Control of a multi-purpose robot arm

Abstract

The present invention discloses a multi-purpose robotic arm having a controller configured to control its movement according to a plurality of basic operating commands during an operation process. The robotic controller is configured to control the multi-purpose robotic arm in a standard operating mode according to a first subset of the basic operating commands, and to control the multi-purpose robotic arm in an application-specific operating mode during a portion of the robotic arm operation process according to a second subset of the basic operating commands. The basic operating commands of the second subset are at least partially included by the first subset, and at least one of the operating parameters of the second subset is limited by an application operating value. The application operating value is defined by a desired characteristic of the operation of the multi-purpose robotic arm in the application-specific operating mode.

Description

Technical Field

[0001] The present invention relates to a multi-purpose robot arm, the multi-purpose robot arm comprising a plurality of robot joints connecting a robot base and a robot tool flange, wherein a robot controller is configured to control the robot arm according to standard and application specific operating modes. In addition, the present invention relates to a method of controlling the multi-purpose robot arm according to a first layer program code, a second layer program code and a third layer program code. Background Art

[0002] A robot arm comprising a plurality of robot joints and links, wherein motors can move portions of the robot arm relative to each other, is known in the field of robotics. Typically, a robot arm comprises: a robot base, which serves as a mounting base for the robot arm; and a robot tool flange, wherein various tools can be attached to the robot tool flange. A robot controller is configured to control the robot joints to move the robot tool flange relative to the base. For example, in order to instruct the robot arm to perform a plurality of work instructions. The robot joints can be rotational robot joints configured to rotate portions of the robot arm relative to each other, prismatic joints configured to translate portions of the robot arm relative to each other, and / or any other kind of robot joints configured to move portions of the robot arm relative to each other.

[0003] Typically, a robot controller is configured to control the robot joints based on a dynamic model of the robot arm, wherein the dynamic model defines the relationship between the forces acting on the robot arm and the resulting acceleration of the robot arm. Typically, the dynamic model includes a kinematic model of the robot arm, knowledge about the inertia of the robot arm, and other parameters that affect the movement of the robot arm. The kinematic model defines the relationship between different parts of the robot arm and may include information about the robot arm (such as the lengths, dimensions of the joints and links), and may be described, for example, by Denavit-Hartenberg parameters, etc. The dynamic model allows the controller to determine which torques the joint motors will provide in order to, for example, move the robot joints at a specified speed, acceleration, or to keep the robot arm in a static pose.

[0004] Typically, various end effectors can be attached to the robot tool flange or other parts of the robot arm, such as grippers, vacuum grippers, magnetic grippers, thread lathes, welding equipment, dispensing systems, vision systems, etc.

[0005] The robot arm needs to be programmed by the user or robot integrator who defines various instructions for the robot arm, such as predefined movement patterns and work instructions, such as grasp, wait, release, thread engagement instructions. The instructions may be based on various sensors or input signals that typically provide a trigger signal for stopping or starting a given instruction. The trigger signal may be provided by various indicators, such as a safety curtain, a vision system, a position indicator, etc.

[0006] When the robotic arm is a multi-purpose robotic arm, many users have difficulty programming the robotic arm to perform the robotic arm operating process accurately and / or precisely enough to meet the requirements of the results of the multi-purpose robotic arm's contribution to the product or work process. Summary of the invention

[0007] The object of the present invention is to solve the above limitations or other problems of the prior art with respect to the prior art. This is achieved by a method and a robot arm according to the independent claims, wherein the multi-purpose robot arm comprises a plurality of robot joints connecting a robot base and a robot tool flange, the multi-purpose robot arm comprising a robot controller configured to control the multi-purpose robot arm in a standard operating mode and in an application-specific operating mode during a portion of an operating process of the robot arm. Wherein the robot controller is configured to control the movement of the multi-purpose robot arm according to a plurality of predetermined basic operating commands during the operating process of the robot arm, the basic operating commands being at least partially defined by one or more operating parameters. Wherein the robot controller is configured to control the multi-purpose robot arm in a standard operating mode according to a first subset of the basic operating commands during a portion of the operating process of the robot arm, wherein at least one operating parameter of the one or more operating parameters defining the first subset of the basic operating commands is limited by a standard operating value. wherein the robot controller is configured to control the multipurpose robotic arm in an application specific operating mode according to a second subset of basic operating commands during a portion of an operating procedure of the robotic arm, wherein the basic operating commands of the second subset are at least partially encompassed by the first subset of basic operating commands, and wherein at least one of the one or more operating parameters defining the basic operating commands of the second subset is limited by an application operating value, wherein an allowable window of operation of the multipurpose robotic arm when operating according to the basic operating commands defined by the standard operating value is different from an allowable window of operation of the multipurpose robotic arm when operating according to the basic operating commands defined by the application operating value, and wherein the application operating value is limited by a desired characteristic of the operation of the multipurpose robotic arm in the application specific operating mode.

[0008] Operating the multi-purpose robotic arm according to a standard operating mode is advantageous because it has the following effect: In this mode, the requirements for accuracy and precision are not critical, which is reflected by the predetermined standard operating values ​​used in this operating mode. Due to the standard operating values, it is allowed to operate the multi-purpose robotic arm at a certain speed, path, joint torque, motor current, etc., which on the one hand leads to, for example, vibrations of the robotic tool, lower accuracy, lower precision or a combination thereof, but on the other hand leads to faster execution of the cycle of the robotic arm operating process. Such vibrations are allowed in the standard operating mode, and thus this mode can be selected, for example, when high speed has priority over the quality or aesthetics of the work performed by the robotic tool.

[0009] Operating the multipurpose robot arm according to an application specific operating mode is advantageous as it has the effect that in this mode the operating parameters are defined by the application operating values, resulting in a tool specific operation of the multipurpose robot arm. By determining the (tool) operating values ​​in dependence on the tool mounted on the robot tool flange, an optimized control according to the specific robot tool is facilitated. In case the robot tool is a welding tool, vibrations of the welding tool are undesirable as these vibrations will propagate to the weld and thus be visible in the form of a "non-straight" weld.

[0010] Therefore, when operating in the standard operating mode, the robot controller does not take into account any robot tool and the performance of the robot tool when controlling the robot arm. Therefore, the standard operating mode can also be referred to as a robot tool independent operating mode. This is in contrast to the application specific operating mode, in which the robot controller takes into account the performance of the robot tool and the robot tool mounted on the robot tool flange when controlling the robot arm. Therefore, the application operating mode can also be referred to as a robot tool related operating mode. Therefore, the standard operating mode can be at least partially defined by, for example, the maximum joint speed, and the application operating mode can be at least partially defined by the maximum adjusted joint speed. Wherein the adjusted joint speed ensures that the specific tool operates more accurately and more precisely without vibrations, etc. It should be mentioned that the values ​​of other operating parameters can also be regarded as defining the standard operating mode and the application operating mode, respectively.

[0011] Having different operating values ​​for the same basic operating commands when used in the standard operating mode and in the application operating mode, respectively, is advantageous, since it has the effect that the same multipurpose robot arm with a welding tool can be operated as a (specific) welding robot one day, and the next day it can be operated as a (specific) threaded joining robot with a screw tool installed. At least some of the basic operating commands used in the standard operating mode and in the application operating mode are identical, since both modes require, for example, forward movement of the robot tool in a given plan or along one side of a product to be processed by the robot tool. However, depending on the specific robot tool and / or its use, the operating values ​​define, for example, the speed at which the robot tool moves and the permissible windows of torque acting on robot joints that are different from one another.

[0012] In the context of the present invention, the window of operation should be understood as the value of the range of operating parameters that define the operating limits of the robot arm. When the robot arm is operated in one operating mode, the first operating parameter may have one value, and when the robot arm is operated in another operating mode, the first operating parameter may have another value. In particular, according to the present invention, these values ​​are defined by a tool mounted on the robot arm. This is advantageous because it has the following effect: the so-called process force can be allowed by adjusting the value of a specific operating parameter and thereby adjusting the window of the operating parameter (referred to as the operating window). For example, the threaded engagement torque generated by the threaded engagement tool when the threaded engagement tool is in operation can be referred to as a process force.

[0013] Operating the multipurpose robotic arm in both the standard operating mode and the application operating mode during the robotic arm operation process is advantageous because it has the effect that the program code can be reused. Furthermore, the basic operating commands of the program code are made by the programmer before the integrator uses them to adapt the multipurpose robotic arm to the specific process on site. This has the advantage that the integrator only needs to call up the pre-programmed basic operating commands to establish the program code for the specific process. Accordingly, in most cases there will be some local adjustments to the program code, which, however, does not change the fact that the programming performed by the integrator on site can be performed quickly and with a reduced risk of programming errors. The latter is particularly true because programming the multipurpose robotic arm requires knowing the impact of a change on the dynamics and balance of the multipurpose robotic arm.

[0014] The desired characteristics of the operation of a multi-purpose robot arm are typically specific movements that are performed without vibration, thereby allowing the desired increased joint torque or motor current, etc. when operating in the application operating mode. Therefore, it is advantageous to be able to control the multi-purpose robot arm according to the desired characteristics because it has the following effect: the movement and / or control is aligned with the task of the robot operating process and leads to optimized execution of the task. This effect is available without the user or integrator having a detailed understanding of programming the multi-purpose robot arm. This is because the effect is obtained by using a predetermined specific application mode, for which the operation values ​​of the operating parameters of the basic operating commands and tool-specific operating commands are determined by the application operating values. Wherein the tool operating parameters are predetermined and established, for example, based on testing, trial and error, simulation, etc. performed by experts in robot programming and dynamics. Typically, such experts are used in the research and development department of multi-purpose robot arm OEMs or robot tool manufacturers.

