Robotic system and method for monitoring a robotic system

Abstract

The invention relates to a method for monitoring a robot system comprising a robot arm and a peripheral device, the method comprising the steps of: providing a communication peripheral connection between the peripheral device and a robot controller; establishing an operational signal history in a digital memory, wherein the operational signal history is based on operational representations; executing a robot operation process on the robot controller; establishing a peripheral signal associated with the peripheral connection; recording the peripheral signal to obtain a peripheral signal representation; updating the operational signal history by providing the peripheral signal representation as one of the operational representations; and tracking an operation of the robot system based on the operational signal history. The invention further relates to a robot system.

Description

Technical Field

[0001] This invention relates to a robotic arm comprising multiple robotic joints connecting a robot base and a robotic tool flange, wherein a robot controller is configured to control the robotic arm in a robotic application. Additionally, this invention relates to monitoring and operating robot systems. Background Technology

[0002] Robotic arms comprising multiple robot joints and links (where motors enable movement of portions of the robotic arm relative to each other) are known in the field of robotics. Typically, a robotic arm includes: a robot base serving as a mounting base for the robotic arm; and a robot tool flange to which various tools can be attached. A robot controller is configured to control the robot joints to move the robot tool flange relative to the base. For example, to instruct the robotic arm to execute multiple work commands. The robot joints can be rotary robot joints configured to rotate portions of the robotic arm relative to each other, prismatic joints configured to translate portions of the robotic arm relative to each other, and / or any other type of robot joint configured to move portions of the robotic arm relative to each other.

[0003] Typically, robot controllers are configured to control robot joints based on a dynamic model of the robot arm, where the dynamic model defines the relationship between the forces acting on the robot arm and the resulting acceleration of the robot arm. The dynamic model typically includes a kinematic model of the robot arm, knowledge about the robot arm's inertia, and other parameters affecting the robot arm's movement. The kinematic model defines the relationships between different parts of the robot arm and can include information about the robot arm (such as the length and dimensions of joints and links), and can be described, for example, by Denavit-Hartenberg parameters. The dynamic model allows the controller to determine what torque the joint motors will provide in order to move the robot joints at a specified speed and acceleration, or to hold the robot arm in a static posture.

[0004] Typically, various end effectors can be attached to the robotic 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] Typically, robot movements can be programmed with relatively high precision. However, robots frequently interact with other objects, such as peripheral devices, to perform industrial tasks. Due to their complexity and because peripheral devices may not possess the same precision and accuracy as the robot arm of the robot system, such interactions between several components are particularly susceptible to operational errors.

[0006] Typically, robotic systems do not have human operators monitoring their operation, and therefore errors can occur at some point in production that cannot be identified. Furthermore, because robots may need to perform tasks within minute error margins, human operators may not be able to identify errors even when they are monitoring the operation.

[0007] During the operation of a robotic system, for example, if dirt or dust slowly accumulates on joints, robotic tools, peripherals, worktables, or workpieces, errors may gradually increase. These errors may be gradually introduced into the operation, making them even more difficult to detect.

[0008] Once operators realize that the robotic system has been malfunctioning, pinpointing exactly when the error occurred can be extremely challenging. Such tasks may involve, for example, carefully examining a large number of workpieces previously handled by the robotic system.

[0009] Errors are especially likely to occur after the robot system has been reprogrammed (including reprogramming the interaction between the robot arm and peripheral devices).

[0010] U.S. Patent Application 2015 / 0328774A1 discloses a method for controlling a robotic system including an articulated robot and a control device. The articulated robot includes links connected by joints, motors configured to drive the joints respectively, and detection devices configured to detect the amount of rotation of the joints respectively. The control device controls the motors. The method includes the following steps: the control device records joint movement information based on the output of the detection devices; when an abnormality in the operation of the articulated robot is detected, determining the presence or absence of a failure in the articulated robot based on movement information recorded over at least one period from before the detection of the abnormality until the detection of the abnormality; and if a failure is determined to exist in the articulated robot in this determining step, specifying the failed portion of the articulated robot. Summary of the Invention

[0011] The purpose of this invention is to address the aforementioned limitations or other problems of the prior art. This is achieved through a robotic system and a method for monitoring the robotic system. The advantages and beneficial effects of this invention are described in specific embodiments.

[0012] An aspect of the present invention relates to a method for monitoring a robotic system including a robotic arm and peripheral devices, the method comprising the following steps:

[0013] Provides a communication peripheral connection between peripheral devices and the robot controller;

[0014] An operation signal history is established in a digital memory, wherein the operation signal history is based on one or more operation representations;

[0015] The robot operation process is executed on the robot controller;

[0016] Establish peripheral signals associated with the peripheral connections, wherein the peripheral signals are associated with the steps of performing the robot operation process;

[0017] Record the peripheral signals to obtain a representation of the peripheral signals;

[0018] The operation signal history is updated by providing the peripheral signal representation as one of the one or more operation representations; and

[0019] The operation of the robot system is tracked based on the history of the operation signals.

[0020] This invention is advantageous for testing whether a robot's operation is functioning as expected. For example, if the robot's operation has been reprogrammed, the history of operation signals based on recorded peripheral signals can indicate the efficiency and outcome of the reprogrammed operation.

[0021] Some robotic systems perform repetitive tasks with minimal supervision. If an error is introduced into such a repetitive task at some point without supervision, identifying when the error was introduced at a later time is challenging. Such errors can be introduced, in particular, through interactions between the robotic arm and peripheral devices that work in sync with it.

[0022] Establishing an operational signal history (with peripheral signal representations stored thereon as operational representations) allows for the continuous recording and storage of communications between the robot controller and any peripheral devices, indicating the robot system's performance and any errors that may have occurred. Therefore, this invention advantageously allows for improved monitoring of errors that have occurred during the operation of the robot system.

[0023] Typically, peripheral signals can be simple binary signals, making them easy to record and store. Therefore, it is advantageous to focus on recording peripheral signals as this allows for the simple recording, storage, and / or analysis of the operation of the robotic system.

[0024] This invention can be further used to facilitate the recording of the operation of robot systems, which is advantageous. This can be used, for example, to record the mass of any workpiece that the robot system interacts with during its operation.

[0025] This invention can further enable predictive maintenance of robot systems, for example, by tracking changes in the history of operating signals that can indicate the deterioration of the robot arm and / or peripheral devices.

[0026] In some testing scenarios, the robot arm itself may not even need to be operated. The execution of robot manipulation procedures on the robot controller can be achieved by executing software on the robot controller to test that software. Once testing is complete, the software can be designed to operate the robot arm, but during the testing phase, the robot arm is disabled. In this context, tracking the operation of the robot system can be interpreted as tracking the simulated operation of the robot system.

[0027] Compared to conventional robotic systems and methods, this invention allows for extended tracking of peripheral devices and their operations associated with the robot-operation process. Such tracking may involve comparing data from different operational cycles. Furthermore, this invention advantageously facilitates the simulation of actual operations.

[0028] Operation signal history can be understood as one or more digitally stored data entities. Operation signal history can be stored on digital storage, for example, as one or more data files. Simple examples of data file types that can be used for operation signal history are .txt files, .csv files, and .xls files, but it should be noted that operation signal history is not limited to these examples.

[0029] The relationship between peripheral signals and the execution of robot operations can be understood as the interdependence between the peripheral signals and the robot operations. Peripheral signals may, for example, depend on the robot operations, or vice versa. For instance, a peripheral device might be a sensor that detects the position of a workpiece, and the robot arm might be positioned to move the workpiece when it is detected at a specific location. Alternatively, a peripheral device could be an indicator light that shows whether the robot arm is idle.

[0030] Updating the operation signal history can be understood as editing an existing operation signal history by adding (e.g., cascading) new peripheral signal representations and new peripheral timestamps. The update step can then, for example, result in the addition of a new subset of the operation representations from the one or more operation representations. The update step can be performed in combination with the step of establishing a digital memory. The operation signal history can, for example, be established during the first update of the operation signal history. The digital memory can, for example, be based on a local hard drive or cloud storage. Furthermore, the digital memory can receive peripheral signal representations, for example, via a communication connection with the robot controller or via a separate communication connection with a separate device recording peripheral signals, to obtain peripheral signal representations.

