System for diagnosing a robot condition

Abstract

Robot data transmission method comprising the following steps: Collecting data from each of a variety of robots in real time; Transmitting the data from a controller of each of the robots to a first data acquisition device in real time, wherein the data transmitted to the first data acquisition device is temporarily stored in the data storage with the ability to save data for a certain duration; Caching the data in the first data acquisition device using a multi-segment queuing mechanism with a retention policy, wherein the retention policy secures the data in the first data acquisition device based on a triggering event, priority, duration, size, transfer rate, and / or data transformation to optimize throughput or data storage requirements, and wherein the first data acquisition device sorts the data into priority segments and interrupts data transmission with a lower priority segment and transmits the data from a higher priority segment to the second data acquisition device or the server; and Transferring the data to a second data collection device based on the retention policy.

Description

FIELD OF INVENTION

[0001] The invention relates to a system and method for diagnosing a robot condition to minimize downtime in a multi-robot manufacturing plant. BACKGROUND OF THE INVENTION

[0002] Modern manufacturing plants often use a number of robots to automate production processes. Robots can be arranged in cells, with several robots each performing the same process. For example, several robots can be arranged together to perform exactly the same welding process on a workpiece. Several robots can be used alternately in an assembly line, with each robot performing the same steps in a production sequence. Such manufacturing plants or specific areas of these manufacturing plants can be found in the documents EP 1 176 486 A1, US 2003 / 0 200 060 A1, US 2002 / 0 161 478 A1, US 7 826 469 B1, and DE 10 2006 059 378 A1.

[0003] Although robots are effective at maximizing performance, they are not without drawbacks. Unlike their human counterparts, robots generally cannot communicate when they encounter a problem. For example, the robot's bearings or encoders may fail without warning after a period of time based on various operating conditions such as travel distances, temperatures, and load conditions.

[0004] Under normal operating conditions, maintenance periods can be scheduled at regular intervals. However, regularly scheduled intervals may be unreasonably long when operating conditions are less exceptional than normal, resulting in premature component replacement and unnecessarily increasing maintenance costs.

[0005] Alternatively, regularly scheduled intervals may not be sufficient when operating conditions are more extreme than normal. In this case, the robots may encounter unexpected problems before the scheduled maintenance period. Unexpected failures are particularly problematic in high-volume manufacturing systems for a variety of reasons.

[0006] First, manufacturing facilities generally try to keep the number of spare parts inventoried in-house as low as possible to minimize costs. Consequently, spare parts must be ordered frequently. In the case of robots, many spare parts can have long lead times, resulting in extended periods of robot downtime.

[0007] Furthermore, production schedules are generally pre-planned days or weeks in which each robot in the manufacturing facility is expected to perform a specified amount of work. Unexpected downtime of a single robot can negatively impact an entire manufacturing facility because manufacturing processes following the inoperative robot may be short of expected workpieces. As a result, production may fall behind schedule.

[0008] Consequently, there is a need for a system and method for proactively determining necessary maintenance and optimization of robots in order to plan and minimize downtime, extend the mechanical life of the robot and reduce maintenance costs. SUMMARY OF THE INVENTION

[0009] Accordingly and in accordance with the present invention, a system and method for proactively determining necessary maintenance and optimization of robots has surprisingly been discovered.

[0010] In a first embodiment, a robot data transmission method includes the step of collecting data from each of a plurality of robots in real time. The data collected from the plurality of robots is then transmitted in real time by a controller of each of the robots to a first data collection device. The data is cached within the first data collection device using a multi-segment queuing mechanism. The queuing mechanism is configured with a retention policy. The data is then transmitted to a second data collection device based on the retention policy of the queuing mechanism of the first data collection device.

[0011] In another embodiment, an analytical and predictive robot reporting method comprises the step of collecting data in a first data acquisition device. The collected data is then transmitted to and stored in a second data acquisition device. The second data acquisition device may be remote or local to the first data acquisition device. The data is then analyzed with the second data acquisition device, and a report is generated based on the analysis of the data. The report identifies a determination for a parameter change of a control device, an abnormal condition, or a failure, and the report is distributed to at least one recipient.

[0012] In yet another embodiment, an analytical and optimization reporting system for robots comprises at least one robot with a programmable controller. The controller of the robot is configured to collect dynamic data from the robot. A first data acquisition device is in real-time communication with the controller of the robot and is configured to receive the dynamic data from the controller. The first data acquisition device is configured to buffer the dynamic data until complete. The system further comprises, in communication with the first data acquisition device, a second data acquisition device. The second data acquisition device is configured to receive and analyze the dynamic data from the first data acquisition device. A receiver is in communication with the second data acquisition device. DESCRIPTION OF THE CHARACTERS

[0013] The above and other advantages of the present invention will be readily apparent to those skilled in the art from the following detailed description, particularly when considered in light of the drawings described herein. Fig. 1 is a schematic diagram of a system according to a first embodiment of the disclosure; Fig. 2 is a schematic diagram of a system according to a second embodiment of the disclosure; Fig. 3 is a schematic diagram of a system according to a third embodiment of the disclosure; and Fig. 4 is a schematic block diagram of a method for diagnosing a robot condition according to an embodiment of the disclosure. DETAILED DESCRIPTION

[0014] The following detailed description and accompanying drawings describe and illustrate various embodiments of the invention. The description and drawings are provided to enable one skilled in the art to make and use the invention and are not intended to limit the scope of the invention in any way.

