Method for monitoring data of interchangeable arm end tool of robot and monitoring system

Abstract

The invention relates to a method and a monitoring system for monitoring data of interchangeable arm end tools of a robot. Each arm end tool is assigned a unique identifier maintained in a database. At each facility where the robot is installed, a data collection device communicates with all the controllers and provides centralized storage and monitoring of use and maintenance data for each arm end tool. The controller downloads current data of the arm end tool from the data collection device whenever the arm end tool is attached to the robot. Likewise, the controller uploads updated data of the arm end tool to the data collection device whenever the arm end tool is detached from the robot. The data collection device maintains cumulative usage data for each arm end-of-arm tool, provides a user interface for the data to allow monitoring by a person, and sends notifications of important maintenance requirements to be handled and any performance issues. The data is also stored on a cloud server for global access.

Description

Technical Field

[0001] The present disclosure relates generally to the field of industrial robots and end-of-arm tooling (EOAT), and more particularly to methods and systems for monitoring usage and maintenance data of robotic end-of-arm tooling that are interchangeable between different robots, the methods and systems comprising assigning a unique identifier to each EOAT and transmitting the EOAT usage and maintenance data from a controller for the robot to a data collection device for centralized management of the data. Background Art

[0002] The widespread use of industrial robots to perform manufacturing, machining, assembly, and material movement operations is well known. Most operations performed by industrial robots involve the use of end-of-arm tooling, such as grippers for grasping and moving parts from one position or orientation to another, material removal tools such as drills or milling cutters, or welding lasers or torches. Each end-of-arm tooling comes in a variety of different types; for example, a gripper can take the form of a suction cup gripper, a mechanical finger gripper, or a servo-controlled gripper.

[0003] Like any other type of mechanical component, end-of-arm tooling is subject to wear and tear, which can eventually lead to decreased performance and / or complete failure. These end-of-arm tools also require regular maintenance to ensure optimal performance and longevity. For these reasons, it's common practice to track end-of-arm tool usage data—including the amount of service time, the number of operating cycles performed, and more.

[0004] It's also common for end-of-arm tooling to be interchangeable between different robots. That is, a particular gripper might be used on one robot for a period of time, removed when the first robot is configured to perform a different task, and then attached to a second robot on the same production line or in the same factory as the first. Because each robot has its own controller, only a single controller monitors usage data for the specific end-of-arm tooling attached to that robot. This makes monitoring usage data for interchangeable end-of-arm tooling across multiple robots manual, if performed at all.

[0005] In view of the foregoing, there is a need for robotic end-of-arm tooling monitoring technology that tracks usage and maintenance data for individual end-of-arm tooling that can be used interchangeably across different robots. Summary of the Invention

[0006] According to the teachings of the present disclosure, a method and system for monitoring the use of robotic end-of-arm tooling that is interchangeable across multiple robots is described and illustrated. Each end-of-arm tool is assigned a unique identifier that is maintained in a database. At each plant or facility where a robot is installed, a data collection device communicates with all controllers within the facility. The data collection device provides centralized collection and monitoring of usage and maintenance data for each end-of-arm tool. Whenever an end-of-arm tool is attached to a robot, the controller downloads the current data for the particular end-of-arm tool from the data collection device. Similarly, whenever an end-of-arm tool is detached from a robot, the controller uploads updated data for the end-of-arm tool to the data collection device. The data collection device maintains cumulative usage data for each end-of-arm tool, provides a user interface for the data to allow plant maintenance personnel to monitor it, and sends notifications of important pending maintenance requirements and any logged performance issues. Data from the data collection device is also stored on a cloud server for global access. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is an illustration of an industrial robot and controller, wherein the robot is equipped with a mechanical gripper-type end-of-arm tool as known in the art;

[0008] Figure 2 is an illustration of an industrial robot equipped with a welder end-of-arm tool as known in the art;

[0009] Figure 3 is a block diagram illustration of a system for monitoring usage and maintenance data of interchangeable robotic end-of-arm tooling according to an embodiment of the present disclosure; and

[0010] Figure 4 is a flow chart of a method for monitoring usage and maintenance data of interchangeable robotic end-of-arm tooling according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0011] The following discussion of embodiments of the present disclosure directed to data monitoring of interchangeable robotic end-of-arm tooling is merely exemplary in nature and is in no way intended to limit the disclosed apparatus and techniques or their applications or uses.

[0012] It is well known to use industrial robots for various manufacturing, assembly and material movement operations. Many operations performed by industrial robots involve the use of end-of-arm tools such as grippers, drills, caulking guns, welding lasers or torches, etc.