[0031] Tracking the operation of the robotic system can be understood as slowly or quickly replaying the history of operational signals, visualizing the history of operational signals, jumping to specific states or times as a step to optimize code / execution of the robot's operation process, or as a step in root cause analysis. The operation of the tracking robotic system can be performed partially or fully automatically on a programming device (e.g., a programming device that tracks the history of operational signals to identify deviations from expected operations). The operation of the tracking robotic system may further involve interaction with a human operator.

[0032] Performing a robot operation on a robot controller can be understood, for example, as executing robot operation software on the robot controller, such as operating a robot system controlled by the robot controller. Performing a robot operation does not necessarily involve physical manipulation of the robot arm / robot system. For example, performing a robot operation can be done to test the robot system, the robot operation process, the robot operation software, and / or the robot controller.

[0033] Generally, peripheral devices can be understood as devices located outside the robot arm that facilitate interaction with the surrounding environment, such as a workpiece or an operator. A workpiece should be understood as an object to be handled by the robot arm or robot system (e.g., to be processed, moved, packaged, painted, welded, polished, etc.). In typical implementations, peripheral devices may be, for example, conveyor belts, sensors, cameras, indicator lights or displays, valves, user input mechanisms, actuators, auxiliary robot systems / arms, etc. An example of a user input mechanism is, for example, a button activated by the operator whenever an application object is ready to be handled by the robot. In some implementations, peripheral devices are integrated into the robot controller. For example, a separate core of the robot controller is configured to perform separate processes, such as control processes, such as controlling external devices. An example of integrated peripheral devices is a state machine integrated into the robot controller. In other implementations, peripheral devices are not integrated into the robot controller.

[0034] The communication peripheral connection between the peripheral device and the robot controller can be, for example, a wired connection, or it can be a wireless connection. Such a connection can, for example, enable the robot controller to control the peripheral device, and / or the robot controller to control the robot arm, depending on the input from the peripheral device via the connection. In various embodiments of the invention, the connection can thus facilitate both unidirectional and bidirectional communication between the peripheral device and the robot controller. In some embodiments, the connection is facilitated at least in part by a programmable logic circuit (PLC). Recording of peripheral signals can be performed anywhere along the communication peripheral connection. Additionally, this can also be performed within the peripheral device and within the robot controller.

[0035] In an embodiment of the invention, the steps of performing the robot operation process are executed to operate the robot system controlled by the robot controller.

[0036] In an embodiment of the present invention, the steps of performing the robot operation process are executed to operate the peripheral device.

[0037] Performing robot operation procedures to manipulate robot arms, peripheral devices, or robot systems is advantageous because it allows tracking the physical operation of any of these devices. For example, tracking a single operation cycle or multiple operation cycles of repetitive operations.

[0038] In an embodiment of the invention, the steps of performing the robot operation process are executed to simulate the operation of the robot system controlled by the robot controller.

[0039] In an embodiment of the invention, the steps of performing the robot operation process are executed to simulate the operation of the robot arm controlled by the robot controller.

[0040] In an embodiment of the invention, the steps of performing the robot operation process are executed to simulate the operation of the peripheral device.

[0041] Performing robot operation procedures to simulate the operation of a robot arm, peripheral devices, or robot system is advantageous because it allows for the planning and adjustment of the future operation of any of these devices. In such simulations, any signal can also be simulated, such as peripheral signals.

[0042] In an embodiment of the invention, the method includes the following steps: subsequently operating the robot system controlled by the robot controller based on the steps of tracking the operation of the robot system.

[0043] By first executing the robot operation process and tracking the operation of the robot system, it is possible to evaluate the operation, for example, to approve, modify, or adjust it for future operations. Therefore, it is advantageous to operate the robot system subsequently based on the operation of the tracked robot system, which ensures improved subsequent operations.

[0044] The steps of operating the robot system based on tracking the robot system can also be understood as establishing an updated robot operation process based on the operation of the tracking robot system, and executing the updated robot operation process on the robot controller to operate the robot system.

[0045] In an embodiment of the invention, the method includes the following steps: subsequently reconfiguring either the peripheral device or the peripheral connection based on the steps of tracking the operation of the robot system.

[0046] By first executing the robot's operation process and tracking the operation of the robot system, it is possible to evaluate the operation and configuration of peripheral devices. This can then allow for the reconfiguration of peripheral devices and / or peripheral connections based on tracking to improve the system, which is advantageous. Reconfiguration can be understood, for example, as reprogramming, replacing, repositioning, repairing, reconnecting, etc.

[0047] In an embodiment of the invention, the step of tracking the operation of the robot system includes: processing the operation signal history on a programming device communicatively connected to the digital memory to track previous operations of the robot system.

[0048] Programming devices, such as computers, allow users to easily and flexibly facilitate the operation of tracking robot systems, which is advantageous. Digital memory can be an integrated part of the programming device, or it can be separated from the programming device, for example, as an external storage device or cloud storage device.

[0049] In an embodiment of the invention, the operation signal history is further based on one or more operation timestamps associated with the one or more operation representations.

[0050] The step of recording the peripheral signal further includes: obtaining a peripheral timestamp associated with the representation of the peripheral signal.

[0051] The step of updating the operation signal history further includes: updating the operation signal history by providing the peripheral timestamp as one of the one or more operation timestamps.

[0052] Operation timestamps allow users to track when an associated operation was recorded, for example. Including operation timestamps in the operation signal history is advantageous because it allows users or automates to collaborate with peripheral devices to perform more detailed tracking of the robot arm's operations. This can, for example, allow users to pinpoint the specific time an error was introduced into the robot system's operation. Timestamps also help users ultimately synchronize the operations of various time-related devices.

[0053] In an embodiment of the invention, the step of recording the peripheral signals is performed via the robot controller.

[0054] Recording peripheral signals via the robot controller advantageously minimizes the number of components required to facilitate the invention, which is advantageous. In particular, this even allows for the elimination of the need for a separate control unit, such as programmable logic circuitry for peripheral devices, which is advantageous.

[0055] Recording peripheral signals via a robot controller can be facilitated, for example, by having several internal processes within the robot controller. In such a case, one of these internal processes can be configured to interact with peripheral devices.

[0056] In an embodiment of the present invention, the robot arm includes a plurality of robot joints connecting the robot base and the robot tool flange;

[0057] The robotic joints attached to the flanges of the robotic tools allow for the attachment and manipulation of the robotic tools, which is advantageous.

[0058] In an embodiment of the invention, the robot controller is a multi-core processor, wherein the communication peripheral connection communicates with a first set of cores of the robot controller and executes any portion of the steps of the robot operation process associated with the operation of the robot arm on a second set of cores of the robot controller, wherein the first set of cores and the second set of cores are separate sets of cores.

[0059] In an embodiment of the present invention, the first set of cores and the second set of cores read and execute program instructions in parallel.

[0060] In an embodiment of the present invention, the peripheral device is controlled by the first group of cores.

[0061] Using a multi-core processor as the robot controller allows for the separation of tasks within the robot controller, which is advantageous. This can, for example, allow tasks to be executed in parallel to improve execution time and reduce interference between processes.

[0062] In an embodiment of the present invention, the method further includes the following steps:

[0063] A virtual state signal is established on the robot controller to indicate the state of the robot system and to be associated with the steps of performing the robot operation process; and

[0064] Record the virtual state signal to obtain a state signal representation;

[0065] The step of updating the operation signal history further includes: providing the status signal representation as one of the one or more operation representations.

[0066] In an embodiment of the present invention, the virtual status signal indicates whether the robotic arm is idle.

[0067] Virtual state signals indicate the state of a robot system. The operational cycle of a robot system can include various periods of robot arm movement, robot tooling use, and robot arm idleness. For example, a robot arm may be idle during a period waiting for a new workpiece to be introduced. Virtual state signals can, for example, indicate whether the robot arm is idle. The term "virtual" relates to virtual state signals, which do not necessarily have dedicated physical inputs / outputs on a user-accessible robot controller. Instead, in a typical embodiment of the invention, virtual state signals are recorded within the robot controller. They can, for example, be recorded as signals within an internal process within the robot controller.

