Active support for industrial robots

Abstract

To provide systems and methods for automated support for industrial robots.SOLUTION: The system includes a data collection device which communicates with all robots at a customer site, and uploads data to a remote diagnostic system. The method is activated either automatically when an alarm occurs, or activated by a robot operator or remote support team. Upon the activation, particular diagnostic files are captured and sent from an affected robot's controller to the data collection device and to the remote diagnostic system. The system employs a knowledge base to diagnose a cause of an issue from the diagnostic files, and support team personnel are also involved to reach a diagnosis. Based on contents of the diagnosis, updated software or configuration files are sent to the affected robot to correct the issue and allow the robot to return to service, instructions are sent to the robot operator, or an on-site service technician visit is scheduled.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates to the field of support services for industrial robots, and more particularly to a system and method for providing automation support for industrial robots that is activated when a problem is detected, establishes communication between a remote support system and a robot controller at a customer site, transmits diagnostic files from the affected robot controller to the remote support system, diagnoses the cause of the problem, and transmits corrective data and / or instructions from the remote support system to the affected robot. [Background technology]

[0002] The use of industrial robots to perform a wide range of manufacturing, assembly, and material transfer operations is well known, and modern manufacturing facilities often employ a variety of robots to automate production processes. Robots offer significant advantages over human labor for many factory operations, including speed and reliability of motion performance, the ability to work in hazardous environments such as spray paint booths, and the ability to repeatedly lift and move heavy objects. However, industrial robots are not without their problems. Like other machines, robots are susceptible to a variety of issues (known as faults, errors, failure modes, etc.) that affect their operation. These issues may arise in the software running on the robot controller, or may affect the robot's mechanical components, such as bearings, or electrical components, such as joint motors.

[0003] When a robot experiences a problem, it often requires that the robot be taken out of service. Therefore, it is essential that the problem be diagnosed and corrected as quickly as possible to minimize downtime and lost productivity. This is especially true considering the fact that a single robot outage can adversely affect many other pieces of equipment. For example, in a progressive die stamping line with a series of stamping presses and tending robots, if one tending robot goes down, the entire stamping line will be shut down until the robot is repaired and put back into service.

[0004] Various methods have been attempted to minimize robot downtime. Many robotics customers employ preventative measures that monitor many parameters of robots operating in their factories and use data analysis and prediction to identify potential problems before failure occurs. These techniques are effective in reducing the number of unexpected problems that occur during production operations because they allow robot components to be inspected, repaired, and / or replaced during scheduled preventative maintenance activities. However, despite these preventative measures, robots still experience issues that lead to downtime.

[0005] When a problem occurs during the operation of a robot, an alarm is activated in the robot controller, indicating the nature and severity of the alarm or error. In some cases, a robot operator can perform simple maintenance or repair work to return the robot to operation. However, in many cases, a robot operator does not have the necessary knowledge or experience to understand the details of the alarm code or to perform the repairs necessary to correct the underlying problem. In such cases, the operator must contact the robot manufacturer's service center for service support.

[0006] Robot manufacturer service centers are known to have network connections to server devices at customer sites, which communicate with all of the robot controllers at that site. This communication network allows data files to be transferred from the affected robot controller to a service center technician, who can then attempt to resolve the issue. However, with existing methods, the service center technician must instruct the robot operator on which data file to look for, and then the technician must manually email the file to the remote technician. This process may take two or three attempts if the technician determines that additional data is needed. Furthermore, if the controller is rebooted, important data about the robot's state at the moment the problem occurred may be permanently lost. Summary of the Invention [Problem to be solved by the invention]

[0007] In light of the above, improved systems and methods for providing automated support for robots that can quickly and reliably diagnose and repair robot problems are desirable. [Means for solving the problem]

[0008] In accordance with the teachings of the present disclosure, a system and method for automated support of industrial robots are provided. The system includes a data collection device that communicates with all robots at a customer site and uploads data to a remote diagnostic system. The method can be initiated automatically upon detection of a problem, by a robot operator when an alarm is displayed on the robot controller, or by a remote support team. Upon initiation, a specific diagnostic file is retrieved and sent from the affected robot's controller to the data collection device and then to the remote diagnostic system. The system uses a knowledge base to attempt to diagnose the cause of the problem from the diagnostic file, and support team personnel are also involved in the diagnosis. Based on the diagnosis, updated software or configuration files are sent to the affected robot to correct the problem and return the robot to operation, instructions are provided to the robot operator, and / or a field service technician visit is scheduled if a more complex repair is required.

