What sensors are commonly used in industrial robots?
In the field of industrial automation, robots need sensors to provide the necessary information to perform related operations correctly.
A report predicts that by 2021, the global industrial robot sensor market will grow steadily at a compound annual growth rate (CAGR) of approximately 8%. For robotic sensing applications including consumers and automobiles, another report clearly pointed out that by 2027, the vision system alone will achieve a market of 5.7 billion US dollars, and the force sensor market will exceed 6.9 billion US dollars.
The most commonly used sensors in industrial robots are listed below:
Two-dimensional vision is a camera that can perform a variety of tasks from detecting moving objects to positioning parts on a conveyor belt. Many smart cameras can detect parts and assist the robot in determining the position of the part. The robot can appropriately adjust its actions based on the received information.
Three-dimensional vision sensor
The three-dimensional vision system must have two cameras or laser scanners with different angles to detect the third dimension of the object. For example, part picking and placing is the use of 3D vision technology to detect objects and create 3D images, analyze and select the best picking method.
Force/torque sensor
If the vision sensor gives the robot eyes, then the force/torque sensor gives the robot a sense of touch. The robot uses force/torque sensors to sense the strength of the end effector. In most cases, the force/torque sensor is located between the robot and the fixture, so that all forces fed back to the fixture are monitored by the robot.
With the force/torque sensor, applications such as assembly, manual guidance, teaching, and force limitation can be realized.
Collision detection sensor
This kind of sensor comes in various forms, and its main application is to provide a safe working environment for operators, and collaborative robots need them most.
Some sensors can be some kind of tactile recognition system, which senses pressure through a soft surface and sends signals to the robot to restrict or stop the robot's movement.
Some sensors can also be directly built into the robot. Some companies use accelerometer feedback, while others use current feedback. In both cases, when the robot senses an abnormal force, it triggers an emergency stop to ensure safety.
In order for industrial robots to cooperate with humans, we must first find ways to ensure the safety of workers. These sensors come in various forms, from cameras to lasers, etc., and their purpose is to tell the situation around the robot. Some safety systems can be set so that when someone appears in a specific area/space, the robot will automatically decelerate, and if the person continues to approach, the robot will stop working.
The simplest example is the laser safety sensor on the elevator door. When the laser detects an obstacle, the elevator door will immediately stop and retreat to avoid collision.
Other sensors
There are many sensors on the market that are suitable for different applications. Such as seam tracking sensors.
Tactile sensors are also becoming more and more popular. This type of sensor is generally installed on the gripper to detect and feel what is being grasped. Sensors are usually able to detect the force and get the force distribution, so as to know the exact position of the object, so that you can control the grasping position and the grasping force of the end effector. There are also some tactile sensors that can detect changes in heat.
Vision and proximity sensors are similar to those required for autonomous vehicles, including cameras, infrared, sonar, ultrasonic, radar, and lidar. In some cases, multiple cameras can be used, especially for stereo vision. By combining these sensors, the robot can determine the size, recognize the object, and determine its distance.
Radio frequency identification (RFID) sensors can provide identification codes and allow licensed robots to obtain other information.
Microphone (acoustic sensor) helps industrial robots receive voice commands and recognize abnormal sounds in the familiar environment. If a piezoelectric sensor is added, it can also identify and eliminate noise caused by vibration, and prevent the robot from misunderstanding voice commands. Advanced algorithms can even allow robots to understand the emotions of the speaker.
Temperature sensing is part of the robot's self-diagnosis, which can be used to determine its surrounding environment and avoid potentially harmful heat sources.
Using chemical, optical and color sensors, robots can evaluate, adjust and detect problems in their environment.
For humanoid robots that can walk, run or even dance, stability is a major issue. They require the same type of sensors as smartphones in order to provide accurate position data of the robot. In these applications, a 9-degree-of-freedom (9DOF) sensor or inertial measurement unit (IMU) with a 3-axis accelerometer, a 3-axis gyroscope, and a 3-axis magnetometer is used.
Sensor is the key component to realize software intelligence. Without sensors, many complicated operations cannot be realized. They not only implement complex operations, but also ensure that these operations are well controlled during the process.
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