[0013] Figure 11 is a diagram of an industrial robot and a controller, wherein the robot is equipped with a mechanical gripper-type end-of-arm tool as known in the art. The robot 100 is controlled by a controller 110 to perform operations as known in the art. The controller 110 communicates with the robot 100 via a cable 112. Figure 1 In the present invention, a robot 100 is equipped with a mechanical finger-type gripper 120. The mechanical finger-type gripper is used to grasp a part or workpiece 130 from an initial position and posture (such as on a conveyor belt) and place the workpiece 130 at a target position and posture (such as in a shipping container). The gripper 120 is an example of an end-of-arm tool. In addition to controlling the movement of the robot arm, the controller 110 controls the clamping and unclamping operations of the gripper 120 and monitors and records data related to the gripper 120, such as the number of clamping / unclamping cycles and the clamping / unclamping response time.

[0014] Figure 2 is an illustration of an industrial robot equipped with a welder end-of-arm tooling known in the art. Robot 200 communicates with and is controlled by controller 210 in the manner described above. The end-of-arm tooling on robot 200 is a welding torch 220. Welding torch 220 is another example of an end-of-arm tooling. In addition to controlling the movement of robot 200, controller 210 controls the operation of welding torch 220 (activation and deactivation, and the energy level at which it is activated) and monitors and records data regarding welding torch 220, such as the cumulative amount of time that welding torch 220 has been activated.

[0015] supply Figure 1 and Figure 2 These examples of end-of-arm tooling are provided for illustration purposes only; various other types of end-of-arm tooling exist, as described above. Many of these end-of-arm tooling types are interchangeable between robots. That is, a particular end-of-arm tooling type can be installed on one robot for a period of time, removed from that robot, and then installed on a different robot.

[0016] As described above, the controller controls the operation of the end-of-arm tooling and also records data about the usage of the end-of-arm tooling (operating time, clamping / unclamping cycles, etc.). In order to schedule predictive / preventive maintenance for each end-of-arm tooling, and to detect early signs of performance degradation, it is important to monitor the usage, maintenance and tool performance data of the end-of-arm tooling. However, current monitoring methods are based on the end-of-arm tooling being permanently attached to a single robot, wherein all information related to the end-of-arm tooling is associated with a specific robot and stored on a single controller. When a specific end-of-arm tooling is removed from one robot and transferred to another, the usage and tool performance data from the controller is not transferred between the controllers. As a result, the accumulated usage data of the interchangeable end-of-arm tools is traditionally lost or must be manually recorded and monitored. Furthermore, with current methods, any maintenance information can only be updated or tracked during the period that the end-of-arm tooling is attached to the robot.

[0017] This disclosure describes a method and system that overcomes the limitations of current methods for monitoring end-of-arm tool data. Using the disclosed technology, all interchangeable end-of-arm tools have critical data stored independently of the robot based on a unique end-of-arm tool identifier. All end-of-arm tool information is stored on a data collection device that communicates with all controllers at a facility. Key end-of-arm tool data can be automatically exchanged between different robots / controllers and the data collection device. Maintenance performed on the end-of-arm tool can be recorded while the end-of-arm tool is attached to the robot (in use) or detached. Maintenance information can be accessed from the data collection device via a network interface from any controller, human-machine interface (HMI), PC / workstation, etc. Key data for each end-of-arm tool is transferred from the controller to the data collection device when the end-of-arm tool is detached from the robot and / or on a fixed schedule (e.g., daily). When the end-of-arm tool is attached to the robot, key data for each end-of-arm tool is retrieved from the data collection device by the controller. These features and capabilities are further described with respect to the following figures.

[0018] Figure 3 is a block diagram illustrating a system for monitoring usage and maintenance data of interchangeable robotic end-of-arm tools according to an embodiment of the present disclosure. The robotic system 300 includes a system that operates as previously described with respect to FIG. Figure 1 and Figure 2 The robot 302 and controller 304 in question. The robot 302 is equipped with an end-of-arm tooling 306 (gripper) for performing operations such as picking up a part and moving the part to a different location.

[0019] Robotic system 300 operates at facility 330 (indicated by a large dashed outline), such as a manufacturing facility or assembly plant. Robotic system 310 (including a robot, a controller, and an end-of-arm tool) also operates at facility 330. Multiple other robotic systems 312 (each including a robot, a controller, and an end-of-arm tool) also operate at facility 330. Robotic systems 300, 310, and 312 can include a mix of different types of robots that use different types of end-of-arm tooling for different operations. For example, in facility 330, robots can be configured with end-of-arm tooling to perform part movement, drilling, welding, caulking / adhesive application, and other operations. Any suitable combination of robot types and end-of-arm tooling can be employed.