[0068] Other examples of status signals can provide indications of what part of an operation cycle is being executed at a particular time, such as moving an object, grasping an object, moving a robotic arm without an object, or interacting with external devices such as peripherals.

[0069] Compared to analog electrical currents in robot joints, which are difficult to interpret, status signals can optionally be presented to the human operator in an easily interpretable manner, such as via Boolean signals that indicate specific operations.

[0070] Recording virtual state signals is advantageous because it allows for comparison between recorded peripheral signals and recorded virtual state signals, which in combination provides improved tracking of the robot system's operation.

[0071] In an embodiment of the present invention, the step of recording the virtual state signal further includes: obtaining an associated state timestamp, wherein the step of updating the operation signal history further includes: providing the state timestamp as one of one or more operation timestamps.

[0072] Including state timestamps as operation timestamps allows users or automated evaluations to perform more detailed tracking of the robot system's state. This can, for example, allow tracking in conjunction with recordings of peripheral signals to provide a more detailed understanding of how the robot system was operated at a given time in the past.

[0073] In an embodiment of the present invention, the method further includes the following step: truncating the operation signal history.

[0074] In an embodiment of the invention, the step of truncating the operation signal history includes: deleting a subset of the one or more operation timestamps located outside the operation truncation time window, and deleting an associated subset of the one or more operation representations.

[0075] Truncating the operation signal history can be understood, for example, as removing or deleting the oldest entry in the operation signal history. This is advantageous because it introduces a limitation on the storage space required to store the operation signal history on digital memory. This is particularly relevant for size-constrained digital memory, operation signal history with high time resolution, or operation signal history that includes data requiring large amounts of storage space (such as images or detailed records of robot arm movements / positions).

[0076] Entries or subsets of the operation signal history can be deleted, for example, based on a runtime truncation time window, such that entries or subsets outside that time window are deleted. Alternatively, the number of entries in the operation signal history may have an upper limit, and entries are deleted such that the upper limit is not exceeded. Or alternatively, there may be a maximum amount of storage available for the operation signal history, and entries are deleted such that the maximum amount is not exceeded.

[0077] In an embodiment of the invention, the step of tracking the operation of the robot system includes: providing a graphical representation of the operation signal history to a human operator of the robot system.

[0078] Graphical representations provide human operators with a quick and / or detailed overview of at least a portion of the history of operational signals. A graphical representation can be, for example, one or more graphs or data tables. It can be presented, for example, on paper, on a monitor, or via indicator lights; however, it should be noted that the invention is not limited to a particular type of representation medium. Graphical representations can also be evaluated based on data from the history of operational signals. For example, the history of operational signals can be automatically analyzed to identify various time ranges of different types of operations. These different types of operations can, for example, indicate whether the robotic arm is idle. These different types of operations can further indicate incorrect / erroneous operation of the robot system or robotic arm.

[0079] Alternatively or additionally, the graphical representation may be based on the analysis of the history of the operating signals. Therefore, the graphical representation can be an analytical representation.

[0080] In an embodiment of the present invention, the method includes the following steps: executing one or more operation cycles, wherein each of the one or more operation cycles includes the step of performing the robot operation process.

[0081] In an embodiment of the invention, the steps of the robot operation process for performing each of the one or more operation cycles are based on the same robot operation process.

[0082] An operation cycle can be understood, for example, as a task repeatedly performed by a robot. Each executed operation cycle may generally be similar, or even identical, but the invention is not limited in this respect. An operation cycle may, for example, involve a robotic arm applying its tool to a workpiece. Another operation cycle will then involve a robotic arm applying its tool to another workpiece. Each operation cycle thus involves performing a robot operation process. And the robot operation process of each operation cycle may or may not be the same robot operation process.

[0083] Recording peripheral signals during each operation cycle is advantageous because it allows for comparisons of how the robot system performs each operation cycle.

[0084] In an embodiment of the invention, each of the one or more operating cycles includes the step of establishing the peripheral signal.

[0085] In an embodiment of the invention, each of the one or more operating cycles includes the step of recording the peripheral signal.

[0086] In an embodiment of the invention, each of the one or more operation cycles includes the step of updating the operation signal history.

[0087] In an embodiment of the invention, each of the one or more operation cycles includes the step of establishing the virtual state signal.

[0088] In an embodiment of the invention, each of the one or more operation cycles includes the step of recording the virtual state signal.

[0089] Recording various data during each operation cycle is advantageous because it allows for practical comparisons of how the robotic system performs different operation cycles.

[0090] In an embodiment of the invention, the step of tracking the operation of the robot system includes: comparing the operation cycle of one of the one or more operation cycles with the operation cycle of another of the one or more operation cycles.

[0091] In an embodiment of the invention, the operational cyclic comparison is performed by a programmed device that identifies differences between the following:

[0092] A subset of the operation signal history associated with one of the one or more operation cycles; and

[0093] A subset of the history of the operation signals associated with another operation cycle in one or more of the operation cycles.

[0094] Comparing a subset of the operation signal history associated with one operation with a subset of the operation signal history associated with another operation cycle can increase the probability of identifying a bias in a subset of the subsets, which is advantageous for identifying errors.

[0095] In an embodiment of the invention, the step of tracking the operation of the robot system is performed after the step of executing one or more operation cycles.

[0096] In an embodiment of the invention, the steps for tracking the operation of the robot system are performed at least 1 hour, for example at least 2 hours, for example at least 5 hours, such as at least 10 hours, after the initial operation cycle in one or more operation cycles, wherein the initial operation cycle is the first operation cycle in time among the one or more operation cycles.

[0097] Following the execution of an operation cycle, tracking the operation of a robot system often allows for a more detailed evaluation than, for example, real-time tracking of the operation, which is advantageous.

[0098] In particular, the ability to track robotic systems for several hours allows for the identification of slow, gradual changes, which is advantageous.

[0099] Furthermore, the operation of the tracking robot system for several hours allows for comparison of the history of operational signals from several operating cycles.

[0100] In an embodiment of the invention, the step of providing the communication peripheral connection includes: providing multiple communication peripheral connections between multiple peripheral devices and the robot controller, wherein the step of establishing the peripheral signal includes: establishing multiple peripheral signals respectively associated with the multiple peripheral connections, wherein the step of recording the peripheral signal includes: recording the multiple peripheral signals to obtain multiple peripheral signal representations respectively associated with the multiple peripheral signals, wherein the step of updating the operation signal history includes: providing the multiple peripheral signal representations as a subset of the operation representations in the one or more operation representations.

[0101] Many modern robotic systems involve multiple peripheral devices. Therefore, recording the communication between the robot controller and these peripheral devices often allows for a more accurate depiction of how the robotic system operates in practice, which is advantageous. In particular, operational representations with several peripheral devices allow for tracking not only each individual peripheral device but also the interactions and interrelationships between them, which is also advantageous.

[0102] In an embodiment of the present invention, the method further includes the step of performing predictive maintenance on the robot system based on the step of tracking the operation of the robot system.

[0103] Tracking operations of robotic systems enable predictive maintenance. Predictive maintenance can be understood, for example, as monitoring the history of operational signals to predict when maintenance might be necessary or beneficial. This can be achieved, for instance, by tracking changes in the history of operational signals that indicate deterioration of the robotic arm and / or peripheral devices. This allows maintenance to be performed before any failures occur, and it is advantageous to strategically plan maintenance to minimize disruption to production.

[0104] In an embodiment of the present invention, at least one of the plurality of peripheral signal representations is a logic signal representation.

[0105] Logic signals are advantageously used in many different contexts, including for control purposes, because they are easy to interpret. Logic signals can also be understood as digital signals or binary signals.

[0106] In an embodiment of the invention, the robot controller is configured to control the movement of the robot arm by controlling the motor torque of the joint motors supplied to the robot joints of the robot arm.

[0107] This can be, for example, as part of the process of performing robot operations. The robot controller can be configured, for example, to control the movement of the robot arm based on the dynamic model of the robot arm, the direction of gravity acting on the robot arm, and / or signals from one or more joint sensors.