[0009] Additional features of the disclosed systems and methods will become apparent from the following description and claims, taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a schematic diagram of a system for remote support center personnel to provide automated support to an industrial robot at a customer site in a first mode in which an operator manually activates the support system, according to an embodiment of the present disclosure. FIG.

[0011] [Figure 2] FIG. 2 is a schematic diagram of an automatic support system for the industrial robot shown in FIG. 1 in a second mode in which the robot controller automatically activates the system, according to an embodiment of the present disclosure.

[0012] [Figure 3]FIG. 2 is a schematic diagram of an automated support system for the industrial robot shown in FIG. 1 in a third mode in which a remote support center initiates the system, according to an embodiment of the present disclosure.

[0013] [Figure 4] FIG. 1 is a flowchart illustrating a method for providing active support for an industrial robot according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0014] The following discussion of embodiments of the present disclosure directed to systems and methods for providing automated support for industrial robots is merely exemplary in nature and is in no way intended to limit the disclosed apparatus and techniques or their applications or uses.

[0015] The use of industrial robots for a variety of manufacturing, assembly, and material transfer operations is well known. Modern manufacturing facilities often use a variety of robots to automate manufacturing processes, such as spray painting and welding robots, robots that pick up and move parts or packages, and machine tending robots. However, like any type of machine, robots are susceptible to problems that affect their operation, including various faults, errors, and failure modes. These problems can arise in almost any part of the robotic system, such as the software running on the robot controller, the robot's electrical or mechanical components, or subsystems. Returning a robot to operation as quickly as possible after a problem occurs is extremely important to robot operators.

[0016] Various methods have been used to minimize robot downtime. Many robotics customers employ proactive measures to monitor numerous parameters of robots operating within their facilities and use data analysis and prognostics to identify potential problems before failure occurs. One such system is disclosed in U.S. patent application Ser. No. 14 / 951,557 (hereinafter, the "'557 application"), which later issued as U.S. Patent No. 10,616,080, assigned to the same assignee as this application and incorporated herein by reference in its entirety. Techniques such as those in the aforementioned patent are effective in allowing robot components to be inspected, repaired, and / or replaced during routine preventative maintenance activities, thereby reducing the number of problems that arise unanticipated during production operations. However, despite these proactive measures, robots still experience problems that result in downtime.

[0017] When a problem occurs during the operation of a robot, an alarm is activated in the robot controller indicating the nature and severity of the warning or error. When this occurs, an operator often needs to contact the robot manufacturer's support center to request service support. The support center may have a network connection to a server device at the customer site, which allows the transfer of data files from the affected robot's controller to a support center technician so the technician can attempt to diagnose and resolve the problem. However, existing methods require the support center technician to explain to the robot operator which data files to look for, and the technician must then manually locate the files and email them to the remote technician. This process is time-consuming, may need to be repeated each time the technician identifies additional data needed, and does not always allow for the recovery of critical files that capture the robot's state at the moment the failure occurred.

[0018] The present disclosure describes a system and method for providing automated support for industrial robots, and the disclosed technology overcomes the shortcomings of current remote robot support methods. The disclosed technology automates and standardizes the process of obtaining data from the affected robot's controller, transmitting the data from the customer site to a centralized database, diagnosing the problem, and transmitting instructions and corrective actions to the customer site.