[0020] Each of the above robot systems is annotated using a shorthand notation that identifies the robots and end-of-arm tools within facility 330. For example, robot system 300 includes robot 1 with end-of-arm tool 1; robot system 310 includes robot 2 with end-of-arm tool 3; robot system 312 includes robot 3 with end-of-arm tool 6, robot 4 with end-of-arm tool 4, robot 5 with end-of-arm tool 9, and robot 6 with end-of-arm tool 5. The random pairing of end-of-arm tool numbers relative to robot numbers illustrates that end-of-arm tools can be used interchangeably on different robots at different times. In actual implementations, robot and end-of-arm tool identifiers will be more than a single number; the identifiers will likely include multiple alphanumeric characters and can uniquely identify each robot or end-of-arm tool globally within an organization.

[0021] As described above, the controller in each of the robotic systems 300, 310 and 312 is configured to record and monitor usage, maintenance and tool performance data for the end-of-arm tool currently attached to the robot. This includes recording usage data for the uniquely identified end-of-arm tool, such as the date and time the end-of-arm tool was attached to the robot, and all relevant usage data about the end-of-arm tool - such as the cumulative operating time of the welding torch, the number of operating / closing cycles, the number of clamping / unclamping cycles of the gripper, etc. The controller is also aware of maintenance data, such as the clamping cycle count when the last lubrication maintenance was performed. Tool performance data can also be monitored to detect early signs of degradation in the performance of the end-of-arm tool; for a gripper, tool performance data can include, for example, gripper response time (time from clamping signal to actual clamping). Usage and maintenance data can be tracked locally at the controller for the current attachment of the end-of-arm tool in a manner known in the art.

[0022] The robotic systems 300, 310, and 312 are all in communication with a data collection device 320. The data collection device 320 is typically a computer or server with sufficient data storage. The data collection device 320 and the controllers of the robotic systems 300, 310, and 312 are typically connected to a local area network operating at the facility 330. The connection can be hardwired, wireless, or a combination thereof.

[0023] The controller of each of the robotic systems 300, 310, and 312 is in bidirectional communication with a data collection device 320. The data collection device 320 is configured with a database that stores usage and maintenance data for all end-of-arm tools in the facility 330. When an end-of-arm tool is attached to a particular robot, the robot's controller retrieves the current data for the end-of-arm tool from the data collection device 320. For example, when end-of-arm tool 3 is attached to robot 2, the controller in the robotic system 310 retrieves data for end-of-arm tool 3 from the data collection device 320. This may include the cumulative amount of time the end-of-arm tool 3 has been in use, the time since the last maintenance or repair was performed, individual maintenance / repair records (e.g., maintenance event "ABC" performed on date MM / DD / YY), the cumulative number of on / off cycles, etc. The data retrieved from the data collection device 320 for an end-of-arm tool may also include "tool calibration data," discussed further below.

[0024] Data from the controllers is also transmitted back to the data collection device 320 for centralized storage. The controllers of each of the robotic systems 300, 310, and 312 can transmit their usage data to the data collection device 320 in real time, on an event basis, or on a periodic basis. For example, in a preferred embodiment, the controllers transmit their usage data to the data collection device 320 each time the end-of-arm tool is detached from the robot, or once a day when the end-of-arm tool has been attached to the robot for more than one day. The data transmitted from each controller to the data collection device 320 includes usage data for the particular end-of-arm tool that is incrementally updated by the controller. That is, if the end-of-arm tool 3 has a total of 87 hours of operating time when attached to the robot 2, and accumulates an additional 4 hours of operating time before being detached from the robot 2, the controller of the robot 2 will send a new accumulated operating time of 91 hours to the data collection device 320.

[0025] In an alternative embodiment, one of the controllers functions as a data collection device. That is, data collection device 320 does not exist as a separate, standalone computing device. Instead, one of the controllers from one of the robotic systems 300 , 310 , or 312 functions as a data collection device, configured with a database for storing usage and maintenance data for all end-of-arm tools in facility 330 .

[0026] There may also be one or more maintenance stations 340 at the facility 330. A maintenance station 340 is a robot dedicated to non-production activities such as maintenance, servicing, repair, calibration, and testing of end-of-arm tooling. A maintenance station 340 is designated as a robot M1 with an attached end-of-arm tooling 2. The maintenance station 340 is also in communication with the data collection device 320. For example, the end-of-arm tooling 2 may perform a servicing or maintenance activity on the end-of-arm tooling 2 while attached to the robot M1, in which case the occurrence of the maintenance activity is uploaded to the data collection device 320. In this example, when the end-of-arm tooling 2 is put back into production on another robot, the end-of-arm tooling 2 may have a total accumulated operating time of 134 hours, but its time since maintenance will be zero hours.