[0108] The robot controller's control of the robot arm's movement can be combined, for example, with other functionalities related to aspects of the present invention. For instance, the robot controller can simultaneously perform the recording of peripheral signals.

[0109] In an embodiment of the present invention, the method includes the following steps: identifying abnormal peripheral devices based on the history of the operating signals.

[0110] For example, an abnormal peripheral device can be identified by recognizing an abnormal portion of the peripheral signal associated with the peripheral connection of the abnormal peripheral device. Alternatively, an abnormal peripheral device can be identified among several peripheral devices out of a plurality of peripheral devices.

[0111] In an embodiment of the present invention, the peripheral signal indicates the status of the peripheral device.

[0112] Peripheral signals can be represented, for example, as logic / Boolean signals. Such signals are easy to interpret, which is advantageous, especially considering that robotic systems can involve complex interactions between many different components.

[0113] An aspect of the present invention relates to a robot system comprising:

[0114] ● Robotic arm, which includes multiple robotic joints connecting a robot base to a robotic tool flange;

[0115] ● Robot controller, configured to control the operation of the robot arm;

[0116] ● Peripheral devices, which are communicatively connected to the robot controller via peripheral connections; and

[0117] ● Digital memory, which includes the history of operating signals.

[0118] The operation signal history includes one or more operation representations;

[0119] The robot controller is configured to record peripheral signals associated with the peripheral connections to obtain a peripheral signal representation;

[0120] The operation signal history is arranged to receive the peripheral signal representation as one of the one or more operation representations.

[0121] The robot system according to the invention can be used, for example, to facilitate the method of the invention and thus may have the same or similar advantages.

[0122] In an embodiment of the present invention, the robot controller is a multi-core processor.

[0123] In an embodiment of the invention, the robot controller is communicatively connected to a plurality of peripheral devices via a plurality of corresponding peripheral connections, wherein the robot controller is arranged to record a plurality of peripheral signals associated with the plurality of peripheral connections respectively to obtain a plurality of peripheral signal representations associated with the plurality of peripheral signals respectively, wherein the operation signal history is arranged to receive the plurality of peripheral signal representations as a subset of operation representations among the one or more operation representations.

[0124] In an embodiment of the invention, the robot controller has at least two internal processes, wherein a first process among the at least two internal processes is configured to interact with the peripheral device, and a second process among the at least two internal processes is configured to control the robot arm.

[0125] In an embodiment of the invention, the robot controller is configured to execute the at least two internal processes.

[0126] In an embodiment of the present invention, the first process is configured to control the operation of the peripheral device.

[0127] In an embodiment of the invention, the first process of the robot controller is arranged to record the peripheral signals.

[0128] The first internal process may be executed, for example, on a first set of cores on the robot controller, and the second internal process may be executed, for example, on a second set of cores on the robot controller. The first and second sets of cores may be separate cores. The robot operation process may correspond to the second process in at least two internal processes. The first process in at least two internal processes may also be referred to as an auxiliary operation process or an auxiliary control process.

[0129] By executing multiple individual processes on the same robot controller, the setup of a robot system can be simplified. Auxiliary circuitry systems used to monitor or control peripheral devices can be expensive, require specialized expertise, occupy significant physical space, and be time-consuming to install. As suggested by embodiments of the present invention, all these disadvantages can be advantageously avoided by executing multiple individual processes on the robot controller. Furthermore, this can even accelerate the execution of operational cycles due to the reduced need for intermediate signal processing.

[0130] In an embodiment of the present invention, the peripheral device is directly communicatively connected to the robot controller via the peripheral connection.

[0131] In the context of this invention, a direct communication connection can be understood as direct communication between a peripheral device and a robot controller, i.e., communication without auxiliary circuitry such as a PLC. For example, if a peripheral device is directly communicatively connected to the robot controller, the communication connection between the peripheral device and the robot controller does not involve auxiliary circuitry such as a PLC. Attached Figure Description

[0132] Figure 1 A robotic arm according to the present invention is shown;

[0133] Figure 2 A simplified structural diagram of the robot arm and robot controller is shown.

[0134] Figure 3 An embodiment of the present invention is shown;

[0135] Figure 4 An embodiment of the present invention arranged to store operation timestamps is shown;

[0136] Figure 5 An embodiment of the invention, arranged to store state signal representations, is shown;

[0137] Figure 6 An embodiment of the present invention, arranged to store multiple peripheral signal representations, is shown;

[0138] Figure 7An embodiment of the invention arranged to allow interaction with a human operator is shown;

[0139] Figure 8 The method of the present invention having one or more operating cycles is shown; and

[0140] Figure 9 The present invention illustrates a method for simulating the operation of a robotic system. Detailed Implementation

[0141] The invention has been described with reference to exemplary embodiments intended only to illustrate the principles of the invention. Those skilled in the art will be able to find several embodiments within the scope of the claims. Furthermore, it should be understood that where embodiments include multiple identical features, only some features may be labeled with reference numerals.

[0142] Figure 1 A robot arm 101 is shown, which includes a plurality of robot joints 102a, 102b, 102c, 102d, 102e, and 102f, which connect a robot base 103 and a robot tool flange 104. The base joint 102a is configured to rotate the robot arm 101 about the base axis 105a (shown as a dashed line), as indicated by the rotation arrow 106a; the shoulder joint 102b is configured to rotate the robot arm about the shoulder axis 105b (shown as a cross indicating the axis), as indicated by the rotation arrow 106b; the elbow joint 102c is configured to rotate the robot arm about the elbow axis 105c (shown as a cross indicating the axis), as indicated by the rotation arrow 106c; the first wrist joint 102d is configured to rotate the robot arm about the first wrist axis 105d (shown as a cross indicating the axis), as indicated by the rotation arrow 106d; and the second wrist joint 102e is configured to rotate the robot arm about the second wrist axis 105e (shown as a dashed line), as indicated by the rotation arrow 106e. Robot joint 102f is a tool joint including a robot tool flange 104, which is rotatable about a tool axis 105f (shown as a dotted line), as indicated by rotation arrow 106f. Therefore, the illustrated robot arm is a six-axis robot arm with six degrees of freedom and six rotational robot joints. However, it should be noted that the invention can be provided in robot arms including fewer or more robot joints and other types of robot joints, such as prism robot joints that provide translation of portions of the robot arm, for example, linear translation.

[0143] The robot tool flange reference point (also known as TCP) 107 is indicated at the robot tool flange and defines the origin of the tool flange coordinate system, which defines the three coordinate axes x and y. 凸缘 y 凸缘 z 凸缘In the illustrated embodiment, the origin of the robot tool flange coordinate system has been placed on the tool flange axis 105f, where one axis (z) 凸缘 ) Parallel to the axis of the tool flange, and the other axis x 凸缘 y 凸缘 It is parallel to the outer surface of the robot tool flange 104. Furthermore, the base reference point 108 defines three coordinate axes x... 基座 y 基座 z 基座 The origins of the robot base coordinate system coincide. In the illustrated embodiment, the origin of the robot base coordinate system has been arranged on the base axis 105a, where one axis (z... 基座 ) is parallel to the base axis 105a, and the other axis x 基座 y 基座 Parallel to the bottom surface of the robot base. The direction of gravity 109 associated with the robot arm is also indicated by the arrow, and it should be understood that the robot arm can be positioned and oriented in any gravity-related location, limited only by the operational freedom of the robot joints.

[0144] The robotic arm includes at least one robot controller 110, which is configured to control the robotic arm 101 and may be provided as a computer including an interface device 111, enabling a user to control and program the robotic arm. The controller 110 may be provided as follows: Figure 1 The external devices shown may be devices or devices integrated into the robot arm, or combinations thereof. The interface device may be provided, for example, as a teach pendant known in the field of industrial robotics, which can communicate with the controller 110 via wired or wireless communication protocols. The interface device may include, for example, a display 112 and multiple input devices 113, such as buttons, sliders, touchpads, joysticks, trackballs, gesture recognition devices, keyboards, etc. The display may be provided as a touchscreen that functions as both a display and an input device. The interface device may also be provided as an external device configured to communicate with the robot controller 110, such as a smartphone, tablet computer, PC, laptop computer, etc.