[0019] FIG. 1 is a schematic diagram of a system 100 for providing automation support for industrial robots at a customer site by personnel at a remote support center, according to an embodiment of the present disclosure, used in a first mode in which an operator manually activates the support system. The customer site 110 represents a factory or other facility where one or more robots are operating. The term "customer" herein refers to the company that purchases and operates the robot, which may be, for example, a product manufacturer or food packager. The robot manufacturer, in turn, sells and services the robot, provides technical support when problems arise, etc.

[0020] In this example, customer site 110 has many robots in operation, including at least robot 120 and robots 130-134. Robots 120 and 130-134 are merely examples of what may be multiple robots at customer site 110, and the robots may be different types and models and configured to perform various operations, as shown in different graphical representations. The robots at customer site 110 may include any combination of articulated robots and delta (parallel link) robots. As shown graphically, each robot is understood to include a physical robot and a corresponding robot controller. Thus, robot 120 includes articulated robot arm 122 and robot controller 124.

[0021] The robots 120 and 130-134 communicate with a data collection device 140 located at the customer site 110. The arrows from the robots 130-134 to the data collection device 140 are not highlighted in the figure because they are not relevant to the following discussion. The active support methodology of this disclosure will be fully described with respect to an example including the robot 120. The data collection device 140 is a computer or server that provides data storage and processing, a local area network connection (wired or wireless) to all robots at the customer site 110, and an Internet connection. The data collection device 140 may be part of an existing system, where the data collection device 140 periodically receives operational parameter data from the controllers of each of the robots 120 and 130-134, which is analyzed to monitor the health of the robots during normal operation. The data collection device 140 can also receive specific data files from individual robots at the site 110 in the event of a problem, according to the techniques described below in this disclosure.

[0022] A worker 150 at site 110 is responsible for operating the robot and may be called upon to perform specific tasks when problems arise, as described below. A support team 160 is made up of a group of technical experts from the robot manufacturer who can help diagnose and resolve any issues that arise. The support team 160 is located at a location remote from the customer site 110. Members of the support team 160 may be located at a single location, multiple locations, or individually distributed. It is important to understand that they have access to data at the customer site 110 to help resolve any robot issues that may arise.

[0023] Data files from data collection device 140 can be automatically uploaded to diagnostic system 180 via cloud (Internet) connection 170. Diagnostic system 180 is a globally accessible server / computer that includes a database, software for performing analysis, diagnosis, and communication, and a user interface. In one embodiment, the database within diagnostic system 180 is configured to manage data for each individual customer site. That is, a worker 150 at customer site 110 can easily access and view data for their own site, but not data for other sites. Additionally, members of support team 160 can easily select, view, and analyze all data and files from site 110 via the diagnostic system's 180 user interface.

[0024] The above discussion of Figure 1 describes the people, devices, and connectivity involved in system 100. The following describes how system 100 is used in a first mode in which a worker 150 manually activates the support system. Figures 2 and 3, described below, illustrate other modes of activation and operation of system 100.

[0025] The manual activation technique shown in FIG. 1 begins when a worker 150 determines that there is a problem with one of the robots at the customer site 110. In this example, the issue or problem is with the robot 120. The problem can be identified by an alarm (audible, visual, electronic notification, or any combination thereof) from the robot's 120 controller 124. Upon learning of the problem with the robot 120, the worker 150 contacts the support team 160 (indicated by the arrow labeled step □) and explains the alarm, error, or problem the robot 120 is experiencing. The contact can be made by any suitable means, including phone, email, regular text message, or a dedicated messaging service available as part of the active support methodology. These various forms of communication are also applicable to any and all subsequent communications between the worker 150 and the support team 160. The support team 160 then provides the worker 150 with instructions for the next step, so the arrow in step 1 is shown as a double-headed arrow.