[0015] As in Fig. 1 to 3, a system 10 for minimizing downtime includes at least one robot 12. In the illustrated embodiment, the system 10 includes a plurality of robots 12. Each of the robots 12 includes a multi-axis robot arm 14 configured to perform an operation on a workpiece, such as cutting, welding, or servicing.

[0016] The robot 12 includes at least one programmable controller 16 having a memory for storing a variety of data types. As used herein, a "controller" is defined to include a computer processor configured to execute software or a software program in the form of instructions stored in the memory. The memory may be any suitable type of memory or a combination thereof. As also used herein, a "storage device" is defined as a non-transitory and tangible, computer-readable storage medium on which the software or software program, as well as data sets, tables, algorithms, and other information, may be stored. The controller 16 may be in electrical communication with the storage device for the purpose of executing the software or software program.

[0017] The controller 16 may include a user interface 20 to allow a user to enter data or programs into the controller 16 or to access the data stored therein. The user interface 20 may include a display for presenting the information to the user.

[0018] The controller 16 may be a robot controller 16, in which case the controller 16 is coupled to the robot 12 to actively perform a series of operations. It will be understood that the present invention is not limited to robot controllers 16. As a non-limiting example, the controller 16 may be a passive controller 16, such as a monitoring device that monitors predetermined conditions of the robot 12.

[0019] A plurality of sensors 22 on robot 12 collect dynamic data from robot arm 14 based on specified conditions. Sensors 22 may include, for example, displacement sensors for measuring the distance and direction of the robot arm joint, thermometers for measuring operating temperatures of the joint, and load cells for measuring operating loads on the joints. Sensors 22 are in communication with controller 16, with controller 16 collecting the dynamic data from sensors 22 in real time.

[0020] The system 10 may also include a first data acquisition device 24 in real-time communication with the programmable controllers 16. As in Fig. 1 and Fig. 3, the first data acquisition device 24 may be a physical hard disk located external to the controllers 16, wherein the first data acquisition device 24 is in communication with the plurality of controllers 16 via a functional network 26. In another embodiment of the system 10, the first data acquisition device 24 may be a logical or virtual hard disk included in the memory device of the controller 16 of each robot 12, as shown in Fig. 2 is shown.

[0021] The functional network 26 may be a local or remote network of the programmable controllers 16 or a direct connection between the controllers 16 and the first data acquisition device 24. Furthermore, the functional network 26 may include wireless communication features such as Wi-Fi, Bluetooth, or cellular data networks.

[0022] The first data acquisition device 24 includes a multi-segment queuing mechanism with a plurality of prioritized segments. For example, the queuing mechanism may have a high-priority segment and a low-priority segment. The queuing mechanism includes a data storage policy and is configured to cache data based on the event, priority, duration, size, transfer rate, and / or data transformation to optimize data throughput or data storage requirements.

[0023] At least one second data acquisition device 28 may be in communication with the first data acquisition device 24 via the functional network 26. The second data acquisition device 28 may be a network server configured to process the dynamic data received from the first data acquisition device 24. As shown in Fig. 1 and Fig. 2, the second data collection device 28 may be an independent network server connected to the first data collection device 24 via the functional network 26. The second data collection device 28 may be located in the same room or building as the first data collection device 24, or it may be located in a completely different building that may or may not be in the same geographical proximity as the first data collection device 24.

[0024] As in Fig. 3, the second data acquisition device 28 may be arranged alternately locally with the first data acquisition device 24, wherein the first data acquisition device 24 and the second data acquisition device 28, which form a unit, form a data acquisition unit 30 via the functional network 26 in connection with each of the plurality of controllers 16.

[0025] The second data acquisition device 28 is configured to analyze the dynamic data received from the first data acquisition device 24 and determine when maintenance or optimization of a particular robot 12 of the system 10 is necessary. Maintenance may include repairing or replacing specific components of the robot 12 based on abnormal conditions or failures detected by the second data acquisition device 28. Optimization may involve changing parameters of the controller 16 to maximize the effectiveness of the robot 12.

[0026] The system 10 further includes a receiver 32 in communication with the first data collection device 24 and / or the second data collection device 28 via the functional network 26. In the illustrated embodiments, the receivers 32 include a smart device such as a mobile phone or a tablet and a network terminal such as an office computer. However, the receiver 32 may be any device capable of receiving analyzed dynamic data from the second data collection device 28, such as a second server, application software, a web browser, an email, and a robotic teaching device. Alternatively, the receiver 32 may be a person receiving a printout directly from the second data collection device 28.