[0145] The robot tool flange 104 includes a force-torque sensor 114 (sometimes simply referred to as a force sensor) integrated into the robot tool flange 104. The force-torque sensor 114 provides a tool flange force signal indicating the force-torque provided at the robot tool flange. In the illustrated embodiment, the force-torque sensor is integrated into the robot tool flange and configured to indicate the force and torque applied to the robot tool flange relative to a robot tool flange reference point 107. The force sensor 114 provides a force signal indicating the force provided at the tool flange. In the illustrated embodiment, the force sensor is integrated into the robot tool flange and configured to indicate the force-torque applied to the robot tool flange relative to the reference point 107 and the tool flange coordinate system. However, the force-torque sensor can indicate the force-torque 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-torque sensor is provided as a six-axis force-torque sensor, configured to indicate the force along three vertical axes and the torque around the three vertical axes. For example, the force-torque sensor can be provided as any force-torque sensor capable of indicating force and torque relative to a reference point, such as any force-torque sensor disclosed in WO2014 / 110682A1, US4763531, and US2015204742. However, it should be understood that the force sensor associated with this invention does not necessarily need to be capable of sensing torque applied to the tool sensor. It should be noted that the force-torque sensor can be provided as an external device disposed on the flange of the robot tool or omitted.

[0146] An accelerometer 115 is disposed at the robot tool joint 102f and configured to sense the acceleration of the robot tool joint 102f and / or the acceleration of the robot tool flange 104. The accelerometer 115 provides an acceleration signal indicating the acceleration of the robot tool joint 102f and / or the robot tool flange 104. In the illustrated embodiment, the accelerometer is integrated into the robot tool joint and configured to indicate the acceleration of the robot tool joint in the robot tool coordinate system. However, the accelerometer can indicate the acceleration of the robot tool joint relative to any point that can be connected to the robot tool flange coordinate system. The accelerometer can be provided as any accelerometer capable of indicating the acceleration of an object. The accelerometer can be, for example, provided as an IMU (Inertial Measurement Unit) capable of indicating both linear and rotational acceleration of an object. Note that the accelerometer can be provided as an external device disposed on the robot tool flange or omitted.

[0147] Each robot joint includes a robot joint body and an output flange capable of rotation or translation relative to the robot joint body, the output flange being directly or via an arm portion known in the art to an adjacent robot joint. The robot joint includes a joint motor configured, for example, via a drive mechanism or directly connected to a motor shaft, to rotate or translate the output flange relative to the robot joint body. The robot joint body may, for example, be formed as a joint housing, and the joint motor may be disposed within the joint housing, with the output flange extending beyond the joint housing. Additionally, the robot joint includes at least one joint sensor providing sensor signals indicating at least one of the following parameters: the angular and / or linear position of the output flange, the angular and / or linear position of the motor shaft of the joint motor, the motor current of the joint motor, or an external force and / or torque attempting to rotate the output flange or motor shaft. For example, the angular position of the output flange may be indicated by an output encoder, such as an optical encoder or a magnetic encoder, which indicates 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 input encoders such as optical encoders or magnetic encoders, which 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 in embodiments where a drive is provided allows the relationship between the input and output sides of the drive to be determined. The joint sensor can also be provided as a current sensor indicating the current through the joint motor, and thus the joint sensor is used to obtain the torque provided by the motor. For example, in conjunction with a multiphase motor, multiple current sensors can be provided to obtain the current through each phase of the multiphase motor. It should also be noted that some robot joints may include multiple output flanges capable of rotation and / or translation by joint actuators. For example, one robot joint may include a first output flange that rotates / translates a first portion of the robot arm relative to the robot joint; and a second output flange that rotates / translates a second portion of the robot arm relative to the robot joint.

[0148] The robot controller 110 is configured to control the movement of the robot arm and robot joints by controlling the motor torque provided to the joint motors based on the dynamic model of the robot arm, the direction of gravity work 109, and joint sensor signals.

[0149] Figure 2 It shows Figure 1A simplified structural diagram of the robot arm 101 is shown. Robot joints 102a, 102b, and 102f are shown in structural form, and for simplicity, robot joints 102c, 102, and 102e, and the robot links connecting the robot joints, have been omitted. Furthermore, the robot joints are shown as individual components; however, it should be understood that they are... Figure 1 The components are interconnected as shown. The robot joint includes output flanges 216a, 216b, 216f and joint motors 217a, 217b, 217f or another actuator, wherein the output flanges 216a, 216b, 216f are rotatable relative to the robot joint body. The joint motors 217a, 217b, 217f are respectively configured to rotate the output flanges 216a, 216b, 216f via output shafts 218a, 218b, 218f. It should be understood that the joint motors or joint actuators may be configured to rotate the output flanges via a transmission system such as gears (not shown). In this embodiment, the output flange 216f of tool joint 123f constitutes tool flange 104. At least one joint sensor 219a, 219b, 219f provides sensor signals 220a, 220b, 220f, 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 Joint sensor parameters can, for example, indicate attitude parameters, such as the position and orientation of the output flange relative to the robot joint body, the angular position of the output flange, the angular position of the joint motor shaft, and the motor current of the joint motor. For instance, the angular position of the output flange can be indicated by output encoders such as optical encoders or magnetic encoders, which 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 input encoders such as optical encoders or magnetic encoders, which indicate the angular position of the motor shaft relative to the robot joint. Motor current can be obtained and indicated by a current sensor.

[0150] The robot controller 110 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, and 223f to the joint motors. The motor control signals 223a, 223b, and 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，fFurthermore, the robot controller 110 is configured to determine the motor torque based on a dynamic model of the robot arm as known in the prior art. The dynamic model allows the controller 110 to calculate which torque the joint motors should provide to each of the joint motors to enable the robot arm to perform the desired movement. The dynamic model of the robot arm can be stored in memory 221 and can be based on joint sensor parameters J. 传感器 , a, J 传感器，b J 传感器，f Adjustment can be achieved by adjusting the motor torque provided by the joint motor, for example, by adjusting the current through the phase of the multiphase electric motor, as is known in the field of motor adjustment.

[0151] Robotic tool joint 102f includes a force sensor 114 that provides a tool flange force signal 224, which indicates the force-torque FT provided to the tool flange. 凸缘 For example, force signal - torque FT 凸缘 It can be indicated as a force vector in the robot tool flange coordinate system. and torque vector

[0152] Equation 1

[0153] in It is along x 凸缘 The indicating force of the shaft, It is along y 凸缘 The axis indicates the force, and It is along z 凸缘 The indicating force of the shaft.

[0154] In embodiments where the force sensor is provided as a combined force-torque sensor, the force-torque sensor may also additionally provide a torque signal indicating the torque applied to the tool flange, for example, as a separate signal (not shown) or as part of a force signal. The torque can be indicated as a torque vector in the robot tool flange coordinate system:

[0155] Equation 2

[0156] in It revolves around x 凸缘 The shaft's indicated torque, It revolves around y 凸缘 The shaft's indicated torque, and It revolves around z 凸缘 The indicated torque of the shaft.

[0157] The robot tool joint 102f includes an accelerometer 115 that provides an acceleration signal 225 indicating the acceleration of the robot tool flange, wherein the acceleration can be indicated relative to the tool flange coordinate system.

[0158]

[0159] in It is along x 凸缘 The sensing acceleration of the shaft, It is along y 凸缘 The shaft's sensing acceleration, and It is along z 凸缘 Sensing acceleration of the shaft.

[0160] In embodiments where the accelerometer sensor is provided as a combined accelerometer / gyroscope (e.g., IMU), the accelerometer sensor may additionally provide an angular acceleration signal indicating the angular acceleration of the output flange relative to the robot tool flange coordinate system, for example, as a separate signal (not shown) or as part of an acceleration signal. The angular acceleration signal can indicate the acceleration vector in the robot tool flange coordinate system.

[0161] Equation 3

[0162] in It revolves around x 凸缘 Angular acceleration of the axis, It revolves around y 凸缘 The angular acceleration of the axis, and It revolves around z 凸缘 Angular acceleration of the axis.