[0015] According to an embodiment of the invention, the desired characteristics are determined by a robot tool mounted on a robot tool flange. More precisely, the robot arm comprises a robot tool mounted on a robot tool flange and the desired characteristics are determined by the robot tool. This is advantageous because it has the effect that the applied operation values ​​are specifically adapted to the robot tool and thus the desired characteristics of the movements of the multipurpose robot arm are optimized for this specific robot tool. Thus, the end result of the robot operation process is optimized at least from a visual point of view, which is often decisive for the customer's willingness to purchase the product. The robot tool may be any tool suitable for mounting on a robot tool flange, i.e. a tool that can modify, move, analyze, etc. an object.

[0016] According to an embodiment of the invention, a desired property is to at least partially suppress vibrations of the robot arm and / or the robot tool by reducing the movement speed. This is advantageous even if it reduces the operating speed, since it has the effect that the robot tool is more precise and, for example, when welding or spraying, the vibrations are not transmitted to the welding or spraying. Thus, the end result of the robot operation process is optimized, at least from a visual point of view, which is often decisive for the consumer's willingness to buy a product.

[0017] According to an embodiment of the present invention, a desired characteristic is to allow increased torque by increasing the upper limit allowed for the torque acting on the joint of the robot.

[0018] According to an embodiment of the present invention, the plurality of predetermined basic operation commands comprises at least 2 basic operation commands, preferably at least 5, and most preferably at least 10 basic operation commands. This is advantageous because it has the following effect: complex robot operation processes can be controlled according to the present invention, including multiple changes in the movement direction of the multi-purpose robot arm.

[0019] According to an embodiment of the invention, the robot controller is configured to control the multipurpose robot arm in a standard operating mode during a first portion of an operating process, to control the multipurpose robot arm in an application-specific operating mode during a subsequent portion of the robot arm operating process, and to control the multipurpose robot arm in the standard operating mode again during a final portion of the robot arm operating process. This is advantageous because it has the effect that the robot arm is only used in the application-specific operating mode when the robot tool is in use. In the standard operating mode, the operating values ​​can be designed to optimize speed without compromising safety. This is in contrast to the application operating values ​​used in the application-specific operating mode, where the operating values ​​are designed to optimize the operation of the robot, which can sometimes compromise safety. This can be permissible because in such cases the robot tool is at a safe point in the robot cell where people cannot be injured.

[0020] According to an embodiment of the invention, the robot controller is configured to control the multi-purpose robot arm in an application-specific operating mode only when the robot tool is active. This is advantageous because it has the effect that when the tool is not activated, the multi-purpose robot arm may be operated according to standard values ​​of operating parameters, resulting in faster and less accurate operation. The multi-purpose robot arm is operated according to application operating values ​​of operating parameters of basic operating commands (or tool-specific operating commands) only in the application-specific operating mode. Thus, the multi-purpose robot arm is controlled according to standard operating values ​​of operating parameters as long as the multi-purpose robot arm is not actively using its robot tool.

[0021] According to an embodiment of the present invention, the robotic controller is configured to activate the robotic tool when the robotic tool is in a predetermined position defined by the program code.

[0022] According to an embodiment of the invention, the multipurpose robot arm is in an application specific operating mode when the robot controller is in a predetermined position defined by the program code. This is advantageous because it has the effect that the application specific operating mode is first entered before the tool is about to be used for operation, i.e. before welding, threading, placement, etc. is about to take place. In this way, the robot tool is in an inaccessible position or the use period for welding, threading, placement, etc. is limited so that it does not affect the wear of the multipurpose robot arm or the tool and thus does not affect its end of life. In this way, better performance of the robot tool is obtained without compromising the safety and wear of the robot arm.

[0023] According to an embodiment of the invention, when the robot tool moves to a position where the program code terminates the use of the robot tool, the robot arm is inactive. This is advantageous because it has the effect that the operation of the robot arm returns to the standard operating mode again and thus to its more flexible standard setting.

[0024] According to an embodiment of the present invention, the basic operation command includes one basic operation command from a list including: forward, backward, upward, downward, move to waypoint, rotate right, rotate left, and home. The basic operation commands are advantageous because they have the following effect: an integrator can easily use a combination thereof to establish a portion of a control program code for multiple purposes. The "home" command may include several basic operation commands required to return the robot tool from a current position to a starting position.

[0025] According to an embodiment of the present invention, the application operating mode also includes tool specific operating commands. Having tool specific operating commands is advantageous because it has the effect that an integrator can easily combine these operating commands with the basic operating commands and thereby theoretically develop a program code for controlling a multi-purpose robot arm by only specifying the start / end points of the operating commands. In practice, it may also sometimes be necessary to adjust the operating values ​​as described below.

[0026] According to an embodiment of the invention, the robot controller is configured to control at least one of the second subset of basic operating commands, which are also part of the first subset of basic operating commands, in dependence on the application operating value. This is advantageous because it has the effect that, for example, a forward movement performed in the application specific operating mode can be performed with higher accuracy and / or with higher precision than when performed in the standard operating mode. This means that even though the forward movement may be slower, it preferably allows the robot tool to perform more precise and accurate work.

[0027] According to an embodiment of the present invention, an applied operational value of a force operational parameter is determined by establishing an expected process force or an expected process torque to be applied from the robotic tool.

[0028] According to an embodiment of the invention, the application operating value of the force operating parameter is determined by establishing an expected process force or an expected process torque applied during an application specific operating mode. This is advantageous because it has the effect that the application operating value only cancels and / or allows elimination of process forces, and not forces applied from the outside (such as a collision of a person with the multi-purpose robotic arm). Thus, even when operating in an application specific operating mode, the multi-purpose robotic arm still stops operating, for example in the event of a collision of it with a person.

[0029] According to an embodiment of the present invention, a multi-purpose robot arm having the same robot tool is controlled with a first set of applied operating values ​​during a first robot arm operation and with a second set of applied operating values ​​during a second robot arm operation. This is advantageous because it has the effect that the same multi-purpose robot arm having the same robot tool can be optimized to perform two different robot arm operation processes using the same robot tool.

[0030] According to an embodiment of the present invention, the applied operating value is a soft stop value, and wherein the robot controller is configured to stop the operation of the multi-purpose robot in the event of crossing the soft stop value. This is advantageous because it has the following effect: for a given robot tool, the applied operating value can be used to stop the operation of the multi-purpose robot arm. Thus, if, for example, the welding process is allowed to continue below a given vibration level, and the level is defined by one or more applied operating values, the robot controller can stop the welding process if one or more applied operating values ​​are exceeded. It should be mentioned that the soft stop value can be both a maximum value, a minimum value and an average value of the operating value.

[0031] According to an embodiment of the invention, the applied operating value is a minimum value of an operating parameter associated with one selected from a list comprising acceleration, speed, torque, force, current vibration, temperature and weight. This is advantageous because it has the effect that the operation of the multi-purpose robotic arm is adapted to the operation performed with a specific robotic tool.

[0032] According to an embodiment of the invention, the applied operating value is a maximum value of an operating parameter associated with one selected from a list comprising acceleration, speed, torque, force, current vibration, temperature and weight. This is advantageous because it has the effect that the operation of the multi-purpose robot arm is adapted to the operation performed with a specific robot tool.

[0033] Different robotic tools require different windows of operation to achieve optimal results for the work being performed. The optimal results may be measured in terms of speed, accuracy, precision, aesthetics, etc. Thus, depending on the specific robotic tool, a specific value of the application operation value is selected to define both the upper and lower limits of the allowable window of operation or at least one of the upper and lower limits of such window.

[0034] According to an embodiment of the present invention, standard operation values ​​and application operation values ​​are predetermined for a plurality of basic operation commands. This is advantageous because it has the following effects: program codes for operation commands for a multi-purpose robot arm can be easily and quickly established on site to complete the robot arm operation process.

[0035] According to an embodiment of the present invention, a standard operating value and a plurality of different application operating values ​​are predetermined for at least one basic operating command. This is advantageous because it has the effect that a program code for an operating command of a multi-purpose robot arm can be easily and quickly established on site to complete a robot arm operating process, regardless of which robot tool is mounted on the robot tool flange.

[0036] According to an embodiment of the invention, the operating values ​​of basic operating commands used in an application-specific operating mode are predetermined and less restrictive than the operating values ​​of substantially the same operating commands used in a standard operating mode. This is advantageous because it has the following effect: it allows a multi-purpose robot arm for a limited portion of the robot's operating process to exceed the soft stop threshold of the operating parameter. As a result, tightening can be performed with greater torque, the rotating tool can be accelerated / decelerated faster, i.e. the allowed window for the operation of certain operating parameters related to a specific robot tool is extended in a specific portion of the robot's operating process. Therefore, the values ​​of the operating parameters that partially define the operating window of the standard operating mode cause the robot arm to stop "earlier" than when the robot arm is operating in the application operating mode, because the values ​​of the same operating parameters allow, for example, higher values, thereby making the operating window less restrictive in the application operating mode.