[0026] In step 2, the worker 150, following instructions from the support team 160, initiates an active support method for the robot 120. This may be done physically at the robot's 120 controller 124 using a "teach pendant" device that communicates with the controller 124, or via a user interface that allows monitoring and control of all robots at the customer site 110. Once the active support method is initiated, the robot 120 sends a message to the data collection device 140 indicating that a diagnostic file is required (step 3). The message from the robot 120 to the data collection device 140 preferably indicates the exact type of error, fault, or alarm that has occurred (e.g., a code), thereby identifying the diagnostic file required. Diagnostic files may include log files containing historical data, debug files, and other files containing data about the operation of the robot 120 that may be useful in diagnosing the problem. It will be appreciated that the diagnostic files required for a collision detection alarm (when part of the robot 122 collides with another object) will be significantly different from those required for, for example, a joint motor failure or a controller operating system error.

[0027] In step 4, the data collector 140 communicates with the robot 120 and pulls (transfers) the necessary diagnostic files from the controller 124 of the robot 120. The data collector 140 may make copies of diagnostic files already present on the controller 124 of the robot 120, and the data collector 140 may execute commands on the controller 124 to generate any other debug or log files required as part of the diagnostic files.

[0028] As described above, in some embodiments of system 100, data collection device 140 periodically receives operational parameter data from the controllers of each of robots 120 and 130-134. This operational parameter data is received even when the robots are operating normally without problems or errors. The operational parameter data is analyzed by data collection device 140 and / or diagnostic system 180 to identify any preventative maintenance that may be required for either robot. For example, the operational parameter data may indicate that a particular joint in robot 132 has reached the end of its useful life (in terms of accumulated rotation angles, duty cycles, etc.) and that the joint should be repaired or replaced. This type of continuous robot diagnostic activity is disclosed in the aforementioned '557 application and is unrelated to the active support method disclosed herein.

[0029] In step 5, the data collection device 140 transmits the diagnostic file (related to the robot 120 error) to the diagnostic system 180 via the cloud 170. The diagnostic file is stored in the diagnostic system 180 database, and once the upload / save process is complete, the diagnostic system 180 indicates that the data is now accessible via the user interface in step 6. In step 7, both the support team 160 and the worker 150 can access and download the diagnostic data file obtained related to the robot 120 problem or error.

[0030] In some instances, the worker 150 may have sufficient knowledge and experience to diagnose and resolve the problem themselves based on a review of a diagnostic data file obtained in connection with an error in the robot 120. In those instances, the active support method of the present disclosure provides the advantage of simplifying and accelerating the diagnostic process by automatically obtaining and presenting a diagnostic file to the worker 150. The worker 150 simply invokes the active support method for the robot 120 and then, after a short time, accesses the diagnostic file from the diagnostic system 180. Using previous / existing methods, the worker 150 would have had to learn from the support team 160 which diagnostic file was needed for the specific error or problem with the robot 120 and how to find, replicate, or create the needed file. The worker 150 would then have had to analyze the diagnostic file themselves and would also have had to email the diagnostic file to the support team 160.

[0031] When support team 160 accesses the diagnostic data file obtained in connection with the error in robot 120, an automatic diagnosis may be performed by diagnostic system 180. For example, diagnostic system 180 may determine that the diagnostic data matches a known issue that has been resolved in a newer version of an operating system software module or configuration file. This diagnosis is displayed in a user interface when support team 160 accesses diagnostic system 180.

[0032] If diagnostic system 180 does not diagnose the problem based on the diagnostic data, support team 160 will attempt to diagnose the problem using their own knowledge and experience, knowledge databases, and all data available to them.

[0033] Once the problem is diagnosed, either analytically by support team 160 or automatically by diagnostic system 180, support team 160 provides a diagnosis and, in some cases, a solution to the problem in step 8. The communication from support team 160 to operator 150 in step 8 can take many different forms. For example, in the case of a robot collision alert, support team 160 may instruct operator 150 to check the area around robot 120 to ensure all robot operating and safety areas are clear of foreign objects. In the case of a mechanical or electrical failure of a component of robot 120, support team 160 may notify operator 150 that a field service technician will be visiting to repair or replace the affected component. In other cases, support team 160 may ask operator 150 to perform a relatively simple repair task under the guidance of support team 160 or using an augmented reality maintenance system. Many other types of communication from the support team 160 to the worker 150 are also possible in step 8, including any form of explanation, status update, instructions for action that the worker 150 should take, etc.