[0027] The maintenance station 340 can also be used to place new end-of-arm tooling into service - including performing calibration activities and uploading "tool calibration data" to the data collection device 320. Tool calibration data is calibration data about a specific end-of-arm tooling that must be known by the robot that is using the end-of-arm tooling. In the case of a servo motor driven gripper, the tool calibration data defines the relationship between the servo motor rotational position (encoder angle data) and the translation distance between the two parallel gripper fingers. Other types of end-of-arm tools may require other types of tool calibration data. If desired, the tool calibration data is defined for each end-of-arm tool and can be defined as tabular data, one or more parameters (such as coefficients and constant terms to be used in equations), or any other suitable form.

[0028] The usage and maintenance data stored on the data collection device 320 can be viewed and analyzed via a user interface 350 on any suitable networked device in the facility 330. The user interface 350 can be provided on a personal computer or workstation with a display and keyboard, on a touchscreen tablet or mobile phone, on another human-machine interface (HMI) such as a display on a programmable logic controller (PLC), or on any other suitable device. In one embodiment, the user interface 350 is a web interface. In another embodiment, a mobile device application ("app") is provided.

[0029] User interface 350 provides for the input of data to and the output of data from data collection device 320. A variety of users can use user interface 350 to view usage and maintenance data—either individually or in aggregate. For example, a graph 352 can be viewed that plots the number of gripping cycles per day for a particular end-of-arm tool over time. Other queries can be performed, such as viewing a table showing the time since the last lubrication service for all gripper tools. User interface 350 provides flexible querying and viewing of the data on data collection device 320 in a manner that is understandable to anyone skilled in database and user interface design.

[0030] The user interface 350 also enables data to be uploaded to the data collection device 320 for users with appropriate privileges. For example, the user interface 350 can be used to enter a new end-of-arm tool into the database of the data collection device 320 - including the type of end-of-arm tool and its maintenance requirements. Moreover, some types of repair and maintenance activities do not need to be performed at the maintenance station 340, but can be performed on a simple workbench with the end-of-arm tool completely disassembled. When such repair or maintenance activities are completed at the workbench, the user interface 350 can be used to record the activities of that particular end-of-arm tool. For example, if a lubrication service is performed on the end-of-arm tool at the workbench, the user interface can be used to update the database on the data collection device to indicate that the time since the last lubrication service is zero. This recording of maintenance activities can be completed via the user interface when the end-of-arm tool is not attached to any robot.

[0031] The data collection device 320 is also preferably configured to send alerts and notifications 360 to designated users or stations based on any type of trigger, threshold, or analysis of usage and tool performance data. The intent of the alerts and notifications 360 is to provide immediate notification to appropriate individuals that one or more end-of-arm tools require attention. Alerts may include, for example, "push notifications" (such as text messages to key plant personnel and / or alerts on affected controllers) of urgently needed maintenance activities or detected performance degradation. Other less urgent notifications may include emails listing maintenance activities that are expected to be required on specific end-of-arm tools in the coming weeks. Alerts and notifications 360 may include any suitable combination of media type (text, email, etc.), data triggers and content, recipients, etc., as known to those skilled in the art.

[0032] Figure 3The foregoing discussion describes the distributed management of usage and maintenance data using the data collection device 320 and the controller. The usage and maintenance data for each end-of-arm tool managed by the system includes, but is not limited to, a unique identifier for the end-of-arm tool, usage or "odometer" data (such as gripping cycles, rotation angles, travel distance, or operating time of a welder), service time, robot attachment history (to which robot it is attached), date and time of all attachment / detachment events, current end-of-arm tool position (if attached, to which robot), maintenance requirements, maintenance history (what maintenance was performed and when), the next required and / or scheduled maintenance, calibration data, and data regarding critical or abnormal events (such as collisions of the end-of-arm tool with objects). Tool performance data, such as gripping response time, can also be recorded and analyzed periodically, where performance degradation can be used as an indication of required maintenance or repairs.

[0033] Data collection devices 320 periodically transmit all usage and maintenance data for robotic systems 300, 310, and 312 to cloud server 370. Cloud server 370 is a data storage center in the "cloud" (accessible from the internet) with one or more server computers and data storage capabilities. Data collection devices 320 can transmit usage and maintenance data to cloud server 370 as it is received, daily, or at any other suitable time period. Typically, data flow is unidirectional—from data collection devices 320 in facility 330 (and from other data collection devices in other facilities) to cloud server 370, which serves as the organization's global repository for data. Cloud server 370 can be a data storage, analysis, and viewing system that manages all of a company's robotic system data—including everything beyond end-of-arm tooling data.