[0037] According to an embodiment of the invention, the operation values ​​of the basic operation commands used in the application-specific operation mode are predetermined and more restricted than the operation values ​​of the same basic operation commands used in the standard operation mode. This is advantageous because it has the effect of reducing the operation of the multipurpose robot arm to a limited part of the robot operation process by narrowing the allowed window of operation. Thereby, the multipurpose robot arm is limited, for example, in terms of the speed of forward movement, thereby increasing the time the multipurpose robot arm has to perform a specific job, which for some specific tasks leads to a higher quality or a more aesthetic appearance of the resulting task.

[0038] According to an embodiment of the invention, the operating values ​​used in the standard operating mode are protected from being changed. This is advantageous because it has the effect that an inexperienced integrator cannot mistakenly change values ​​that compromise safety, thereby operating a multi-purpose robot arm where it could collide with a person with, for example, a higher torque soft stop threshold.

[0039] According to an embodiment of the invention, the operating values ​​used in the application operating mode are freely variable. This is advantageous because it has the effect that in this operating mode, there is less risk of collision with a person, for example due to the position of the robot tool, and therefore additional torque cannot come from such a collision and can therefore be allowed for specific parts of the robot operating process.

[0040] According to an embodiment of the invention, it is allowed to adjust the operating value within a predetermined window defined by the hard stop threshold. This is advantageous because it has the effect that failure to adjust the operating value may cause damage to the multi-purpose robot arm and preferably also to objects in the robot cell.

[0041] According to an embodiment of the present invention, the multi-purpose robot facilitates the control of at least two robotic tools selected from a list comprising: welding tools, processing tools, cutting tools, machine maintenance tools, assembly tools, quality tools, material tools and material addition tools. A multi-purpose robot arm that facilitates the control of several different robotic tools is advantageous because it has the following effect: the production cost of a more expensive multi-purpose robot including a robot base, robot joints and tool flanges can be reduced because the same multi-purpose robot can be used with this wide variety of different less expensive robotic tools. A further advantage is that the owner of a multi-purpose robot can perform a range of different highly specialized tasks by changing tools without having to purchase more multi-purpose robots or different specialized robots, which results in an increase in the required footprint for additional robotic units on the production site.

[0042] According to an embodiment of the invention, the welding tool is a tool facilitating welding of objects according to at least one method from the list comprising: Tig, laser, ultrasonic, plasma, spot welding and brazing.

[0043] According to an embodiment of the present invention, a handling tool is a tool that facilitates handling of objects according to at least one of the methods in the list comprising: transferring, sorting, packaging, palletizing, labeling and lifting. The tool that facilitates handling of objects may be, for example, a mechanical gripper, a vacuum gripper, a robotic hand, etc.

[0044] According to an embodiment of the invention, the cutting tool is a tool that facilitates cutting of an object according to at least one of the methods selected from the list consisting of: laser, water jet and plasma. The tool that facilitates cutting may be provided, for example, in the form of a laser cutter, a water jet cutter and / or a plasma cutter.

[0045] According to an embodiment of the present invention, a machine tending tool is a tool that facilitates tending an object according to at least one of the methods of the list comprising: CNC, metal casting, IMM and pressing. CNC is an abbreviation for Computerized Numerical Control Machine Tools, and IMM is an abbreviation for Injection Molding Machines.

[0046] According to an embodiment of the invention, the assembly tool is a tool that facilitates assembling an object according to at least one of the methods selected from the list consisting of inserting, mounting, positioning, threading, nut driving, nailing, riveting, pressing, winding and cabling.

[0047] According to one embodiment of the invention, the quality tool is a tool facilitating quality inspection of an object according to at least one of the methods of the list comprising: inspection, measurement, testing and metrology.

[0048] According to an embodiment of the invention, the material tool is a tool facilitating machining of an object according to at least one of the methods selected from the list consisting of: removing, deburring, milling, polishing, routing and drilling.

[0049] According to one embodiment of the invention, the material adding tool is a tool facilitating adding material to an object according to at least one method from the list comprising: dispensing, spraying and dipping.

[0050] Furthermore, the present invention relates to a method of controlling a multipurpose robotic arm, the multipurpose robotic arm comprising a plurality of robotic joints connecting a robot base and a robot tool flange, the multipurpose robotic arm comprising a robotic controller, the robotic controller controlling the multipurpose robotic arm during an operation of the robotic arm according to: a first level program code, the first level program code monitoring an operating value of an operating parameter during operation of the multipurpose robotic arm, wherein the first level control initiates a hard stop of the operation of the multipurpose robotic arm if the operating value exceeds a predetermined safety range; a second level program code, the second level program code controlling basic movements of the multipurpose robotic arm according to basic operating commands defined by standard operating values, and a third level application code controlling basic movements of the multipurpose robotic arm according to basic operating commands defined by application operating values. wherein during a first portion of the operation of the robotic arm, the multipurpose robotic arm is controlled by the second level program code by a plurality of basic operating commands defined by the standard operating values. wherein during a second part of the robotic arm operating process, the multi-purpose robotic arm is controlled by a third level application code, wherein the third level application code is determined by the desired characteristics of the operation of the multi-purpose robotic arm in an application specific operating mode, and wherein during the first part and the second part of the robotic arm operating process, the robotic arm is also monitored by the first level program code.

[0051] This is advantageous because it has the effect that a programmer or integrator can program a multi-purpose robot to become a specific robotic arm simply by using program code from the three levels. Therefore, the integrator does not have to be an expert in programming, thereby widening the group of people who can be hired as integrators. This is advantageous in times and areas where the demand for qualified labor is high. The program code of the first level cannot be accessed for modification because it is part of the safety system. The program code of the second layer cannot be accessed for modification because it is part of the standard code for mobile robots. Accordingly, modifications are allowed, although not preferred, because the modifications made will not be tested. The program code of the third level is used to optimize the operation of the robot tool, thereby

[0052] As mentioned, the desired characteristics required of a robotic tool mounted on a robotic tool flange are directly related to the end result of the work performed by the robotic tool. Thus, the desired characteristic may be vibration suppression, which, if achieved, results in more precise or accurate spraying, welding, path following, precise stacking, etc.

[0053] The integrator is usually not allowed to change the operating values, such as the soft stop values ​​of the operating parameters, so some specific applications cannot be well performed by the robot arm because the robot arm is a multi-purpose type of robot arm. In addition, the integrator may not know which parameters to adjust to which values ​​to obtain the desired characteristics of the movement of the multi-purpose robot arm. In order to allow the multi-purpose robot arm to perform specific applications / jobs, it is sometimes necessary to change these soft values, and this can be done via the third-level program without accessing the first-level program code or the second-level program code. Because this is done via the third-level program, the integrator does not grid anything in the second-level program to change the soft stop values ​​used during basic operating commands in the standard operating mode. Therefore, back to the research and development department, the selected operating parameters are defined for a specific tool / application / job, and the application operating values ​​of these operating parameters are the only time that the integrator can change. In many cases, its change is not even necessary. In addition, the changed values ​​are only used when the third-level program is executed during the robot operating process cycle when the robot tool is activated or just before the robot tool is activated.

[0054] According to an embodiment of the invention, the desired characteristics are determined by the robot tool mounted on the robot tool flange. This is advantageous as it has the effect that the application operation values ​​are specifically adapted to the robot tool and thus the desired characteristics of the movements of the multipurpose robot arm are optimized for that specific robot tool, resulting in a higher quality visually apparent end result.

[0055] According to an embodiment of the present invention, the operational values ​​of the third level application code are accessible for updating by the robot integrator. This is advantageous because it has the effect of reducing programming errors that lead to malfunctions of the multi-purpose robot arm because the robot integrator is only allowed to change limited top-level operational values.

[0056] According to an embodiment of the present invention, the operating parameters of the third level application code are used to control the multi-purpose robot arm within a limited time period, wherein the limited time period is less than 30% of the time of the robot operation process, preferably less than 20% of the robot operation process, and most preferably less than 10% of the robot operation process. This is advantageous because it has the effect of shortening only the time period during which the robot operation process starts when the robot tool is in the starting position and ends when the robot tool is in the starting position again to prepare for performing a subsequent robot operation process. The shortened time is advantageous at least in the case where the soft stop threshold is increased and there is a risk of collision.

[0057] According to an embodiment of the present invention, the robot controller includes a first level program code, which is configured to monitor the operating value of the operating parameter during operation of the multi-purpose robot arm, wherein if the operating value exceeds a predetermined safety range, the first level program code initiates a hard stop of the operation of the multi-purpose robot arm.

[0058] The dependent claims describe possible embodiments of the robot arm and the method according to the invention. Advantages and beneficial effects of the invention are described in the detailed description of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Figure 1 shows a robot arm according to the present invention;

[0060] Figure 2 A simplified block diagram of a robot arm is shown;

[0061] Figure 3 A simplified overview of the robot operation process is shown;

[0062] Figure 4 A robotic arm including a welding tool is shown; and

[0063] Figure 5 A robotic arm including a threading tool is shown. DETAILED DESCRIPTION

[0064] The present invention has been described in view of the exemplary embodiments intended only to illustrate the principles of the invention. The skilled person will be able to provide several embodiments within the scope of the claims. Throughout the specification, the reference numerals of similar elements providing similar effects have the same last two digits. In addition, it should be understood that in the case where an embodiment includes multiple identical features, only some of the features may be marked by reference numerals.