[0034] In addition to informing the operator 150 of the actions being taken, communication from the support team 160 in step 8 may also include taking direct action to resolve the problem. This is indicated by the branching arrow in step 8 pointing to the data collection device 140. For example, when diagnostics indicate that a new version of an operating system software module or configuration file resolves the problem, the appropriate file can be copied by the support team 160 to the data collection device 140, which then copies the file to the controller 124 of the robot 120. The controller 124 can then be automatically restarted at the direction of the data collection device 140, at which point the operator 150 is notified that the robot 120 is ready to be put back into service. This type of start-to-finish active support provides significant value to the robot operator (customer); the operator 150 simply initiates the active support method, and all steps of data acquisition / transfer, diagnosis, and resolution are performed automatically.

[0035] Even if a definitive diagnosis of the problem cannot be made, the support team 160 communicates with the operator 150 in step 8 to recommend and discuss other possible corrective actions.

[0036] 2 is a schematic diagram of the automated support system 100 for the industrial robot shown in FIG. 1 used in a second mode in which the robot controller automatically activates the system, according to an embodiment of the present disclosure. In the automatic activation mode of FIG. 2, the active support method is initiated without any action by the worker 150.

[0037] The auto-activation technique shown in FIG. 2 begins when the controller 124 determines that there is a problem with the robot 120, and the operator 150 may be made aware of the problem via an alarm. To activate the active support method, the robot 120 sends a message to the data collection device 140 indicating that a problem has been detected and that a diagnostic file is required (Step 1). The message from the robot 120 to the data collection device 140 preferably indicates the exact type of error, fault, or alarm that has occurred (by identifying an error or fault code), which identifies the diagnostic file required. As discussed above with respect to FIG. 1, diagnostic files may include log files containing historical data, debug files, and any other files containing data about the operation of the robot 120 that may be useful in diagnosing the problem.

[0038] In step 2, the data collector 140 communicates with the robot 120 and pulls (transfers) the necessary diagnostic files from the controller 124 of the robot 120. The data collector 140 can make copies of diagnostic files already present on the controller 124 of the robot 120, and the data collector 140 can execute commands on the controller 124 to generate other debug or log files required as diagnostic files.

[0039] In step 3, the data collection device 140 transmits the diagnostic file (related to the robot 120 error) to the diagnostic system 180 via the cloud 170. The diagnostic file is stored in the diagnostic system 180 database, and once the upload / save process is complete, the diagnostic system 180 indicates in step 4 that the data is now accessible via a user interface. In step 5, both the support team 160 and the worker 150 can access and download the diagnostic data file obtained related to the robot 120 error. Notification that the data file is available is provided to the support team 160 and the worker 150 via email or other means, such as messaging.

[0040] The remaining problem diagnosis, communication, and resolution (step 6) is similar for both Figure 2 (automatic initiation) and Figure 1 (manual initiation). This includes diagnosing the problem by the diagnostic system 180 and / or support team 160, communicating the diagnosis to the operator 150 by the support team 160, taking action by the operator 150 to resolve the problem, and, if possible, the support team 160 resolving the problem by sending files and / or commands (e.g., installing a new version of a configuration file or rebooting a controller) to the data collection device 140 for execution by the robot 120. Diagnosing and resolving the problem may also include the operator 150 independently reviewing the diagnostic files to diagnose and resolve the problem.

[0041] The automatic activation of the active support method shown in FIG. 2 provides a faster and easier support solution for the customer. In some cases, the problem is resolved and the robot is returned to active operation without the operator 150 having to do anything; the operator 150 only knows what is happening in steps 5 and 6. Even if the service technician cannot completely resolve the problem during the on-site visit, such as when a robot component needs to be replaced, the active support method is quick and easy for the operator 150. There is no need to ask the support team for instructions on the required diagnostic files or to identify and email the diagnostic files to the support team 160.