[0034] Cloud server 370 provides the ability to view and analyze usage and maintenance data via user interface 380. User interface 380—typically a web-based interface available over the Internet, but also potentially available via a mobile device application ("app")—allows data to be viewed, sorted, filtered, analyzed, and downloaded in any manner desired by the user. Cloud server 370 can also be configured to send alert and notification messages 390 in the same manner as previously discussed. In the case of alert and notification messages 390, the data being analyzed includes all end-of-arm tools from all of the company's global sites.

[0035] Figure 4is a flowchart 400 of a method for monitoring usage and maintenance data of interchangeable robotic end-of-arm tooling according to an embodiment of the present disclosure. At box 402, a data collection device is provided that communicates with all controllers at a facility. The data collection device includes a database that is configured to store usage and maintenance data for each of a plurality of uniquely identified end-of-arm toolings. The end-of-arm tooling data includes the items listed previously. The data collection device also includes application software configured to manage the sharing of the end-of-arm tooling data by the various controllers, and software for enabling viewing and analysis of the data via a user interface. The arrows on the flowchart 400 specify the direction of data flow to / from the database provided at box 402.

[0036] At block 404, when a single end-of-arm tool is attached to a robot in the facility, the controller downloads the end-of-arm tool data for that single end-of-arm tool from the data collection device. This includes the previously listed data (usage, maintenance, calibration, etc.) for the end-of-arm tool based on the end-of-arm tool's unique identifier. Additionally, the attachment event (end-of-arm tool ID, date, time, and the ID of the robot to which the end-of-arm tool was attached) is logged in a database on the data collection device. From this point on, the controller tracks incremental and cumulative usage data for the single end-of-arm tool until the end-of-arm tool is detached from the robot.

[0037] At block 406, the controller updates usage data for a single end-of-arm tool while the tool is attached to the robot. This includes updating "odometer" values ​​(such as the number of clamp / unclamp cycles, rotation angle, travel distance, or welder run time), as well as updating data such as service time. While a single end-of-arm tool is attached to the robot, the controller is responsible for recording and monitoring the current usage data for that particular end-of-arm tool.

[0038] At block 408, when a single end-of-arm tool is detached from the robot, the controller uploads the end-of-arm tool data for that tool to the data collection device. This can include all of the previously listed data (usage, maintenance, calibration, etc.); however, in most cases, only the cumulative usage data (service hours, welder operating hours, number of clamping / unclamping cycles, etc.) needs to be updated in the database on the data collection device, as most other end-of-arm tool data (maintenance requirements and history, tool calibration data, etc.) changes infrequently and is already recorded in the database on the data collection device. Only data values ​​updated at the controller need to be uploaded to the database on the data collection device. In addition, the detachment event (end-of-arm tool ID, date, time, robot ID) is recorded in the database on the data collection device. At this point, after detachment, the end-of-arm tool can be used on another robot or maintained at a maintenance robot station. In either case, the controller will download the latest end-of-arm tool data from the data collection device when the end-of-arm tool is attached. A detached end-of-arm tool can also be made available for maintenance at a workstation, in which case the repair or maintenance activities performed will be recorded in the database on the data collection device via the user interface.

[0039] Upload of usage data from the controller to the data collection device may also be triggered on a regular schedule (e.g., daily) at block 408. Regular (e.g., daily) transmission of usage data back to the data collection device ensures that the data collection device has current data in the event that the end-of-arm tool remains attached to a particular robot for an extended period of time (days or weeks).

[0040] The remaining method steps of flowchart 400 are not meant to be performed in any particular order, and in fact many different method steps may be performed simultaneously on different robots or other devices, by different users, etc. At box 410, a controller on the maintenance robot station uploads relevant end-of-arm tool data to a data collection device. In the case of a maintenance robot station, the end-of-arm tool data uploaded to the data collection device will typically be related to repair or maintenance activities performed on the end-of-arm tool while on the maintenance robot or tool calibration data for the end-of-arm tool. At box 410, a new end-of-arm tool may also be put into service via the maintenance robot, in which case all data for the new end-of-arm tool (end-of-arm tool ID, odometry value set to zero, maintenance requirements, and tool calibration data (if appropriate)) will be uploaded to the database of the data collection device.