[0163] The force sensor and acceleration sensor in the illustrated embodiment are arranged at the robot tool joint 102f; however, it should be understood that the force sensor and acceleration sensor can be arranged at any part of the robot arm.

[0164] Figure 1 and Figure 2 The robotic arm shown can be used, for example, in a robotic system (e.g., a robotic system according to the invention).

[0165] In an exemplary embodiment of the invention, the robot system includes two peripheral devices: an object sensor and a conveyor belt. A robot tool is attached to a robot tool flange and arranged to perform welding on an application object. The object sensor is arranged to detect the presence of an application object at the welding position. An auxiliary control process receives application input signals from the object sensor and the robot control process, and establishes logic signals accordingly. Furthermore, the auxiliary control process provides logic output signals to the conveyor belt and the robot control process based on the logic signals. When no application object is present at the welding position, the auxiliary control process is arranged to start the conveyor belt via the logic output signals. Then, when the object sensor detects an object at the welding position, the auxiliary control process stops the conveyor belt and initiates movement of the robot arm and welding via the logic output signals to the robot control process. When welding, as controlled by the robot control process, has been completed, movement of the conveyor belt is initiated based on the application input signals from the robot control process. From here, the robot system is ready to receive new application objects via the conveyor belt to repeat the welding process explained above. In this implementation, the robot controller records peripheral signals on the communication peripheral connections between the robot controller and each of the peripheral devices, and updates the operation signal history accordingly, thereby enabling the tracking robot system.

[0166] Figure 3 An embodiment of the invention is illustrated. Robot system 100 includes a robot arm 101 controlled by a robot controller 110. In addition to the description of the robot arm's motion illustrated above, the robot controller is further communicatively connected to a peripheral device 336 via a peripheral connection 352. This connection can be used, for example, to perform control of the peripheral device 336 via the robot controller 110, or it can be used as an input to the robot controller 110, causing the robot controller to operate based on that input. In some embodiments of the invention, the peripheral connection 352 is a bidirectional communication connection, for example, such that the peripheral device 336 is controlled by the robot controller 110 based on an input, and that the robot controller 110 controls the robot arm 101 based on an input from the peripheral device 110. Any communication signals on the peripheral connection 352, such as signals arranged to perform control, can be understood as peripheral signals.

[0167] The robot system is further associated with a digital memory 354 (e.g., a hard disk-based digital memory or cloud storage), which is communicatively connected to the robot controller 110. The digital memory 354 has an operation signal history 353 stored thereon. The operation signal history is based on operation representations 355; that is, it includes a list of operation representations 355.

[0168] The robot system 100 is configured to operate based on robot operation processes executed on a robot controller. The robot operation process can be, for example, a program, software, or code, which the robot controller 110 can read / process and thereby communicate with the robot arm and / or peripheral devices, such as to operate any of these devices.

[0169] After the robot operation process is executed on the robot controller 110, the robot system 100 is configured to record the peripheral signals of the peripheral connection 352 to obtain a peripheral signal representation 357. This can be done, for example, by simply measuring the voltage of the peripheral connection 352. This can also be facilitated by the robot controller 110, for example, by causing the robot controller to provide the peripheral signal representation 357 as an output, such as as an output to a programming device or directly to a digital memory 354.

[0170] Peripheral signal representation 357 is added to the operation signal history 353 as operation representation 355, for example, to expand the number of existing operation representations 355.

[0171] Since the peripheral signal representation 357 has been added as the operation representation 355 to the operation signal history 353, users or automated evaluations can monitor and assess the operation of the robot system 100, especially its interaction with the peripheral device 336.

[0172] In a typical embodiment of the invention, peripheral signals are represented, for example, by storing them continuously at a specific frequency such as 1 Hz, 1 kHz, or the clock frequency of the robot system, or at key points during the operation cycle.

[0173] Figure 4 An embodiment of the invention is shown, which is arranged to store an operation timestamp 456.

[0174] This implementation plan has the same characteristics as Figure 3 The implementation shown has a similar structure. However, Figure 4 The illustrated implementation is further arranged to store a peripheral timestamp 458. In addition to being based on the operation representation 355, the operation signal history 353 is further based on the operation timestamp 456. The operation timestamp 456 may, for example, be associated with the operation representation 355. Therefore, the operation timestamp 456 may, for example, be a data entity that enables precise location of the time when the associated operation representation 355 was recorded / stored.

[0175] When recording peripheral signals to obtain peripheral signal representation 357, the system is configured to establish a peripheral timestamp 458 associated with that peripheral signal representation 357. This value of the peripheral timestamp 458 may be provided, for example, by the robot controller 110, or from another time source such as an external time source.

[0176] Then, the outer timestamp 458 is added as the operation timestamp 456 to the operation signal history 353.

[0177] By storing peripheral signal representation 357 as operation representation 355 and peripheral timestamp 458 as operation timestamp 456, a user or automated evaluation can perform a more detailed assessment of the robot system's operation. In particular, the timeline of the operation and possible events, such as the introduction of errors into the operation, can be reconstructed.

[0178] In some embodiments of the invention, the value of each record of the peripheral signal representation 357 has an associated peripheral timestamp 458, while in other embodiments, only a subset of the values ​​of the records of the peripheral signal representation 357 have an associated peripheral timestamp 458.

[0179] In some implementations, users and / or automated evaluation systems will be able to infer the timing of recorded peripheral signal representations / operational representations without operation timestamps. For example, if peripheral signal representations are recorded and stored at a specific frequency, knowledge of that frequency can be used to calculate how much time has elapsed since a given operation representation was stored.

[0180] Figure 5 An embodiment of the invention is shown, which is arranged to store a state signal representation 560.

[0181] This implementation plan has the same characteristics as Figure 4 The implementation shown has a similar structure. However, Figure 5 The embodiment shown is further arranged to store state signal representations 560 and state timestamps from internal robot controller processes 564a, 564b originating from robot controller 110.

[0182] In this embodiment, the robot controller 110 has at least two internal processes 564a and 564b that are communicatively connected within the robot controller 110. The robot controller 110 may be, for example, a multi-core processor, and the internal processes 564a and 564b may be processes that execute on a single core or a group of cores of the multi-core processor, respectively. Figure 5 In an exemplary implementation, a group of cores facilitates an internal process 564a for controlling the robotic arm 101, and a group of cores facilitates an internal process 564b for interacting with the peripheral device 336. Any such communication in these separate processes 564a, 564b is facilitated by a signal that may be referred to as a virtual state signal, which may, for example, indicate the state of the robotic arm 101, the peripheral device 336, the group of peripheral devices, and / or the robotic system 100.

[0183] The robot controller 110 is arranged to record virtual state signals to provide a state signal representation 560. It is further arranged to provide a state timestamp 561 associated with the state signal representation 560. The system is then arranged to provide the state signal representation 560 as an operation representation 355 of the operation signal history 353, and to provide the state timestamp 561 as an operation timestamp 456 of the operation signal history 353.

[0184] This allows for the monitoring of improvements to the robot system 100, as the recorded peripheral signal representation 357 can be analyzed together with the status signal representation 560, since both are stored in the operation signal history 353. Such additional details allow for the reconstruction of improvements to past operations of the robot system.

[0185] In some embodiments of the invention, the state signal representation 560 and the operation representation 355 are stored, but the operation timestamp 456 and the state timestamp 561 are not stored. In some other embodiments of the invention, the state signal representation 560 and the operation representation 355 are stored, while one of the operation timestamp 456 or the state timestamp 561 is also stored. For example, the state signal representation 560 and the operation representation 355 are recorded and stored at least partially synchronously, such that storing only one type of timestamp is sufficient to backtrack the timing of either the state signal representation 560 or the operation representation 355.

[0186] In some other embodiments of the invention, the robot system may be associated with a state machine or state device, on which different states of the robot system are associated. During robot operation, the robot may cycle through different states of the state machine. Similar operation cycles may typically cycle through similar states of the state machine. The states cycled through by the robot system may be saved as operation representations in the operation signal history.