[0042] 3 is a schematic diagram of the automated support system 100 for an industrial robot shown in FIGS. 1 and 2 used in a third mode in which the system is activated by a remote support team 160, according to an embodiment of the present disclosure. In the remote activation mode of FIG. 3, the active support method is also initiated without any action by the operator 150.

[0043] 3 begins when support team 160 discovers a problem with a particular robot (in this example, robot 120) while monitoring operational data through diagnostic system 180 (Step 1). As described above, diagnostic system 180 periodically receives robot operational parameter data from customer site 110. Diagnostic system 180 also includes algorithms that analyze the data to identify parameters that are out of normal range, moving in an abnormal direction, etc. Thus, by periodically monitoring diagnostic system 180, support team 160 can identify problems with the robot before operator 150 identifies the problem or before an alarm is triggered in the robot controller itself.

[0044] In step 2, the support team 160 notifies the operator 150 that a problem or potential issue has been identified with the robot 120 and requests the appropriate diagnostic files from the data collection device 140. As previously mentioned, the diagnostic files may include log files containing historical data, debug files, and any other files containing data about the operation of the robot 120 that may be useful in diagnosing the problem. In step 3, the data collection device 140 communicates with the robot 120 indicating that a particular diagnostic file is required, and in step 4, the required diagnostic file is transferred from the controller 124 to the data collection device 140.

[0045] In step 5, the data collection device 140 sends the diagnostic files to the diagnostic system 180 via the cloud 170. The diagnostic files are stored in the database of the diagnostic system 180, and once the upload / save process is complete, in step 6, the diagnostic system 180 indicates that the data is now accessible via its user interface. In step 7, both the support team 160 and the operator 150 can access and download the diagnostic data files obtained in connection with the problem or error in the robot 120. Notification that the data files are available is provided to the support team 160 and the operator 150 via email or other means, such as messaging, in step 7.

[0046] The remaining diagnosis, communication, and resolution of the problem or issue (step 6) is similar for Figure 3 (support team initiated), Figure 1 (manually initiated), and Figure 2 (automatically initiated). This includes diagnosis of the problem by the diagnostic system 180 and / or support team 160, communication of the diagnosis by the support team 160 to the operator 150, possible action by the operator 150 to resolve the problem, and possible resolution of the problem or issue by the support team 160 sending files and / or commands (e.g., installing a new version of a configuration file or rebooting a controller) to the data collection device 140 for execution by the robot 120. Diagnosis and resolution of the problem may also include the operator 150 independently reviewing diagnostic files to diagnose and resolve the problem.

[0047] The support team's invocation of the active support method shown in Figure 3 provides customers with a quick and easy alternative support solution. In some cases, the problem is resolved and the robot is returned to active operation without the operator 150 having to do anything; the operator 150 only needs to know what happened in steps 2, 7, and 8. Even in cases where a service technician needs to replace a robot component during a site visit, the active support method is quicker and easier than existing methods that require the operator 150 to identify, copy, and email a diagnostic file to the support team 160.

[0048] FIG. 4 is a flowchart diagram 400 illustrating a method for providing active support for an industrial robot, according to an embodiment of the present disclosure. The method of FIG. 4 is performed using the system 100 shown in FIGS. 1-3. In box 402, the active support method is initiated when a problem or issue with a robot at a customer site is identified. The problem or issue can be identified by a robot operator at the customer site, by the robot's own controller, or by a robot manufacturer's support team located remotely from the customer site. In box 404, a diagnostic file related to the robot problem is identified and transferred from the robot controller to a data collection device at the customer site. The diagnostic file may be identified by the support team and communicated to the data collection device, or it may be identified by the data collection device itself based on an error or alarm code provided by the robot controller.