[0041] At block 412, the end-of-arm tool data is viewed and / or analyzed by a user. The end-of-arm tool data is viewed and analyzed via a user interface that communicates with a database on a data collection device, as described above with respect to Figure 3As discussed. The user interface can be run on a PC with a keyboard and monitor, on a touch screen device (such as a tablet device or mobile phone), or on any other suitable device. The data collection device is configured with data viewing / analysis software that enables predefined queries and reports to be run against the database, and also enables ad hoc queries and analysis. For example, a user can request detailed data about a specific end-of-arm tool (odometer / usage data, maintenance history, etc.), summary data about all end-of-arm tools at the facility or a specific type of end-of-arm tool (such as a list of the next maintenance due for each end-of-arm tool, sorted by oldest at the top), charts of performance metrics (such as grip response time versus time), or a report listing all end-of-arm tools with significant usage and maintenance data. The data viewing and analysis at box 412 can be performed at any time by any authorized user using any device or instance of the above-described user interface.

[0042] At block 414, the user uploads the relevant end-of-arm tool data from one of the user interfaces to the data collection device. In the case of user interface data upload, the end-of-arm tool data uploaded to the data collection device will typically be related to a repair activity or maintenance activity performed on the end-of-arm tool at a workstation (i.e., somewhere other than attached to a maintenance robot). A new end-of-arm tool may also be placed into service via the user interface, in which case all data for the new end-of-arm tool (end-of-arm tool ID, odometry value set to zero, maintenance requirements) will be uploaded to the data collection device. For end-of-arm tools that require tool calibration data, this will require the use of a maintenance robot station and will not be uploaded from the user interface.

[0043] At block 416, warnings and notifications are sent from the data collection device to designated users (based on user roles, such as maintenance managers, plant managers, etc.) and / or designated stations (such as robots whose currently attached end-of-arm tooling is degrading or requiring maintenance). Warnings and notifications can include push-type notifications, such as text messages and pop-up warnings and alerts, intended to be immediately viewed and acted upon, and can also include awareness messages, such as emails, that can be viewed by users in less urgent situations. In most cases, warnings and notifications are triggered by the end-of-arm tooling exceeding a usage threshold or approaching a calendar event associated with a maintenance requirement (such as clamp / unclatch cycles exceeding 95% before requiring lubrication, or a scheduled maintenance event occurring within seven days), or by degrading end-of-arm tooling performance (such as a rapid increase in clamping response time). Configuration of warnings and notifications on the data collection device—including defining the type of event, triggering threshold, notification type, recipients, etc.—can be completed by the system administrator.

[0044] At block 418, the end-of-arm tooling data is uploaded from the data collection device to a cloud server. The data collection device manages the end-of-arm tooling data for a specific site or facility. By uploading data to the cloud on a regular basis (e.g., daily), end-of-arm tooling data for all facilities company-wide can be monitored and analyzed. The cloud server can be a repository system for all company robotics data, not just end-of-arm tooling data. The cloud server can be accessed by users via the internet. All data on the cloud server can be viewed and analyzed via a web user interface or application, and alerts and notifications can be automatically sent in the manner discussed above.

[0045] It should be understood that the above system includes defined user roles, role-based security, and privileges, such as those provided by most advanced database systems. For example, a specific individual user may be assigned a role such as Plant Manager, which allows him or her to receive specific alerts and notifications. The same applies to other roles, such as End-of-Arm Tool Maintenance Manager. Similarly, only users / roles with specific privileges will be allowed to update maintenance records for end-of-arm tools or add new end-of-arm tools to the database. Most users in an organization will typically be assigned a General role, which allows them to view any data in the database on the data collection device via the user interface.

[0046] As discussed above, robotic end-of-arm tooling requires regular maintenance to improve performance and lifespan, and existing methods of monitoring end-of-arm tooling usage do not accommodate the interchangeability of end-of-arm tooling across different robots. The disclosed technology for robotic end-of-arm tooling usage monitoring allows end-of-arm tooling to be interchanged between different robots while continuously and automatically maintaining critical usage data for each end-of-arm tool. End-of-arm tooling data is kept up to date through the use of a centralized data collection device accessed by all robots, where data is stored and monitored based on a specific end-of-arm tool (rather than a controller) using a unique end-of-arm tooling identifier. Maintenance on the end-of-arm tooling can be recorded while the end-of-arm tooling is attached to or removed from the robot, and calendar-based maintenance items are still tracked while the end-of-arm tooling is removed. These features provide significant advantages to any robotics customer who interchanges end-of-arm tooling across different robots in a facility.