[0187] Figure 6 An embodiment of the present invention is shown, arranged to store multiple peripheral signal representations 357a, 357b. This embodiment has the same characteristics as... Figure 3 The implementation shown has a similar structure. However, Figure 6 The embodiment shown is characterized by multiple peripheral devices, namely two peripheral devices 336a and 336b. Each of the peripheral devices 336a and 336b is connected to the robot controller 110 via a communication peripheral connection 352a, 352b having peripheral signals.

[0188] These two peripheral devices could be, for example, a sensor and a conveyor belt.

[0189] Other implementations may have at least three peripheral devices, such as at least four peripheral devices, such as at least five peripheral devices, such as six or more peripheral devices.

[0190] The robot system 100 is configured to record the peripheral signals of both peripheral connections 352a and 352b to obtain peripheral signal representations 357a and 357b for each of the peripheral connections 352a and 352b. These individual peripheral signal representations 357a and 357b are then provided as operation representations 355 to the operation signal history 353.

[0191] The two peripheral signals 357a and 357b can be recorded and provided to the operation signal history during synchronization, or the recording and provision of the two signals 357a and 357b can be desynchronized.

[0192] Storing data from multiple communication lines to peripheral devices 336a and 336b provides users or automates with a more detailed understanding of the robot system's operation. For example, it provides a more detailed understanding of the complex interactions between the robotic arm and multiple peripheral devices 336a and 336b.

[0193] Figure 7 An embodiment of the invention arranged to allow interaction with a human operator 763 is shown. This embodiment has... Figure 3 The implementation shown has a similar structure. However, in Figure 7 In the embodiment shown, both the robot controller 110 and the digital memory 354 are communicatively connected to a programming device 762 that enables interaction with a human operator 763.

[0194] The programming device 762 has access to the operation signal history 353. Therefore, the operation signal history 353 can be evaluated and / or displayed on the programming device 762, such as an operation representation 355 of the operation signal history 353. The programming device can, for example, be arranged to perform automated evaluation of the operation signal history 753.

[0195] Operation signal history 353, a visual representation of the operation signal history, an evaluated version of the operation signal history, or the output of the evaluation of the operation signal history can be provided to the human operator 763 via programming device 762. This allows the human operator 763 to evaluate the operation of robot system 100. This further allows the human operator to interact with the operation of the robot system via a communication connection between programming device 762 and robot controller 110. This may, for example, allow the human operator to stop or pause operation. This may further allow the human operator to reconfigure peripheral device 336 or its connection 352. This may even allow the human operator to update the robot operation process (based on which the robot system operates) based on tracking the operation of the robot system, for example, to subsequently execute an updated robot operation process. This may additionally allow the human operator to identify whether any errors or inaccuracies have occurred during previous operations of the robot system.

[0196] In some embodiments, the operation of the tracking robot system 100 (including interaction with a human operator 763) is performed concurrently with the operation of the robot system. The history of operational signals can be continuously updated, for example, by providing peripheral signal representations. This allows the human operator to track the robot system during its operation. In other embodiments, the operation of the tracking robot system 100 (including interaction with a human operator 763) is performed to track previous operations of the robot system 100, such as previous operational cycles. For example, tracking whether errors have occurred within some past intervals, such as the past 8 hours.

[0197] Figure 8 A method for tracking and manipulating a robot system according to an embodiment of the present invention is shown. The method comprises several steps and is based on one or more operating cycles 859. Other steps may be manual steps involving the handling of the robot arm or peripheral devices.

[0198] Sometimes robotic systems and robotic arms are used to perform tasks / operations that are at least somewhat repetitive. Each repetition of a repetitive task may be referred to as operation cycle 859. In the illustrated embodiment, four method steps M3 to M6 are part of operation cycle 859.

[0199] In the first step of method M1, a communication peripheral connection is provided between peripheral device 336 and robot controller 110. This connection may be provided / established, for example, during the installation of robot system 100 or during the integration of peripheral device 336 at a later stage.

[0200] In the next step of method M2, an operation signal history 353 is established in digital memory 354. The operation signal history 353 is based on one or more operation representations 355. The operation signal history 353 can typically be established before operating the robot, for example, by performing a robot operation procedure. However, in some embodiments of the invention, the operation signal history 353 is established when the peripheral signal representation 457 is first stored as an operation representation 355. The operation signal history 353 can be established automatically or manually in digital memory 354.

[0201] In the next step of method M3, a robot operation process is executed on the robot controller. This execution may be, for example, to enable the operation of the robot system (e.g., robot arm 101 and / or one or more peripheral devices 336). The robot operation process may include separate internal processes on the robot controller, such as a process responsible for controlling the robot arm, and another process responsible for communicating with any peripheral devices 336. Such separate processes may typically communicate internally, for example, using virtual state signals. The execution of the robot operation process may also be performed to test or simulate the operation of the robot system without having to physically operate / move the robot arm 101. Such testing / simulation may, for example, show whether the software works as expected. Such software may, for example, be the software on which the robot operation process is based.

[0202] In the next step M4, a peripheral signal is established within peripheral connection 352. In a sense related to the robot's operation process, the establishment of this peripheral signal is associated with the steps of executing the robot's operation process. This signal may, for example, change during the robot's operation process, or the robot's operation process may depend on the peripheral signal as input.

[0203] In the next step M5, the peripheral signals are recorded to obtain a peripheral signal representation 357. This representation can be, for example, analog or digital, and can be recorded inside or outside the robot controller.

[0204] In the next step M6, the operation signal history 353 is updated by providing a peripheral signal representation 357 as an operation representation 355. The peripheral signal representation 357 can be transmitted to the digital memory 354 via a wired connection, wirelessly, or a combination of wired and wireless connections.

[0205] In this exemplary embodiment, the operation loop 859 includes the following steps: performing robot operation procedure M3, establishing peripheral signals M4, recording peripheral signals M5, and updating the operation signal history M6. Once these steps have been performed, the robot system enabling this method can repeat these steps, for example, to perform robot operation procedure M3 again, establish peripheral signals M4, etc. Such repetition can be highly similar to any previously performed operation loop 859. Furthermore, the operation loop can be repeated an arbitrary number of times. Whenever the operation signal history is updated, more data indicating the operation of the robot system is added to the operation signal history. Therefore, by combining the repeated operation of the robot system with system data acquisition and storage, small changes in operation representation data can be tracked. Such changes can indicate errors or indicate the need for maintenance.

[0206] Each operation may or may not include the same method steps as the previous operation. In other embodiments, the operation may include fewer or more steps.

[0207] In the next step, M7, the operation of the robot system is tracked based on the history of operating signals. This step can be performed, for example, by providing a visual representation of the history of operating signals to a human operator associated with the robot system. This step can also be based, for example, on an automated evaluation of the history of operating signals. Such automated evaluation can be performed, for example, by a programmed device. The automated evaluation can, for example, compare the operational representations of different operating cycles and / or process data to identify deviations or trends in the data. Step M7 of tracking the operation of the robot system can also be performed, for example, in conjunction with the automated evaluation as part of an operating cycle, enabling continuous tracking and monitoring of the robot system's operation.

[0208] Figure 9 The present invention illustrates a method for simulating the operation of a robot system 100. Such simulation can be facilitated, for example, by a robot controller 110, i.e., by performing robot operation procedures on the robot controller 110. The simulation can be performed using physical equipment such as the robot controller 110, a connection 352 to a peripheral device 336, etc., but may not necessarily include the mobile robot arm 101.

[0209] In the first step M1, a communication peripheral connection 352 is provided between the peripheral device 336 and the robot controller 110.

[0210] In the next step M2, an operation signal history 353 is established in the digital memory 354. The operation signal history 353 includes one or more digitally stored operation representations 355.

[0211] In the next step M3, the robot operation process is executed on the robot controller 110. This may, for example, execute software configured to operate the robot arm while disabling its movement. This may further result in communication with peripheral devices 336 (including modified peripheral signals).

[0212] In the next step M4, an external signal is established within the external connection 352.

[0213] In the next step M5, the peripheral signals are recorded to obtain peripheral signal representation 357.

[0214] In the next step M6, the operation signal history 353 is updated by providing the peripheral signal representation 357 as the operation representation 355.