[0049] In box 406, the diagnostic file is transferred from the data collection device at the customer site to a database that is part of a cloud-based diagnostic system. In box 408, the diagnostic system notifies the support team and robotic operator that the diagnostic file is available for viewing and download. In box 410, the problem with the robot is diagnosed. This may include the robotic operator or support team diagnosing the problem after viewing the diagnostic file, or may include the diagnostic system diagnosing the problem after analyzing the diagnostic file.

[0050] In box 412, the support team communicates their diagnosis of the problem to the robot operator, and if possible, the support team resolves the problem by sending files and / or commands to the robot controller via the data collection device. Resolution may also include the robot operator performing a repair task or some other action on the affected robot or its controller based on their diagnosis or communication from the support team. In some cases, resolution can only be completed by an on-site visit by a trained service technician, which is scheduled by the support team.

[0051] In the preceding discussion, various computers and controllers have been described. It should be understood that the software applications and modules of these computers and controllers execute on one or more computing devices having processors and memory modules. Specifically, this includes the processors in each of the controllers of the robots 120 and 130-134, the data collection device 140, and the diagnostic system 180. In particular, the processors within these devices are configured to identify a problem with the robot, determine which diagnostic files are needed to support the diagnosis of the problem, transfer the needed diagnostic files to the data collection device, transfer them to the cloud-based diagnostic system, and analyze and communicate the data and diagnostic content in the manner described throughout the preceding disclosure.

[0052] As outlined above, the disclosed techniques for providing automated support for industrial robots offer significant advantages over prior art methods. Using the disclosed active support system and method, all necessary diagnostic files are obtained when an alarm or failure occurs. The diagnostic files are automatically uploaded from the customer site to a cloud-based diagnostic system for access by a team of trained support personnel. There is no need for an inexperienced robot operator to attempt to locate the necessary diagnostic files and then manually email the files to someone on the support team. This allows for faster and more reliable diagnosis of robot problems, allowing for faster problem resolution and getting the robot back up and running.

[0053] While several exemplary aspects and embodiments of systems and methods for providing automated support to industrial robots have been described, those skilled in the art will recognize modifications, permutations, additions, and subcombinations thereof. Accordingly, the appended claims and accompanying claims should be interpreted to include all such modifications, permutations, additions, and subcombinations that are within their true spirit and scope.

Claims

1. 1. A method of providing active support for an industrial robot, comprising: To determine if a robot in a factory has a problem that needs to be resolved; identifying one or more diagnostic files necessary to diagnose the problem; transferring the diagnostic file from the robot controller to a data collection device located at the factory by the data collection device; uploading the diagnostic file by the data collection device to a cloud-based diagnostic system located remotely from the factory; notifying robot operators at the factory and a support team located remotely from the factory that the diagnostic file is available by the diagnostic system; determining a diagnosis of the problem based on the diagnostic file; resolving the problem based on the diagnosis; and A method comprising:

2. 10. The method of claim 1, wherein determining whether the robot has encountered a problem requiring resolution is performed by the robot operator, who then notifies the support team of the problem.

3. 2. The method of claim 1, wherein determining whether the robot has encountered a problem requiring resolution is performed by the controller of the robot, which then notifies the data collection device of an alarm or error code.

4. 10. The method of claim 1, wherein determining whether the robot has encountered a problem requiring resolution is performed by the support team, which then communicates information about the problem to both the robot operator and the data collection device.

5. The method of claim 1 , wherein identifying one or more diagnostic files is performed by the controller or the data collection device of the robot based on an alarm or error code.

6. The method of claim 1 , wherein identifying one or more diagnostic files is performed by the support team.

7. 10. The method of claim 1, wherein determining a diagnosis of the problem is performed by the diagnostic system by comparing the diagnostic file to files stored in a knowledge base of previous robot problems and diagnoses.

8. The method of claim 1 , wherein determining the diagnosis of the problem is performed by the support team.

9. The method of claim 1 , wherein determining the diagnosis of the problem is performed by the robot operator.

10. The method of claim 1 , wherein resolving the problem based on the diagnosis includes the robot operator or service technician performing an action on the robot or the controller.