[0047] Throughout the preceding discussion, various computers and controllers have been described and suggested in conjunction with the disclosed methods and systems. It should be understood that the software applications and modules of these computers and controllers are executed on one or more computing devices having processors and memory modules. Specifically, this includes processors in the computers in the controllers (304 and others), data collection device 320, and cloud server 370. Specifically, the processors in the controllers and data collection device 320 are configured to collect, update, and share usage and maintenance data, as described above.

[0048] Although various exemplary aspects and embodiments of the technology for data monitoring of interchangeable robotic end-of-arm tooling have been discussed above, those skilled in the art will recognize modifications, permutations, additions, and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced be construed to include all such modifications, permutations, additions, and sub-combinations as come within the true spirit and scope of the claims.

Claims

1. A method for monitoring data of an interchangeable end-of-arm tool of a robot, the method comprising: providing a data collection device having a processor and a memory and in communication with a plurality of controllers for robots at the facility, the data collection device being configured with a database for storing usage and maintenance data for a plurality of uniquely identified interchangeable end-of-arm tools; when a particular one of the end-of-arm tools is attached to the robot, copying the usage and maintenance data of the particular end-of-arm tool to a controller of the robot; updating the usage and maintenance data of the specific end-of-arm tooling while the specific end-of-arm tooling is attached to the robot; as well as When the particular end-of-arm tooling is detached from the robot, updated values ​​of the usage and maintenance data for the particular end-of-arm tooling are copied from the controller of the robot to the data collection device.

2. The method according to claim 1, wherein For each end-of-arm tool, the usage and maintenance data includes a unique identifier for the end-of-arm tool, usage or odometer data that tracks cumulative operating time and travel distance or cycles of work performed by the end-of-arm tool, cumulative service time, the date and time of all attachment / detachment events including robot identification, the identification of the robot to which the end-of-arm tool is currently attached, maintenance requirements, a maintenance history indicating which maintenance was performed and when, and the next required and / or scheduled maintenance.

3. The method according to claim 2, wherein: The usage and maintenance data may also include one or more of: tool calibration data, data regarding critical or abnormal events including end-of-arm tool collisions with obstacles, and tool performance data.

4. The method of claim 1 further comprising copying updated usage and maintenance data for the particular end-of-arm tool from the robot's controller to the data collection device on a regular schedule.

5. The method according to claim 1 further includes uploading specific values ​​of the usage and maintenance data of the end-of-arm tool from the controller of the maintenance robot to the data collection device, including uploading all values ​​of the usage and maintenance data of a new end-of-arm tool, or uploading updated maintenance event and schedule data of an end-of-arm tool on which maintenance has been performed while installed on the maintenance robot.

6. The method according to claim 5, wherein: Particular values ​​of the usage and maintenance data include tool calibration data, wherein the tool calibration data includes calibration information about the end-of-arm tool determined using the maintenance robot, the calibration information being necessary for using the end-of-arm tool on another robot.

7. The method of claim 1 further comprising viewing, by a user via a user interface on a device in communication with the data collection device, the end-of-arm tool data in the database, including viewing predefined reports and running ad hoc queries and analyses on the end-of-arm tool data in the database.

8. The method according to claim 1 also includes uploading specific values ​​of the usage and maintenance data of the end-of-arm tool to the data collection device by a user via a user interface on a device that communicates with the data collection device, including uploading all values ​​of the usage and maintenance data of a new end-of-arm tool, or uploading updated maintenance event and schedule data of an end-of-arm tool on which maintenance has been performed.

9. The method of claim 1 further comprising sending warnings and notifications from the data collection device regarding end-of-arm tool maintenance or performance conditions requiring attention, the warnings and notifications comprising one or more of: warnings sent to a specific controller; and emails, text messages, and push notifications sent to designated users or roles.

10. The method of claim 1, further comprising periodically uploading the usage and maintenance data in the database from the data collection device to a cloud server for storage with usage and maintenance data from other facilities.

11. A method for monitoring data of an interchangeable end-of-arm tool of a robot, the method comprising: providing a data collection device having a processor and a memory and in communication with all controllers at the facility, the data collection device being configured with a database for storing usage and maintenance data for a plurality of uniquely identified interchangeable end-of-arm tools; when a particular one of the end-of-arm tools is attached to the robot, copying the usage and maintenance data of the particular end-of-arm tool to a controller of the robot; updating the usage and maintenance data of the specific end-of-arm tooling while the specific end-of-arm tooling is attached to the robot; copying updated values ​​of the usage and maintenance data for the particular end-of-arm tooling from a controller of the robot to the data collection device when the particular end-of-arm tooling is detached from the robot or on a regular schedule; uploading specific values ​​of the usage and maintenance data of the end-of-arm tool from a controller of the maintenance robot or from a user interface on a device in communication with the data collection device to the data collection device, including uploading all values ​​of the usage and maintenance data of a new end-of-arm tool or uploading updated maintenance event and schedule data for an end-of-arm tool on which maintenance has been performed; as well as End-of-arm tool data in the database is viewed via the user interface.