[0065] Figure 1A multi-purpose robot arm 101 (sometimes simply referred to as a robot arm) is shown, which includes a plurality of robot joints 103a, 103b, 103c, 103d, 103e, 103f connecting a robot base 105 and a robot tool flange 107. Thus, the robot arm includes a robot base, a robot tool flange, and a plurality of robot joints connecting the robot base and the robot tool flange. The base joint 103a is configured to rotate the robot arm around a base axis 111a (shown as a short dashed line), as indicated by the rotation arrow 113a; the shoulder joint 103b is configured to rotate the robot arm around a shoulder axis 111b (shown as a cross indicating the axis), as indicated by the rotation arrow 113b; the elbow joint 103c is configured to rotate the robot arm around an elbow axis 111c (shown as a cross indicating the axis), as indicated by the rotation arrow 113c, the first wrist joint 103d is configured to rotate the robot arm around a first wrist axis 111d (shown as a cross indicating the axis), as indicated by the rotation arrow 113d, and the second wrist joint 103e is configured to rotate the robot arm around a second wrist axis 111e (shown as a short dashed line), as indicated by the rotation arrow 113e. The robot joint 103f is a tool joint comprising a robot tool flange 107 which is rotatable about a tool axis 111f (shown in dashed lines) as indicated by the rotation arrow 113f. Thus, the robot arm shown is a six-axis robot arm with six degrees of freedom, which are provided as six rotational robot joints, however, it should be noted that the present invention may be provided in a robot arm comprising fewer or more robot joints, tool flanges and / or other types of robot joints (such as prismatic robot joints).

[0066] Each of the robot joints is provided as a rotary robot joint, comprising an output flange rotatable relative to the robot joint, and the output flange is connected to an adjacent robot joint directly or via an arm portion known in the art. The robot joint comprises a joint motor, which is configured to rotate the output flange, for example via a transmission or directly connected to a motor shaft. In other embodiments, at least one of the robot joints may be provided as a prismatic joint, comprising an output flange that is translated relative to the robot joint by a robot joint motor, and the output flange is connected to an adjacent robot joint directly or via an arm portion known in the art.

[0067] In addition, the robot joint includes at least one joint sensor that provides a sensor signal, which indicates at least one of the following parameters: the angular position of the output flange, the angular position of the motor shaft of the joint motor, the motor current of the joint motor, and the external force that attempts to rotate / move the output flange or the motor shaft. For example, the angular position of the output flange can be indicated by an output encoder such as an optical encoder or a magnetic encoder, which can indicate the angular position of the output flange relative to the robot joint. Similarly, the angular position of the joint motor shaft can be provided by an input encoder such as an optical encoder or a magnetic encoder, which can indicate the angular position of the motor shaft relative to the robot joint. It should be noted that both an output encoder indicating the angular position of the output flange and an input encoder indicating the angular position of the motor shaft can be provided, which makes it possible to determine the relationship between the input side and the output side of the transmission device in an embodiment in which a transmission device has been provided. The joint sensor can also be provided as a current sensor indicating the current passing through the joint motor, and thus the joint sensor is used to obtain the torque provided by the motor. For example, in combination with a multi-phase motor, multiple current sensors can be provided to obtain the current passing through each phase of the multi-phase motor.

[0068] The force sensor 109 may be disposed at the robot tool joint 103f and is configured to sense the force applied to the robot tool flange 107. The force sensor 109 provides a force signal indicative of the force provided at the tool flange. In the illustrated embodiment, the force sensor is integrated into the robot tool flange and is configured to indicate the force applied to the robot tool flange relative to a reference point 110 of the robot tool flange. Figure 1 In the example, the reference point 110 coincides with the origin of the tool flange coordinate system, which defines three coordinate axes: x 凸缘 ,y 凸缘 、z 凸缘 In the illustrated embodiment, the origin of the robot tool flange coordinate system has been arranged on the tool flange axis 111f, wherein one axis (z 凸缘 ) is parallel to the tool flange axis and is located at the outer surface of the robot tool. However, the force sensor may indicate the force applied to the robot tool flange relative to any point that can be connected to the robot tool flange coordinate system. In one embodiment, the force sensor is provided as a six-axis force-torque sensor, which is configured to indicate forces along three perpendicular axes and torques around three perpendicular axes. For example, the force-torque sensor may be provided as any force-torque sensor capable of indicating forces and torques relative to a reference point, such as any force-torque sensor disclosed by WO2014 / 110682 A1, US 4763531, US 2015204742. However, it should be understood that the force sensor associated with the present invention does not necessarily need to be able to sense the torque applied to the tool sensor.

[0069] The acceleration sensor 115 may be arranged at the robot tool joint 103f and is configured to sense the acceleration of the robot tool joint 103f and / or the acceleration of the robot tool flange 107. The sensor 115 provides an acceleration signal indicating the acceleration force of the acceleration of the robot tool joint 103f and / or the acceleration of the robot tool flange 107. In the illustrated embodiment, the acceleration sensor is integrated into the robot tool joint and is configured to indicate the acceleration of the robot tool joint relative to a reference point 110 of the robot tool flange. However, the acceleration sensor may indicate the acceleration of the robot tool joint relative to any point that may be connected to the robot tool flange coordinate system. The acceleration sensor may be provided as any accelerometer capable of indicating the acceleration of an object. The acceleration sensor may, for example, be provided as an IMU (Inertial Measurement Unit) capable of indicating both the linear acceleration and the rotational acceleration of an object.

[0070] The robotic arm includes at least one robotic controller 102 configured to control the robotic joints by controlling the motor torques provided to the joint motors based on a dynamic model of the robotic arm, a gravity work direction 112, and joint sensor signals. The robotic controller 102 may be provided as a computer including an interface device 104 that enables a user to control and program the robotic arm. The controller may be provided as Figure 1 The interface device may be provided as an external device as shown, as a device integrated into the robot arm, or as a combination thereof. The interface device may be provided, for example, as a teach pendant known in the field of industrial robots, which may communicate with the controller via a wired or wireless communication protocol. The interface device may, for example, include a display 106 and a plurality of input devices 108, such as buttons, sliders, touch pads, joysticks, trackballs, gesture recognition devices, keyboards, etc. The display may be provided as a touch screen that acts as both a display and an input device.

[0071] Figure 2 Shows Figure 1 103a, 103b and 103f have been shown in structural form, and for the sake of simplicity of the drawing, the robot joints 103c, 103d, 103e have been omitted. In addition, the robot joints are shown as separate elements; however, it should be understood that they are Figure 1The robot joint includes output flanges 216a, 216b, 216f and joint motors 217a, 217b, 217f, wherein the output flanges 216a, 216b, 216f are rotatable relative to the robot joint, and the joint motors 217a, 217b, 217f are configured to rotate the output flanges via output shafts 218a, 218b, 218f. In this embodiment, the output flange 216f of the tool joint 103f includes the tool flange 107. At least one joint sensor 219a, 219b, 219f provides sensor signals 222a, 222b, 222f, which indicate at least one joint sensor parameter J of the corresponding joint. 传感器，a , J 传感器，b , J 传感器，f . The joint sensor parameters indicate at least one posture parameter, which indicates the position and orientation of the output flange relative to the robot joint, such as: the angular position of the output flange, the angular position of the shaft of the joint motor, and the motor current of the joint motor. For example, the angular position of the output flange can be indicated by an output encoder such as an optical encoder or a magnetic encoder, which can indicate the angular position of the output flange relative to the robot joint. Similarly, the angular position of the joint motor shaft can be provided by an input encoder such as an optical encoder or a magnetic encoder, which can indicate the angular position of the motor shaft flange relative to the robot joint.

[0072] The robot controller 102 includes a processor 220 and a memory 221, and is configured to control the joint motors of the robot joints by providing motor control signals 223a, 223b, 223f to the joint motors. The motor control signals 223a, 223b, 223f indicate the motor torque T that each joint motor should provide to the output flange. 马达，a , T 马达，b and T 马达，f , and the robot controller is configured to determine the motor torque based on a dynamic model of the robot arm known in the prior art. The dynamic model allows the controller to calculate the torque that the joint motor should provide to each of the joint motors in order for the robot arm to perform the desired movement. The dynamic model of the robot arm may be stored in the memory 221 and may be based on the joint sensor parameters J 传感器，a , J 传感器，b , J 传感器，f For example, the joint motors may be provided in the form of multi-phase electric motors, and the robot controller may be configured to regulate the motor torque provided by the joint motors by regulating the current through the phases of the multi-phase electric motors, as is known in the art of motor regulation.

[0073] The robot tool joint 103f includes a force sensor 109 that provides a force signal 224 that indicates the force applied to the tool flange. For example, the force signal may be indicated as a force vector in the robot tool flange coordinate system:

[0074] Equation 1

[0075] in is along x 凸缘 The indicated force of the shaft, It is along y 凸缘 The indicated force of the shaft, and It is along z 凸缘 Indicative force of the shaft.

[0076] In embodiments where the force sensor is provided as a combined force-torque sensor, the force-torque sensor may additionally provide a torque signal indicative of the torque applied to the tool flange, for example as a separate signal (not shown) or as part of the force signal. The torque may be indicated as a torque vector in the robot tool flange coordinate system:

[0077] Equation 2

[0078] in is around x 凸缘 Indicated torque of the shaft, is around y 凸缘 The indicated torque of the shaft, and It is around z 凸缘 Indicated torque of the shaft.

