ArticleSensors (Basel, Switzerland)2026
Sensorless Payload Estimation in an Industrial Robot Using Internal Motor-Current Signals.
Article in Sensors (Basel, Switzerland), 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
This article presents a sensorless method for cycle-level payload mass estimation in industrial robots using internal motor-current signals only. The approach is based on automated KUKA Trace acquisition of six-axis current traces from a KUKA KR3 controller, followed by statistical feature extraction and regression using a multilayer perceptron (MLP). Experiments were conducted on two nominally identical KUKA KR3 R540 manipulators under a repeatable handling motion with payloads ranging from approximately 0.4 kg to 2.6 kg, enabling the systematic engineering validation of controller-based current acquisition, feature-based payload regression, and cross-robot validation. This study investigated whether motor-current signals could serve as a reliable virtual sensing source without external force or weight sensors. Under repeated operating conditions, the most accurate MLP configuration achieved a testing mean absolute error (MAE) of 6.75 g and a mean squared error (MSE) of 68.28 g
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