[0215] In the next step, M7, the operation of the robot system is tracked based on the history of operating signals. This tracking can, for example, allow the operator to assess whether the robot's operation and / or peripheral devices are functioning as expected.

[0216] In the next step M8, the robot system is subsequently operated based on the previous tracking of the operation of the robot system 100. Step M7, which tracks the operation of the robot system, has already allowed the operator to evaluate the operation of the robot system. If any errors or suboptimal executions are identified, the tracking can then allow the operator to update the robot operation procedures or change / reconfigure peripheral devices or their connections. If no errors or suboptimal executions are identified, the robot operator can continue to subsequently operate the robot system by executing the tracked robot operation procedures, thus now knowing that the robot operation procedures are working as expected.

[0217] Therefore, according to the information Figure 8 and Figure 9 The described examples of the use of the robot system of the present invention allow users of the robot system to, for example, step through previous executions of one or more robot operation processes, or replay previous executions. Furthermore, in various embodiments, it is possible to jump to a specific section of the control software and begin execution / replay from that specific section. Users can do this, for example, via the display of an interface device. This can, for example, allow for optimization, troubleshooting, and predictive maintenance.

[0218] It should be noted that, generally speaking, any method step in the method steps of this invention can be executed automatically, for example, via a computer or processor (such as a robot controller). For example, the method includes the step of recording peripheral signals. The step of tracking the operation of the robot system may or may not be at least partially automated.

[0219] As can now be clearly seen from the foregoing, the present invention relates to a robot system and a method for monitoring the robot system. By connecting to a peripheral connection between the robot controller and peripheral devices, peripheral signals can be recorded, and the representation of these signals can be used to update the operational signal history. The stored operational signal history can be advantageously used by automated evaluation systems or human operators to provide an understanding of the robot system's operation, to locate errors, or to optimize operation.

[0220] The invention has been illustrated above with reference to specific examples of methods and robotic systems for illustrative purposes rather than limiting them. Specific details such as methods and system structures have been provided to help understand embodiments of the invention; it is understood that embodiments disclosed in different figures and corresponding descriptions can be combined in any manner. It should be noted that detailed descriptions of well-known systems, devices, circuits, and methods have been omitted so as not to obscure the description of the invention with unnecessary detail. It should be understood that the invention is not limited to the specific examples described above, and those skilled in the art can implement the invention in other embodiments without these specific details. Therefore, the invention can be designed and modified in various variations within the scope of the invention as specified in the claims.

[0221] Brief description of the icon numbers

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Claims

1. A method for monitoring a robotic system (100) including a robotic arm (101) and peripheral devices (336), the robotic arm (101) being controlled by a robot controller (110), the method comprising the steps of: A communication peripheral connection (352) is provided between the peripheral device (336) and the robot controller (110); An operation signal history (353) is established in a digital memory (354), wherein the operation signal history (353) is based on one or more operation representations (355); The robot operation process that executes one or more operation cycles on the robot controller (110); Establish a peripheral signal associated with the peripheral connection (352), wherein the peripheral signal is associated with the step of performing the robot operation process; The robot controller (110) records the peripheral signals to obtain a peripheral signal representation (357); The operation signal history (353) is updated by providing the peripheral signal representation (357) as one of the one or more operation representations (355); and The operation of the robot system (100) is tracked based on the operation signal history (353). The tracking operation of the robot system (100) is performed at least 1 hour after the initial operation cycle, allowing comparison of operation signal history from different operation cycles in the one or more operation cycles.

2. The method according to claim 1, wherein the method comprises the following steps: The robot system (100) is subsequently operated by the robot controller (110) based on the steps of tracking the operation of the robot system (100).

3. The method according to claim 1 or 2, wherein the method comprises the following steps: The steps based on the operation of the tracking robot system (100) are used to subsequently reconfigure either the peripheral device (336) or the peripheral connection (352).

4. The method according to claim 1 or 2, wherein the operation signal history (353) is further based on one or more operation timestamps (456) associated with the one or more operation representations (355). The step of recording the peripheral signal further includes: Obtain the peripheral timestamp (458) associated with the peripheral signal representation. The step of updating the operation signal history (353) further includes updating the operation signal history (353) by providing the peripheral timestamp (458) as one of the one or more operation timestamps (456).

5. The method according to claim 1 or 2, wherein the method further comprises the following steps: A virtual state signal is established on the robot controller (110) to indicate the state of the robot system (100) and to be associated with the steps of performing the robot operation process; and Record the virtual state signal to obtain a state signal representation (560); The step of updating the operation signal history (353) further includes: providing the status signal representation (560) as one of the one or more operation representations (355).

6. The method of claim 5, wherein the step of recording the virtual state signal further comprises: Obtaining the associated state timestamp (561), wherein the step of updating the operation signal history (353) further includes: providing the state timestamp (561) as one of one or more operation timestamps (456).

7. The method according to claim 1 or 2, wherein the step of tracking the operation of the robot system (100) comprises: A graphical representation of the operation signal history (353) is provided to the human operator (763) of the robot system (100).

8. The method according to claim 1 or 2, wherein the step of tracking the operation of the robot system (100) comprises: The operation loops of the first operation loop in the one or more operation loops (859) are compared with those of the second operation loop in the one or more operation loops (859).

9. The method of claim 8, wherein the cyclic comparison of operations is performed using a programming device (762) to identify differences between: A subset of the operation signal history (353) associated with the first operation cycle in one or more operation cycles (859); and A subset of the operation signal history (353) associated with the second operation cycle in one or more operation cycles (859).

10. The method according to claim 1 or 2, wherein the step of providing the communication peripheral connection comprises: Multiple communication peripheral connections (352a, 352b) are provided between multiple peripheral devices (336a, 336b) and the robot controller (110), wherein the step of establishing the peripheral signals includes: establishing multiple peripheral signals respectively associated with the multiple peripheral connections (352a, 352b), wherein the step of recording the peripheral signals includes: recording the multiple peripheral signals to obtain multiple peripheral signal representations (357a, 357b) respectively associated with the multiple peripheral signals, wherein the step of updating the operation signal history (353) includes: providing the multiple peripheral signal representations (357a, 357b) as a subset of the operation representations in one or more operation representations (355).

11. The method according to claim 1 or 2, wherein the method further comprises the following steps: Predictive maintenance of the robot system (100) is performed based on the steps of tracking the operation of the robot system (100).

12. The method according to claim 1 or 2, wherein the step of performing the robot operation process is performed to operate the peripheral device.

13. A robot system (100), the robot system comprising: ● Robot arm (101), the robot arm including a plurality of robot joints (102a to 102f), the plurality of robot joints connecting a robot base (103) and a robot tool flange (104); ● Robot controller (110), which is configured to perform one or more operating cycles and thereby control the operation of the robot arm (101); ● Peripheral devices (336), which are communicatively directly connected to the robot controller (110) via peripheral connections (352); and ● Digital memory (354), the digital memory including operation signal history (353), The operation signal history (353) includes one or more operation representations (355); The robot controller (110) is arranged to record peripheral signals associated with the peripheral connection (352) to obtain a peripheral signal representation (357); The operation signal history (353) is configured to receive the peripheral signal representation (357) as one of the one or more operation representations (355). The robot controller is configured to perform tracking operations of the robot system (100) based on the operation signal history (353), and The tracking operation of the robot system (100) is performed at least 1 hour after the initial operation cycle, allowing comparison of operation signal history from different operation cycles in the one or more operation cycles.

14. The robot system of claim 13, wherein the robot controller has at least two internal processes, wherein a first process among the at least two internal processes is configured to interact with the peripheral device, and a second process among the at least two internal processes is configured to control the robot arm.

15. The robot system of any one of claims 13 to 14, wherein the robot controller is communicatively connected to a plurality of peripheral devices via a plurality of respective peripheral connections, wherein the robot controller is arranged to record a plurality of peripheral signals associated with the plurality of peripheral connections to obtain a plurality of peripheral signal representations associated with the plurality of peripheral signals, wherein the operation signal history is arranged to receive the plurality of peripheral signal representations as a subset of the operation representations in the one or more operation representations.

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