[0079] The robot tool joint 103f includes an acceleration sensor 115 that provides an acceleration signal 225 indicative of the acceleration of the output flange 216f. For example, the acceleration signal may indicate an acceleration vector in the robot tool flange coordinate system:

[0080] Equation 3

[0081] in is along x 凸缘 The sensed acceleration of the axis, It is along y 凸缘 The sensed acceleration of the axis, and It is along z 凸缘 The sensed acceleration of the axis.

[0082] In embodiments where the acceleration sensor is provided as a combined accelerometer / gyroscope (e.g., an inertial measurement unit, IMU), the acceleration sensor may additionally provide an angular acceleration signal indicative of an angular acceleration of the output flange relative to the robot tool flange coordinate system, e.g., as a separate signal (not shown) or as part of the acceleration signal. The angular acceleration signal may indicate an acceleration vector in the robot tool flange coordinate system

[0083] Equation 4

[0084] in is around x 凸缘 The angular acceleration of the axis, is around y 凸缘 axis, and It is around z 凸缘 Angular acceleration of the axis.

[0085] The multi-purpose robot arm 101 should be understood as a robot arm to which a variety of different robot tools (not shown) can be connected. When a tool is connected to the robot tool flange 107, the multi-purpose robot arm can be controlled according to the present invention, wherein it changes state from a multi-purpose robot arm to a dedicated robot arm.

[0086] The robot controller 102 should be understood as the above-mentioned control device, which includes a processor 220 that facilitates reading and executing program code and converting it into operating commands for one or more of the robot joints 103 or robot tools. Personal computers (PCs), tablet computers, mobile phones, industrial programmable controllers (also called PLCs) are examples of suitable robot controllers.

[0087] Movement of the robot arm shall be understood as movement of one or more robot joints and the robot tool. Basic operation commands shall be understood as a plurality of program codes which, when called and executed, facilitate predetermined operations of the robot arm, such as movement of the robot arm independent of the robot tool mounted on the robot tool flange, fixing the robot arm in a fixed position, waiting for an input signal, etc. Examples of basic operation commands are move forward, move left, move right, move up, move down, move to a waypoint, rotate a joint, activate a robot joint, wait for an input signal, etc.

[0088] The robot arm operation process should be understood as the operation that the robot arm performs when it is in operation. The program includes a subset of a plurality of available basic operation commands, and thus the robot arm operation process is established by one or more of the basic operation commands that are subsequently executed by the robot controller. A schematic diagram of the robot arm operation process is shown in Figure 3As described above and as will be apparent from the above, the robot arm operation process according to the present invention includes controlling basic operation commands according to a standard operation mode and an application specific operation mode.

[0089] exist Figure 3 In the figure, this is illustrated by a first subset and a second subset of basic operating commands. The first subset refers to the standard operating mode, and the second subset refers to the application operating mode. As shown in the figure, the robot arm operation process includes moving a robot tool and working with the robot tool. When moving the robot tool, the movement is performed with reference to the standard operating mode (i.e., using the standard operating values ​​of the basic operating commands). When the robot tool is working, the work is performed with reference to the application operating mode (i.e., using the application operating values ​​of the basic movements). As shown in the figure, some basic operating commands are used only with a different set of operating values ​​in the two operating modes. It should be mentioned that the robot tool can move in the application mode, i.e., with application operating values, and it can work in the standard operating mode, i.e., with standard operating values.

[0090] In the standard operating mode, the basic operating commands are defined by operating parameters which are again defined by standard operating values. An example of a standard operating mode may be a portion of an operating process of a multi-purpose robotic arm in which the multi-purpose robotic arm moves a robotic tool from a "home" position of the robotic tool to a starting position for an operation, from an end position of an operation of the robotic tool back to the home position, but also some movements in which the robotic tool is activated, such as palletizing objects that are not fragile or do not require precise and / or accurate positioning to a range that can be followed by the standard values ​​of these operating parameters used (to be defined in paragraphs

[0030] -

[0032] ). The home position is the position to which the multi-purpose robotic arm returns when not in use.

[0091] In the application operating mode, the operating parameters of the basic operating commands are defined by application operating values ​​that are different from the standard operating values. This is true for at least a portion of the basic operating commands used in both the standard operating mode and the application-specific operating mode. An example of an application-specific operating mode may be a portion of an operating process of a multi-purpose robot arm, wherein the multi-purpose robot arm is using a robot tool, and wherein the result of the operation of the robot tool requires high precision and / or accuracy (e.g., palletizing fragile objects), the requirements for completing the operation of the robot tool are high (e.g., welding or spraying), and the operation of the robot tool causes high torque in a short period of time (threaded engagement, cutting, sawing). Therefore, when operating in the application-specific operating mode, it can be said that the multi-purpose robot arm is converted into an application-specific robot arm. This means that the multi-purpose robot arm is now dedicated to following requirements regarding a specific task, and this task is also the only task that the multi-purpose robot arm can handle when it is in the application-specific operating mode. It should be mentioned that the application operating value can be defined by the robot tool mounted on the multi-purpose robot arm.

[0092] The robot controller uses operating parameters to control, for example, the acceleration and speed of movement during basic operating commands, the allowed torque acting on the robot joints, etc. For each operating parameter, an operating value that limits the speed, torque, etc. is determined. The standard operating value of the operating parameter is usually selected as a compromise between precision, accuracy and speed of operation of the multi-purpose robot arm. The application operating values ​​of the operating parameters are usually selected with an emphasis on optimizing the work done by the robot tool. Such optimization can be aimed at reducing vibrations when moving the robot tool, reducing noise, increasing accuracy and precision, energy optimization, etc. This purpose can be achieved by understanding the dynamic model of the robot arm and thereby adjusting or optimizing one or more operating values ​​and including one or more operating parameters. Such optimization requires insight into the dynamic model and / or kinematic model of the multi-purpose robot, so it is not possible for a typical robot arm user or integrator to do this.

[0093] During the standard operating mode, the robot controller controls the basic operating commands according to standard predetermined operating values ​​of operating parameters related to the specific basic operating commands. During the application specific operating mode, the robot controller controls one or more of the same basic operating commands according to optimized operating values, which are also predetermined and are called application operating values. The integrator may usually have the right to adjust the application operating values, for example during commissioning of the robot arm, but the integrator usually does not have the right to adjust the standard operating values.

[0094] Predetermined here is understood to be, for example, the value of the operating value determined before the execution of the program code used by the robot controller to control the movement of the multi-purpose robot arm. The standard values ​​of the operating parameters may be part of a standard program package stored in a memory 221 in communication with the robot controller. This is advantageous because it has the effect that when programming the operating procedures of the multi-purpose robot arm, this can be easily done by using predetermined basic operating commands with operating parameters limited or defined by the operating values.

[0095] The operation values ​​of the operation parameters used in the application-specific operation commands are referred to as application operation values. The application operation values ​​are also usually predetermined. Accordingly, when the multi-purpose robot arm is installed and adapted to the specific tasks for which its tools are defined for operation, the predetermined application operation values ​​can be adjusted, for example, by a robot integrator.

[0096] As mentioned, the operating values ​​define values ​​such as speed and torque associated with the movement and general operation of the multi-purpose robotic arm. Thus, the operating values ​​may be set points, reference points, maximum values, minimum values ​​and even average values ​​of the operating parameters used during the robotic arm operation process. Thus, in embodiments of the present invention, the standard operating values ​​and application operating values ​​may be considered as minimum values, maximum values ​​or even average values ​​of the operating parameters used in the basic operating commands.

[0097] Some of these threshold values ​​or set point values ​​together define upper and lower limits (threshold values) for a given operating parameter, and some define upper or lower limits. For example, an upper limit value for speed may together with a starting speed (which in the example may be 0 m / s) define an allowable window for operation of a particular operating parameter, and thereby an allowable window for operation of a basic operating command. The allowable window for operation may also be defined by an upper and lower threshold value.

[0098] It should be mentioned that when the terms accuracy and precision are used, the following should be understood. In the fields of science and statistics, accuracy is the degree to which a measured or calculated quantity corresponds to its actual (true) value. Accuracy is closely related to precision, also known as reproducibility or repeatability, the degree to which further measurements or calculations show the same or similar results. The result of a calculation or measurement can be accurate but not precise; precise but not accurate; neither precise nor accurate; or both precise and accurate. Therefore, when referring to the accurate control of a robotic arm, reference is made to its ability to move through a given point, i.e. how close (or how accurately) the robotic arm moves through such points. Furthermore, when referring to the precise control of a robotic arm, reference is made to its ability to follow the same route through these points, cycle after cycle.

[0099] As mentioned, the program code is used by the robot controller (via basic operation commands) to control the movement of the multi-purpose robot arm. At least a portion of the program code is developed as a standard program package delivered with the multi-purpose robot arm. The program code includes a plurality of different basic operation commands that, when executed by the robot controller, determine the movement of the multi-purpose robot arm. Examples thereof may be forward, backward, up, down, turn right, turn left, move to a waypoint, rotate, etc. In addition, the program code may include specific tool operation commands developed to control a known standard tool or a special tool. The program code for such a special tool may be developed by the developer of the special tool to conform to the interface of the program code of the standard program package.