12. The method according to claim 11, wherein For each end-of-arm tool, the usage and maintenance data includes, for each end-of-arm tool, a unique identifier for the end-of-arm tool, usage or odometer data tracking cumulative operating time and travel distance or cycles of work performed by the end-of-arm tool, cumulative service time, dates and times of all attachment / detachment events including robot identification, identification of the robot to which the end-of-arm tool is currently attached, maintenance requirements, a maintenance history indicating which maintenance was performed and when, and the next required and / or scheduled maintenance, and wherein the usage and maintenance data also includes one or more of: tool calibration data, data regarding critical or abnormal events including collisions of the end-of-arm tool with obstacles, and tool performance data.

13. A monitoring system for an interchangeable end-of-arm tool of an industrial robot, the monitoring system comprising: Multiple robots; a plurality of uniquely identified end-of-arm tools, wherein each of said end-of-arm tools is interchangeable between one or more of said robots; a dedicated controller for the robots, in communication with each of the robots, each controller having a processor and memory; and a data collection device in communication with the controller and configured with a database for storing usage and maintenance data of the end-of-arm tools, wherein when a specific end-of-arm tool among the end-of-arm tools is attached to the robot, the usage and maintenance data of the specific end-of-arm tool is copied from the data collection device to the controller of the robot, the usage and maintenance data of the specific end-of-arm tool is updated by the controller of the robot while the specific end-of-arm tool is attached to the robot, and when the specific end-of-arm tool is detached from the robot, the updated value of the usage and maintenance data of the specific end-of-arm tool is copied from the controller of the robot to the data collection device.

14. The monitoring system according to claim 13, wherein: For each end-of-arm tool, the usage and maintenance data includes a unique identifier for the end-of-arm tool, usage or odometer data that tracks cumulative operating time and travel distance or cycles of work performed by the end-of-arm tool, cumulative service time, the date and time of all attachment / detachment events including robot identification, the identification of the robot to which the end-of-arm tool is currently attached, maintenance requirements, a maintenance history indicating which maintenance was performed and when, and the next required and / or scheduled maintenance.

15. The monitoring system according to claim 14, wherein: The usage and maintenance data may also include one or more of: tool calibration data, data regarding critical or abnormal events including end-of-arm tool collisions with obstacles, and tool performance data.

16. The monitoring system according to claim 13, wherein: Updated values ​​of the usage and maintenance data for the particular end-of-arm tool are copied from the robot's controller to the data collection device on a regular schedule.

17. The monitoring system of claim 13, further comprising a maintenance robot in communication with the data collection device, wherein: Specific values ​​of the usage and maintenance data of the end-of-arm tool are uploaded from the controller of the maintenance robot to the data collection device, including uploading all values ​​of the usage and maintenance data of a new end-of-arm tool, or uploading updated maintenance event and schedule data of an end-of-arm tool on which maintenance has been performed while installed on the maintenance robot.

18. The monitoring system according to claim 17, wherein: Particular values ​​of the usage and maintenance data include tool calibration data, wherein the tool calibration data includes calibration information about the end-of-arm tool determined using the maintenance robot, the calibration information being necessary for using the end-of-arm tool on another robot.

19. The monitoring system according to claim 13, wherein: The data collection device is configured to provide for viewing of end-of-arm tool data in the database by a user via a user interface on a device in communication with the data collection device, including viewing predefined reports and running ad hoc queries and analyses on the end-of-arm tool data in the database.

20. The monitoring system according to claim 13, wherein: The data collection device is configured to enable a user to upload specific values ​​of the usage and maintenance data of an end-of-arm tool to the database via a user interface on a device that communicates with the data collection device, including uploading all values ​​of the usage and maintenance data of a new end-of-arm tool, or uploading updated maintenance event and schedule data for an end-of-arm tool on which maintenance has been performed.

21. The monitoring system according to claim 13, wherein: The data collection device is configured to send warnings and notifications regarding end-of-arm tool maintenance or performance conditions requiring attention, including one or more of: warnings sent to specific controllers; and emails, text messages, and push notifications sent to designated users or roles.

22. The monitoring system according to claim 13, wherein: The data collection device is configured to periodically upload the usage and maintenance data in the database to a cloud server.

23. The monitoring system according to claim 13, wherein: The data collection device is a designated controller among the controllers.

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