11. 2. The method of claim 1, wherein resolving the problem based on the diagnosis includes the support team electronically sending one or more software files, configuration files, and instructions to the controller of the robot.

12. 2. The method of claim 1, wherein the diagnostic files include one or more log files containing historical data, debug files, backup files, software program and configuration files, and files containing data about the robot when the problem occurred.

13. 10. The method of claim 1, wherein the problem requiring resolution comprises a hardware or software failure or error in the controller, a robot collision alert, or a problem with a mechanical element, an electronic element, or a subsystem of the robot.

14. The method of claim 1 , wherein the controller and the data collector of the robot are computing devices having a processor and memory, and the diagnostic system includes a computing device, a database, diagnostic software, and a user interface.

15. The method of claim 1 , wherein the robot is one or more robots operating in the factory, and other data collection devices in other factories also communicate with the diagnostic system.

16. 1. A method of providing active support for an industrial robot, comprising: determining, by a robot controller, whether the robot has encountered a problem requiring resolution; identifying diagnostic files necessary to diagnose the problem; transferring one or more diagnostic files from the controller of the robot to a data collection device located in a factory with the robot, wherein the diagnostic files needed to diagnose the problem are identified by the controller or the data collection device based on an alarm code identifying the problem; uploading the diagnostic file by the data collection device to a cloud-based diagnostic system located remotely from the factory; notifying robot operators at the factory and a support team located remotely from the factory that the diagnostic file is available by the diagnostic system; determining a diagnosis of the problem based on the diagnostic file; resolving the problem based on the diagnosis; and A method comprising:

17. 17. The method of claim 16, wherein determining a diagnosis of the problem is performed by the diagnostic system by comparing the diagnostic file with files stored in a knowledge base of previous robot problems and diagnoses, and resolving the problem based on the diagnosis includes the support team electronically sending one or more software files, configuration files, and instructions to the controller of the robot.

18. 1. A system for providing active support for an industrial robot, comprising: a plurality of robots and control devices operating in a factory; a data collection device located at the factory and in communication with the control device, the data collection device having a processor and a memory; a diagnostic system located remotely from the factory and accessible via an internet connection, the diagnostic system comprising a processor, memory, a database, diagnostic software and a user interface; When a problem with a particular one of the robots is identified, one or more diagnostic files needed to diagnose the problem are identified, the diagnostic files are automatically transferred from a control device of the particular robot to the data collection device and uploaded by the data collection device to the diagnostic system, the diagnostic system notifies robot operators at the factory and a support team located remotely from the factory that the diagnostic files are available, a diagnosis of the problem is determined based on the diagnostic files, and the problem is resolved based on the diagnosis.

19. 20. The system of claim 18, wherein the diagnostic files include one or more log files containing historical data, debug files, backup files, software program and configuration files, and files containing data about the particular robot when the problem occurred.

20. 20. The system of claim 18, wherein the particular robot problem is addressed by the robot operator, who then notifies the support team of the problem, or by the robot's controller, which then notifies the data collection device of an alarm or error code, or by the support team, who then communicates information about the problem to both the robot operator and the data collection device.

21. 20. The system of claim 18, wherein the one or more diagnostic files are generated by the controller of the particular robot, by the data collection device, or by the support team based on an alarm or error code.

22. 20. The system of claim 18, wherein the diagnosis of the problem is identified by the diagnostic system by comparing the diagnostic file to files stored in a knowledge base of previous robot problems and diagnoses, by the support team, or by the robot operator.

23. 20. The system of claim 18, wherein the problem is resolved by the robot operator or service technician performing an action on the specific robot or a controller of the specific robot, or by the support team electronically sending one or more software files, configuration files, and instructions to the controller of the specific robot.

24. 20. The system of claim 18, wherein the problem comprises a hardware or software failure or error in the controller, a robot collision alert, or a problem with a mechanical element, an electronic element, or a subsystem of the robot.

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