[0100] The standard program package may be stored in a memory communicatively connected to the robot controller. The program code may include a first layer of code that monitors the safety of the multi-purpose robot arm. This portion of the program code monitors a predefined operating parameter and initiates a hard stop of the multi-purpose robot arm if its hard stop threshold is crossed. The integrator is not allowed to change any settings of this portion of the program code, in particular not to change the hard stop threshold. The hard stop is considered to be the same as an emergency stop pressed by a person observing a dangerous situation, which requires an immediate stop of the robot arm operating process. The first layer may also be embodied as a redundant system, where two independent systems are configured to execute the first layer code.

[0101] The program code may also include a second layer of code that controls the motion of the multi-purpose robotic arm. This portion of the program code includes basic operating commands that control the motion of the multi-purpose robotic arm within so-called soft stop thresholds. In contrast to a hard stop, a soft stop may not require a complete restart of the robot controller, but only a manual reset to continue operation when activated. If necessary, in some embodiments, the integrator is allowed to access and adjust this portion of the program code. However, this is not beneficial because the basic operating commands and standard operating values ​​are carefully developed relative to the dynamic model to balance the performance, speed and life of the multi-purpose robotic arm, and therefore care should be taken when adjusting the program code.

[0102] The program code may also include a third layer of code that controls tool-specific operating commands. This includes basic operating commands, where standard operating values ​​are replaced by application operating values, and in addition tool-specific operating commands may be used. When running in a multi-purpose robot arm, the integrator is allowed to adjust the code in this layer. This is especially true if adjustments to the application operating values ​​are only allowed to have a predetermined range.

[0103] As mentioned above, the multi-purpose robot arm facilitates the control of a plurality of different robot tools. The robot tools are specifically developed to perform specific tasks and when attached to the robot tool flange, the multi-purpose robot arm is dedicated to solving a specific problem or performing a specific task. Thus, the multi-purpose robot arm can be converted into a welding robot arm, a processing robot arm, a cutting robot arm, a machine tending robot arm, an assembly robot arm, a quality robot arm, a material robot arm, a material addition robot arm, just to mention some of the possible ways to convert the multi-purpose robot arm into a specific robot arm. As shown in the figure, the specific type of robot arm is determined by the robot tool attached to the robot tool flange.

[0104] Typically, a robotic tool attached to a robotic tool flange needs to interact with a robotic controller. Interaction is to be understood as communication between the tool and the robotic controller and vice versa. Communication is typically established from the robotic controller via a program code dedicated to the installed robotic tool together with a program code dedicated to controlling the multi-purpose robotic arm. A non-limiting example of the latter may be basic operating commands, which when executed facilitate the movement of the robotic arm by controlling the robotic joints 103 and the joint motors 217. Communication is typically established from the robotic tool via digital or analog input / output signals transmitted between the tool I / O and the controller I / O. The tool I / O may also include power terminals for powering the robotic tool. Examples of communication between the robotic tool and sensors associated therewith and the robotic controller are described in Figure 1 shown in and relative to Figure 1 Give a description.

[0105] Therefore, the robot controller controls the robot tool, for example, by controlling the current to the tool I / O and changing the state of the output port of the tool I / O interface, and thereby sending, for example, an "open signal" to the valve of the robot tool, thereby allowing the robot tool to spray, weld, extrude, etc.

[0106] In addition to the basic operating commands that control the movement of the multi-purpose robot arm, the program code executed by the robot controller may also include tool-specific operating commands. Tool-specific operating commands are commands developed specifically for tools attached to the robot tool flange. Tool-specific operating commands are commands that are not required to control the basic movements of the multi-purpose robot arm, i.e., specific functions of the robot tool may be controlled. Therefore, when the robot tool is attached, it may be controlled only by the basic operating commands or by a combination of the basic operating commands and the tool-specific operating commands.

[0107] When controlling some robot tools, the setting of standard operating values ​​and thus the window of permitted operation is not adequate to the quality or appearance of the result of the job performed by the robot tool. This problem can be solved by controlling the robot tool in an application operating mode. During the time that the robot is controlled in application mode, the application mode overrides or updates the standard operating values ​​used when the robot arm is controlled according to basic operating commands.

[0108] Typically, the requirements for the end result of the work of the robotic tool are known, and therefore, based on this information, the integrator who installs and commissions the robotic arm knows when to control the robotic arm according to a standard operating mode (i.e., by using basic operating commands with standard operating values) and when to control the robotic arm according to an application-specific operating mode (i.e., by using tool-specific operating commands and / or basic operating commands with application operating values).

[0109] When determining a portion of a robot operating process in which the robot arm is controlled in accordance with an application-specific operating mode, it is also necessary to determine whether the relevant operating parameters can be used with the standard operating values. As noted, this may not always be the case, and therefore by controlling the robot arm in the application-specific operating mode, one or more standard operating values ​​are updated with the tool operating parameters.

[0110] During the development of a robot tool in a research and development department or during the integration of a robot tool into a multi-purpose robot arm, a programmer may determine (in advance) which of the operating parameters and their operating values ​​need to be updated with the application operating values ​​(and which values). Later, the integrator may adjust the application operating values, for example, via a trial and error process, or both, when the multi-purpose robot arm is installed in a robot cell to perform its tasks.

[0111] Predetermined application operating values ​​mean that they are determined or estimated before the multi-purpose robot arm is installed in its robot cell. This means that when the application-specific operating mode program code is used, the relevant operating parameters are already updated with the application operating values. Therefore, in this case, when the robot controller executes this program code, the multi-purpose robot arm operates as a specific robot arm. This is not only advantageous, but also necessary in most cases, because the integrator most likely does not have a deep understanding of the dynamics of the multi-purpose robot and therefore does not know which parameter's value to adjust in order to obtain the desired effect. In fact, adjusting one parameter may have an undesirable effect on non-targeted functions. The predetermined establishment of operating values ​​is advantageous because the integrator does not have to use programming time. If programming is to be performed by the integrator, only the operating values ​​or the combination of predetermined basic operating commands are adjusted in either the standard operating mode and / or the application operating mode. Therefore, the integrator can set up the robot arm more efficiently and with less risk of operational failure.

[0112] This is illustrated by the simple example of the requirement to suppress undesired vibrations. A user or integrator is usually able to record such vibrations, but neither of them knows which operating parameters / operating values ​​need to be adjusted to suppress the vibrations. Furthermore, neither the user, at least, but most likely the integrator, has access to the location in the program code where the relevant parameters are to be adjusted to suppress the vibrations. The present invention solves this problem by including in the program code a dedicated application specific operating mode, the operating values ​​of which are designed to optimize the control of any robotic tool, in this case suppressing vibrations, regardless of which robotic tool is mounted on the robotic arm.

[0113] It should be mentioned that the basic operating commands and tool-specific operating commands of the application-specific operating mode may also be optimized for specific movements or tasks that may be used by a plurality of different robotic tools. Such optimization comprises at least changing the operating values ​​of the operating parameters of the movement commands used in the (second) subset of operating parameters of the application-specific operating mode compared to the same operating parameters used in the standard operating mode. Thus, in the example of vibration suppression, a specific vibration suppression operating mode may be designed and used to optimize the movements of a multi-purpose robotic arm for stable movements of any kind of robotic tool.

[0114] Accordingly, the integrator may utilize a representative from the owner of the multi-purpose robotic arm to evaluate the end result of the work of the robotic tool and, if necessary, adjust one or more of the application operation values.

[0115] In an embodiment, only the integrator may adjust the values ​​of operating parameters defined by or used in an application-specific operating mode. The operating values ​​of operating parameters used in a standard operating mode may not be adjusted. This is because the risk of adjusting something that compromises the safety or health of the robot components is then reduced.

[0116] If adjustment of any of the operating values ​​is permitted, an allowable window of operating values ​​may be predetermined for each of the relevant operating parameters. Thus, no matter which operating value is used in any operating mode, there will preferably be an allowable window of operation of the operating parameter to ensure that at least the hard stop value is not reached. Again, this ensures that the operation complies with the required safety and load of the robot component.

[0117] The application operating mode is entered when the robot tool is in a predetermined position. This position may be the position of the robot tool when the robot tool is activated or just before the robot tool is activated. It may be the position that the robot tool reaches after being activated. This may be the case if the requirements for a particular part of the robot operating process are higher than the requirements for other parts of the robot operating process. The robot controller may know this position from information in the program code provided by the integrator or from inputs from force sensors 109, acceleration sensors 115, etc.

[0118] Furthermore, the application operating mode may also be entered when the program code has reached a specific point in the program code or is at a specific program node. Finally, it should be mentioned that during one robot operation process, the robot controller may change the operating mode between the standard mode and the application mode several times. This may be the case, for example, if a welding tool has to weld several times at different locations of an object. In this case, the application mode may be entered each time the welding tool is activated.

[0119] From the above, it should be understood that when the tool is installed, it can be said to operate in what may be referred to as a multi-purpose control scheme, which is sufficient for a whole range of tasks / tools. However, for some applications, it may not be sufficient to control the robotic tool according to a multi-purpose scheme / setup to obtain the desired or required results of the job performed by the robotic tool.

[0120] In order to solve this problem, according to the present invention, the robot tool that can be mounted on the robot tool flange is divided into several main tool groups, each of which includes several sub-tool groups, see Table 1 below. The inventors of the present invention have also defined basic operating commands whose specific operating parameters may require updated (tool) operating values, suggestions for such updated application operating values ​​and durations that allow the multi-purpose robot arm to be operated according to the application operating values. The duration should be understood as a time period that allows the multi-purpose robot arm to be operated according to the application operating values, and there may be several such "durations" in one robot operation process.

