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The transformation of future manufacturing: How can force control improve product quality?
In the rapidly changing manufacturing industry, force control technology is gradually becoming a key tool to improve product quality. Force control refers to the control of the force applied by a machine or robotic arm when it comes into contact with an object or environment. This technology can not only prevent damage to equipment and objects, but also reduce injuries caused during operation.
With the development of robotics technology, the application of force control has penetrated into various fields, including mechanical processing, medical technology and service robots.
The advantage of force control technology is that it can cope with uncertainties in the manufacturing process with more consistent results. Compared with traditional positioning control, force control is more adaptable to different environments and dynamic changes. Especially in contact work, force control ensures stable contact force, making the processing more consistent, for example in grinding and polishing operations, ensuring uniform material removal.
Applications of force control
In practical applications, force control can be divided into "obvious contact" and "potential contact" scenarios based on the characteristics of contact. In obvious contact applications, the contact between the machine and the workpiece is a core part of the task and needs to be clearly controlled. Such tasks are common in mechanical deformation and surface processing. Applications with potential contact rely heavily on precise positioning of the machine or its components.
Whether in industrial or medical robots, proper force control can significantly reduce accidental injuries and improve work efficiency.
Force measurement technology
In order to achieve effective force control, the instantaneous contact force must be known. Contact forces can be measured directly using force/torque sensors, which are typically mounted on the robot's end effector. Through precise deformation measurement, these sensors provide real-time data on forces and torques.
In addition to direct measurements, forces can also be estimated through indirect methods, in particular by measuring the operating current of the motor. This indirect measurement can effectively reduce costs while increasing the stability and anti-interference ability of the system, because sensors are often the weak link in mechanical systems.
Evolution of control concepts
The development of force control covers a variety of control concepts, including active impedance control and passive impedance control. Passive control does not require direct force measurement, allowing the machine or end effector to flexibly reduce contact forces based on design, while active control can adjust based on end effector deviations, which is particularly important during the process of teaching the robot.
Active impedance control can improve the adaptability of machines to environmental changes, especially in changing industrial environments.
Future Outlook
Force control is rapidly becoming part of the forefront of automation as advances in sensor technology and control algorithms are made, including the incorporation of technologies such as machine vision and artificial intelligence. These innovations not only increase manufacturing flexibility, but also make operations in unpredictable environments much safer.
Force control undoubtedly plays an indispensable role in advancing the future of manufacturing. It not only improves product quality, but also brings significant benefits in risk management and cost control. However, in the face of ever-changing technology and market demands, how will force control technology further our manufacturing industry?
