of time or the restart free-drive period of time.

6. The robot controller of claim 1 , wherein the at least one parameter comprises: acceleration of at least a part of the robotic arm, speed of at least a part of the robotic arm, or position of at least a part of the robotic arm; and

where the at least one threshold value comprises: a threshold acceleration of at least a part of the robotic arm, a threshold speed of at least a part of the robotic arm, or a threshold position of at least a part of the robotic arm.

7. The robot controller of claim 1 , wherein the at least one parameter comprises: force applied to at least a part of the robotic arm and torque applied to the at least part of the robotic arm; and

wherein the at least one threshold value comprises: a threshold force applied to at least a part of the robotic arm and a threshold torque applied to the at least part of the robotic arm.

8. The robot controller of claim 1 , wherein the robot controller is configured to cause the robotic arm to leave the free-drive mode of operation in response to receiving a free-drive deactivation signal.

9. A robotic arm comprising joints connecting a base and a tool flange, each of the joints comprising:

an output flange rotatable in relation to a body of a joint;

a motor configured to rotate the output flange;

at least one sensor for providing a sensor signal indicative of at least one of an angular position of the output flange, an angular position of a shaft of the motor, or a current of the motor; and

wherein the robotic arm comprises at least one robot controller of claim 1 configured to control the joints by controlling motor torque of one or more motors based on one or more sensor signals.

10. A method of operating a robotic arm in a free-drive mode of operation, the method comprising:

keeping the robotic arm in a posture that is static when only gravity acts on the robotic arm;

changing the posture of the robotic arm when an external force different from gravity is applied to the robotic arm;

monitoring a value of at least one parameter of at least one sensor associated with a joint of the robotic arm;

comparing the value of the at least one parameter to at least one threshold value;

keeping the robotic arm in the free-drive mode of operation for a predetermined period of time; and

causing the robotic arm to leave the free-drive mode of operation and return to normal mode of operation when the value of the at least one parameter does not exceed the at least one threshold value within the predetermined period of time.

11. The method of claim 10 , further comprising:

starting a restart free-drive period of time when the value of the at least one parameter exceeds the at least one threshold value;

keeping the robotic arm in the free-drive mode of operation for the restart free-drive period of time; and

causing the robotic arm to leave the free-drive mode of operation when the value of the at least one parameter does not exceed the at least one threshold value during the restart free-drive period of time.

12. The method of claim 11 , further comprising

starting at least one of the predetermined period of time or the restart free-drive period of time following expiration of a free-drive mode signal.

13. The method of claim 11 , further comprising:

restarting at least one of the predetermined period of time or the restart free-drive period of time based on a restart free-drive mode signal.

14. The method of claim 11 , further comprising:

providing feedback to a user, where the feedback is provided based on at least one of a remainder of the predetermined period of time or a remainder of the restart free-drive period of time.

15. The method of claim 10 , further comprising:

leaving the free-drive mode of operation in response to receiving a free-drive deactivation signal.

16. A system comprising a robotic arm, the system comprising:

a base;

a tool flange;

joints connecting the base and the tool flange, each of the joints comprising:

an output flange rotatable in relation to a body of a joint;

a motor configured to rotate the output flange; and

at least one sensor for providing a sensor signal indicative of at least one of an angular position of the output flange, an angular position of a shaft of the motor, or a current of the motor; and

at least one robot controller configured to control the joints by controlling motor torque of one or more motors based on one or more sensor signals, the at least one robot controller being configured to perform operations comprising:

monitoring a value of at least one parameter of at least one sensor, the at least one parameter being based on a sensor signal;

comparing the value of the at least one parameter to at least one threshold value; and

causing the robotic arm to leave a free-drive mode of operation and to return to normal mode of operation when the value of the at least one parameter does not exceed the at least one threshold value;

wherein in the free-drive mode of operation, a posture of the robotic arm is changeable through application of force to the robotic arm and where, in the absence of the force, the at least one robot controller is configured to maintain a posture of the robotic arm.

17. The system of claim 16 , wherein the at least one robot controller is configured to perform operations comprising:

starting a restart free-drive period of time when the value of the at least one parameter exceeds the at least one threshold value; and

causing the robotic arm to leave the free-drive mode of operation when the value of the at least one parameter does not exceed the at least one threshold value during the restart free-drive period of time.

18. The system of claim 17 , wherein the at least one robot controller is configured to start at least one of the predetermined period of time or the restart free-drive period of time following expiration of a free-drive mode signal.

19. The system of claim 18 , wherein the at least one robot controller is configured to restart the predetermined period of time or the restart free-drive period of time based on a restart free-drive mode signal set by a user.

20. The system of claim 16 , wherein the at least one parameter comprises: acceleration of at least a part of the robotic arm, speed of at least a part of the robotic arm, or position of at least a part of the robotic arm; and

where the at least one threshold value comprises: a threshold acceleration of at least a part of the robotic arm, a threshold speed of at least a part of the robotic arm, or a threshold position of at least a part of the robotic arm.

Assignments (2)

Priority Claims (1)

Continuity (1)

References Cited (280)