[0121] Table 1: Main tool group with sub tool groups.

[0122]

[0123]

[0124] Non-limiting examples of settings for various application specific operating modes:

[0125] Example 1

[0126]

[0127] Example 2

[0128]

[0129] Example 3

[0130]

[0131] Example 4

[0132]

[0133] Table 2 shows a non-exhaustive list of operation commands and settings for controlling a multi-purpose robot arm. Some of the listed operation values ​​are only relevant when a specific robot tool is mounted on the robot tool flange. In the Note column, some notes are mentioned to explain the type of operation value and in which tool group they are relevant. It should be noted that not all operation values ​​have notes, as some operation values ​​are self-explanatory to a skilled person.

[0134] Table 2

[0135]

[0136] A generic program code developed for a multi-purpose robotic arm may not allow, for example, a welding process to be performed with sufficient accuracy and / or precision. In this case, when installing and controlling the welding tool, this may be done in part by an application-specific program code that may be delivered from a third party delivering the welding tool. Such application-specific program code interfaces with the program code of the data packet delivered with the multi-purpose robotic arm. Thus, the multi-purpose robotic arm now operates in the scheme of a dedicated welding robot, wherein the application-specific program code is considered to be a "third layer program code" utilizing basic operating commands of a "second layer program code". However, as described above, the basic operating commands may not be sufficient to operate the welding tool, or the operating values ​​that define the allowed window of operation and thereby limit the basic operating commands may not be optimized to control the welding tool.

[0137] In such Figure 4 In the embodiment shown, the welding tool 430 is mounted on the robot tool flange 407, thereby making the multi-purpose robot arm 401 a welding robot arm. Therefore, when the welding tool 430 is activated, the welding robot enters an application-specific operating mode. Figure 4 A welding tool 430 is shown to weld objects 1 and 2 together. As mentioned, in the application-specific operation mode, at least a portion of the basic operation command is associated with the application operation value (from Figure 3 In addition, the operation mode may also include tool-specific operation commands ( Figure 3 not shown).

[0138] More specifically, in a particular embodiment, the welding robot is controlled according to a basic forward operating command, which is therefore part of both the first subset and the second subset of basic operating commands. Figure 4 When the welding tool 430 is moved to the welding start point, i.e., when the welding tool is not activated, the operating speed is lower (e.g., 0.3 m / s-0.5 m / s) than the operating speed used in the same or similar basic forward operating command used in the standard operating mode.

[0139] Another specific embodiment is to make the multi-purpose robot arm 501 a screw engagement robot arm when the thread engagement tool 531 is installed on the robot tool flange 507, see Figure 5 Operating the threading tool according to standard operating values ​​may cause a problem in that the forces and torques distributed from the threading tool to the robot joints are too high due to the inertia of the speed of accelerating and decelerating the threading tool.

[0140] Therefore, just before activating the thread engagement tool (at Figure 5 Before the tool is not activated, for example, when the thread engagement tool is positioned in front of the screw 532 and the thread engagement tool is activated (in Figure 5 The scheme changes from the standard operating mode to the application operating mode when the threaded tool is activated (in the case of a screw threading tool being activated), and thereby the basic "down" operating command that is part of both the standard operating mode and the application-specific operating mode is then controlled according to the application operating value of the allowed torque acting on the robot joint. The application operating value may have one value (e.g. 200 Nm) in the application-specific operating mode related to a screw pulling application, and may have a different value (e.g. 300) in the tool-specific operating mode related to a specific threaded engagement tool attached to the robot arm. Thus, as long as the threaded engagement tool is active, the limits of the forces and torques acting on the robot joint are adjusted to allow a higher torque than when the threaded engagement tool is not activated.

[0141] For example, Figure 1 and Figure 2The robot arm shown may be provided with a threaded engagement tool, and in an application operating mode in which the threaded engagement tool is configured to tighten a screw, the robot controller may be configured to move the robot tool joint in the tightening direction of the screw, whereby the threaded engagement tool will follow the screw during the tightening process. In addition, the robot controller may be configured to monitor the torque provided to the robot tool flange by sensing the torque using a force-torque sensor 109. In the event of a torque being sensed, the robot controller will switch the robot arm in the application operating mode to an operating mode that allows and compensates for the sensed torque. For example, by providing an application operating value that specifies an increased torque limit compared to the standard operating mode.

[0142] In general, referring to the example explanation of the threaded engagement robot, the so-called process force, i.e., the force introduced by the operation of the robot tool (from the inertia of the rotation and its start / stop) is offset by this value, and the standard operating value changes as it changes from its standard operating value to its application operating value. This means that in the threaded engagement example, when operating in both the standard operating mode and the application-specific operating mode, the threaded engagement robot will reach the soft stop threshold (also referred to as the upper limit of the allowable window of operation) due to the impact caused by the external force (e.g., due to a collision with a person) applying the same force to the threaded engagement robot. Therefore, the application operation value can be determined by the magnitude of the expected process force applied from the robot tool.

[0143] As can be clearly seen from the above, the present invention relates to a multi-purpose robot that can be operated as a specific application robot. This is obtained by adjusting the operating values ​​and thus changing the allowed window of operation of one or more operating values. During a part of the robot operation process, the change of the allowed window of operation can limit or extend the limits of the allowed operations of the multi-purpose robot arm / robot tool. The part of the operating mode in which the allowed window of operation is changed is called the specific application operating mode. One difference between the standard operating mode and the specific application operating mode is that in the latter, one or more standard operating values ​​are updated to tool specific operating values.

[0144] The operation of the multipurpose robot arm in an application specific operating mode, i.e. in which the updating of standard operating values ​​is allowed, may be allowed when the robot tool in the robot cell is within a virtually defined area. An example of this is between two specific positions of the robot tool in the robot cell. Thus, the values ​​of the operating parameters of the user adjustable limits, i.e. defining the window of operation in the application specific operating mode, are monitored by the robot controller. If for some unexpected reason these limits are not violated or no violation is recorded and the value violates the hard stop threshold of a specific or other operating parameter, the robot controller performs a hard stop of the robot arm.

[0145] Therefore, by controlling a multi-purpose robotic arm according to the present invention, the quality, accuracy, precision, speed and appearance of tasks performed by the robotic tool can be improved.

[0146] Furthermore, robot tools that could not be fully utilized before can now be fully utilized by the present invention. An example is a threaded engagement tool that exposes a multipurpose robot arm to forces acting on the robot joints when starting and stopping. This force increases with the threaded engagement speed and with the increase in the torque of the tightening screw. Therefore, in order to fully utilize the speed of, for example, the threaded engagement tool and thereby reduce the time spent in the robot operation process, the upper limit of the permissible torque operation value is increased only during the time that the threaded engagement tool is in operation.

[0147] This can be allowed without compromising safety because the threading operation is performed at a known location in the robotic cell, where increased torque can only come from the robotic tool and not from collisions with obstacles such as humans.

[0148] It should be mentioned that the new upper limit should be chosen as a compromise between the benefits obtained and the possibility that, for example, a higher torque may cause damage or wear to robot parts.

[0149] Thus, the robot arm can be operated according to at least two operating modes. In these operating modes, the robot arm is using one or more of the same basic operating commands, however, the operating values ​​defining the basic operating commands are different in the two operating modes. In the standard operating mode, the operating values ​​are standard values, while the operating values ​​used in the application operating mode allow a more flexible operation of the robot tool. Flexibility should be understood here as including more or less restricted optimization to a certain performance (faster, more accurate, etc.).

[0150] Brief Description of Figure Numbers

[0151]

[0152]

Claims

1. A multi-purpose robot arm (101), comprising a plurality of robot joints (103a-103f) connecting a robot base (105) and a robot tool flange (107) of the multi-purpose robot arm (101), the multi-purpose robot arm comprising a robot controller (102), the robot controller being configured to control the multi-purpose robot arm (101) in a standard operating mode and in an application-specific operating mode during a portion of an operating process of the robot arm, wherein the robot controller (102) is configured to control the multipurpose robot arm (101) during the robot arm operation process according to a plurality of predetermined basic operation commands, the basic operation commands being at least partially defined by one or more operation parameters, wherein the robot controller (102) is configured to control the multipurpose robot arm (101) in the standard operating mode according to a first subset of the basic operating commands during a portion of the robot arm operating process, wherein at least one operating parameter of the one or more operating parameters defining the basic operating commands of the first subset is limited by at least one standard operating value, The multi-purpose robot arm (101) is characterized by The robot controller (102) is configured to control the multipurpose robot arm (101) in the application-specific operating mode according to a second subset of the basic operating commands during a portion of the robot arm operating process, wherein the basic operating commands of the second subset are at least partially included by the first subset of basic operating commands, and wherein at least one operating parameter of the one or more operating parameters defining the basic operating commands of the second subset is limited by at least one application operating value, wherein a permitted window for operation of the multipurpose robot arm when operating according to the basic operation command defined by the standard operation value is different from the permitted window for operation of the multipurpose robot arm when operating according to the basic operation command defined by the application operation value, and wherein the application operation values ​​are defined by desired characteristics of the operation of the multipurpose robotic arm (101) in the application specific operation mode, The desired characteristic is determined by a robotic tool (430, 531) mounted on the robotic tool flange (107) to adjust an allowable window of operation for a particular operating parameter.

2. The multi-purpose robotic arm (101) according to claim 1, wherein the desired characteristic is to at least partially suppress vibration by reducing the movement speed.

3. A multipurpose robot arm (101) according to claim 1 or 2, wherein the desired characteristic is to allow increased torque by increasing the allowed upper limit of the torque acting on the robot joint.

4. The multi-purpose robot arm (101) according to claim 1 or 2, wherein the plurality of predetermined basic operation commands include at least 2 basic operation commands.

5. The multi-purpose robot arm (101) according to claim 4, wherein the plurality of predetermined basic operation commands include at least 5 basic operation commands.

6. The multi-purpose robot arm (101) according to claim 4, wherein the plurality of predetermined basic operation commands include at least 10 basic operation commands.

7. A multi-purpose robotic arm (101) according to claim 1 or 2, wherein the robot controller (102) is configured to control the multi-purpose robotic arm (101) in the standard operating mode during a first part of the operating process, control the multi-purpose robotic arm in the application-specific operating mode during a subsequent part of the robotic arm operating process, and control the multi-purpose robotic arm in the standard operating mode again during a final part of the robotic arm operating process.

8. The multi-purpose robotic arm (101) according to claim 1 or 2, wherein the robotic controller (102) is configured to control the multi-purpose robotic arm (101) in the application-specific operating mode only when the robotic tool (430, 531) is active.

9. The multi-purpose robotic arm (101) according to claim 1 or 2, wherein the robotic controller (102) is configured to activate the robotic tool (430, 531) when the robotic tool (430, 531) is in a predetermined position defined by a program code.

10. The multi-purpose robotic arm (101) according to claim 9, wherein the multi-purpose robotic arm (101) is in the application specific operating mode when the robotic controller (102) is in a predetermined position defined by the program code.

11. The multi-purpose robotic arm (101) of claim 9, wherein the robotic arm is inactive when the robotic tool (430, 531) moves to a position where the program code terminates use of the robotic tool (430, 531).

12. The multi-purpose robotic arm (101) according to claim 1 or 2, wherein the application-specific operating mode also includes tool-specific operating commands.

13. A multi-purpose robot arm (101) according to claim 1 or 2, wherein the robot controller (102) is configured to control at least one of the basic operation commands of the second subset according to an application operation value, which basic operation commands are also part of the first subset of basic operation commands.

14. The multi-purpose robotic arm (101) according to claim 1 or 2, wherein the applied operational value of the force operational parameter is determined by establishing an expected process force or an expected process torque applied from the robotic tool (430, 531).

15. The multi-purpose robotic arm (101) according to claim 1 or 2, wherein the application operating value of the force operating parameter is determined by establishing an expected process force or an expected process torque applied during the application specific operating mode.

16. A multi-purpose robot arm (101) according to claim 1 or 2, wherein the multi-purpose robot arm (101) having a robot tool (430, 531) is controlled by a first set of application operation values ​​during a first robot arm operation process, and is controlled by a second set of application operation values ​​during a second robot arm operation process.

17. A multi-purpose robot arm (101) according to claim 1 or 2, wherein the application operation value is a soft stop value, and wherein the robot controller (102) is configured to stop the operation of the multi-purpose robot when the soft stop value is exceeded.

18. The multipurpose robot arm (101) according to claim 1 or 2, wherein the application operation value is a minimum value of an operation parameter related to one selected from a list including speed, torque, force, current vibration, temperature and weight.

19. The multipurpose robot arm (101) according to claim 1 or 2, wherein the application operation value is a maximum value of an operation parameter related to one selected from a list including speed, torque, force, current vibration, temperature and weight.

20. The multi-purpose robot arm (101) according to claim 1 or 2, wherein the standard operation value and the application operation value are predetermined for a plurality of basic operation commands.

21. The multi-purpose robot arm (101) according to claim 1 or 2, wherein the standard operation value and a plurality of different application operation values ​​are predetermined for at least one basic operation command.

22. A multi-purpose robotic arm (101) according to claim 1 or 2, wherein the operating values ​​of the basic operating commands used in the application-specific operating mode are predetermined and are less restrictive than the operating values ​​of the same basic operating commands used in the standard operating mode.

23. A multi-purpose robotic arm (101) according to claim 1 or 2, wherein the operating values ​​of the basic operating commands used in the application-specific operating mode are predetermined and are more restricted than the operating values ​​of the same basic operating commands used in the standard operating mode.

24. The multipurpose robotic arm (101) according to claim 1 or 2, wherein the operating values ​​used in the standard operating mode are protected from changes.

25. The multipurpose robotic arm (101) according to claim 1 or 2, wherein the operating values ​​used in the application specific operating mode are freely variable.

26. The multipurpose robotic arm (101) according to claim 1 or 2, wherein the operating value is allowed to be adjusted within a predetermined window defined by a hard stop threshold.

27. A multi-purpose robot arm (101) according to claim 1 or 2, wherein the multi-purpose robot facilitates controlling at least two of the robot tools (430, 531) selected from a list including the following items: welding tools, processing tools, cutting tools, machine maintenance tools, assembly tools, quality tools, material tools and material addition tools.

28. The multipurpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm comprises a welding tool that facilitates welding of objects according to at least one method from the list consisting of: Tig, laser, ultrasonic, plasma, spot welding and brazing.

29. A multi-purpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm includes handling tools that facilitate handling objects according to at least one of the methods in the list including: transferring, sorting, packaging, palletizing, labeling and lifting.

30. The multipurpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm comprises a cutting tool that facilitates cutting of an object according to at least one of the methods in the list comprising: laser, water jet and plasma.

31. The multipurpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm includes machine maintenance tools that facilitate maintenance of objects according to at least one method from the list consisting of: CNC, metal casting, IMM and pressing.

32. A multi-purpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm includes assembly tools that facilitate assembling an object according to at least one method in a list including: insertion, installation, positioning, threading, nut driving, nailing, riveting, pressing, winding and cable routing.

33. A multipurpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm includes quality tools that facilitate quality inspection of objects according to at least one of the methods in the list including the following items: inspection, measurement, testing and metrology.

34. A multi-purpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm includes material tools that facilitate processing of objects according to at least one method in a list including: removing, deburring, milling, polishing, routing and drilling.

35. The multipurpose robotic arm (101) according to claim 1 or 2, wherein the robotic arm includes a material addition tool that facilitates adding material to an object according to at least one method from the list consisting of: dispensing, spraying and dipping.

36. A method of controlling a multi-purpose robotic arm (101), the multi-purpose robotic arm comprising a plurality of robotic joints connecting a robotic base (105) and a robotic tool flange (107) of the multi-purpose robotic arm (101), the multi-purpose robotic arm (101) comprising a robotic controller (102), the robotic controller controlling the multi-purpose robotic arm (101) during operation of the robotic arm according to: - a first level program code that monitors an operating value of an operating parameter during operation of the multipurpose robotic arm (101), wherein if the operating value exceeds a predetermined safety range, a first level control initiates a hard stop of the operation of the multipurpose robotic arm (101), - a second level program code for controlling basic movements of said multipurpose robot arm (101) according to basic operating commands defined by said operating parameters having standard operating values, and - a third level application code for controlling basic movements of said multipurpose robot arm (101) according to basic operating commands defined by said operating parameters with applied operating values, wherein during a first part of a robot arm operation process, the multipurpose robot arm (101) is controlled by the second level program code through a plurality of basic operation commands defined by the standard operation values, wherein during a first part of the robotic arm operating process, the multipurpose robotic arm is controlled in a standard operating mode according to a first subset of the basic operating commands defined by one or more operating parameters having standard operating values, The method is characterized in that During a second portion of the robotic arm operation process, the multipurpose robotic arm (101) is controlled by the third level application code, wherein during a second portion of the robotic arm operating process, the multipurpose robotic arm is controlled in an application specific operating mode of operation according to a second subset of the basic operating commands defined by one or more operating parameters having application operating values, wherein said third level application code is determined by desired characteristics of operation of said multi-purpose robotic arm (101) in said application specific mode of operation, wherein the desired characteristic is determined by a robotic tool (430, 531) mounted on the robotic tool flange (107) to adjust an allowable window of operation for a particular operating parameter, and Wherein during the first part and the second part of the operation process of the robotic arm, the robotic arm is also monitored by the first level program code.

37. The method of controlling a multi-purpose robotic arm (101) according to claim 36, wherein the operational values ​​of the third level application code are accessible for updating by a robot integrator.

38. A method for controlling a multi-purpose robotic arm (101) according to claim 36 or 37, wherein the operating parameters of the third-level application code are used to control the multi-purpose robotic arm (101) within a limited time period, wherein the limited time period is less than 30% of the time of the robot operation process.

39. The method of controlling a multi-purpose robotic arm (101) according to claim 38, wherein the limited time period is less than 20% of the time of the robot's operating process.

40. The method of controlling a multi-purpose robotic arm (101) according to claim 38, wherein the limited time period is less than 10% of the time of the robotic operation process.

41. A method for controlling a multi-purpose robotic arm (101) according to claim 36 or 37, wherein the method comprises the following pre-operation step: when operating the robotic arm in the application-specific operating mode, defining the value of one or more operating parameters, wherein the one or more operating parameters define a window of operation used by the robotic controller.

Images