[0027] In use, the sensors 22 of each of the robots 12 measure, as shown in Fig.4, the dynamic data in operation including the movement distances of joints, operating load of components, operating temperature of components, high-speed emergency stops of components, reversal motion states of joints and other dynamic data relevant to the operation of the robot.

[0028] The dynamic data measured by the sensors 22 are then collected by the controller 16 and transmitted to or extracted by the first data acquisition device 24.

[0029] The dynamic data is cached in at least one of the segments of the first data acquisition device 24 based on priority, with higher priority dynamic data being cached in the higher priority segment and lower priority dynamic data being cached in the lower priority segment. It will be appreciated that the queuing mechanism may include any number of prioritized segments, with respective dynamic data being cached.

[0030] Dynamic data is backed up in the prioritized segments of the queuing mechanism based on the queuing mechanism's retention policy. The retention policy backs up and prioritizes dynamic data based on a trigger event, priority, duration, size, transfer rate, and / or data transformation to optimize throughput or data storage requirements.

[0031] When a triggering event occurs, the dynamic data is transmitted from the first data acquisition device 24 to the second data acquisition device 28. The triggering event may be received from the controller 16 or an external triggering device. Alternatively, the event may be triggered internally by the first data acquisition device 24. In one embodiment, an entirety of the dynamic data collected in the first data acquisition device 24 may be transmitted to the second data acquisition device 28 when the triggering event occurs. Alternatively, the event may be triggered internally by the first data acquisition device 24. In one embodiment, an entirety of the dynamic data collected in the first data acquisition device 24 may be transmitted to the second data acquisition device 28 when the triggering event occurs.Alternately, upon the occurrence of the triggering event, the first data acquisition device 24 may interrupt transmission of the low priority dynamic data and trigger transmission of the higher priority dynamic data to the second data acquisition device 28.

[0032] Dynamic data received by the second data acquisition device 28 is then analyzed to determine whether maintenance or optimization of the robot 12 is necessary. The maintenance or optimization determination is based on consideration of each type of dynamic data. For example, the second data acquisition device 28 may evaluate travel distance, temperature, high-speed emergency stops, reversing motion states of joints, and other dynamic data in determining whether maintenance or optimization of any of the plurality of robots 12 is necessary. More specifically, intervals between maintenance periods may be increased or decreased if operating conditions of a robot 12 are determined to be less extreme or more extreme than normal operating conditions, respectively.For example, the events of high temperatures, high-speed emergency stops, and reversal motion conditions of joints can lead to a reduced interval between maintenance periods.

[0033] If the second data acquisition device 28 does not determine that maintenance or optimization is necessary, the data collection and analysis process may continue repeatedly. Alternatively, if the second data acquisition device 28 determines that maintenance or optimization of any of the robots 12 is necessary, the second data acquisition device 28 may generate a report containing a readout of the analyzed dynamic data. The report includes information related to capturing previous failure conditions and minimizing downtime of the system 10, including motion and mechanical readiness, process and system readiness, and maintenance notifications.

[0034] The report may contain specific information pertaining to specific robots 12 in system 10. The report may include a maintenance or optimization notification identifying particular components of robot 12 that need to be replaced, such as bearings, encoders, or controllers. The report may also provide predictions pertaining to robots 12 that approximate a need for maintenance or optimization, allowing recipient 32 to optimize future production plans based on an assumed downtime.

[0035] If the report contains a maintenance or optimization notification, the notification is provided to at least one of the receivers 32 so that a maintenance action can be initiated. The notification is received by the receiver 32 and displayed to the user so that the user can initiate the maintenance action, such as creating a work order or scheduling downtime for the robot 12.

[0036] Alternatively, the second data acquisition device 28 may be configured to initiate the maintenance process automatically. If the second data acquisition device 28 determines that any of the robots 12 requires maintenance, the second data acquisition device 28 may generate a work order, component replacement order, or downtime scheduling for the robot 12 without any input from the user.

[0037] The system 10 disclosed herein advantageously improves the efficiency of manufacturing facilities by minimizing downtime. For example, by collecting, storing, and analyzing dynamic data related to operating conditions of each robot 12, intervals between maintenance periods can be set specifically for each individual robot 12.

[0038] In the case of robots 12 exposed to more extreme operating conditions, intervals between maintenance periods can be reduced from a normal interval, preventing unexpected failures. By scheduling maintenance periods based on dynamic data, the downtime of the robot 12 can be planned based on the availability of replacement components, and production schedules can be adjusted in advance to accommodate reduced production capacity.

[0039] Alternatively, intervals between maintenance periods can be extended beyond the normal interval when a robot 12 is subjected to less extreme operating conditions, eliminating unnecessary replacement of components and minimizing maintenance costs.

Claims

[1] Robot data transmission method comprising the following steps: Collecting data from each of a variety of robots in real time; Transmitting the data from a controller of each of the robots to a first data acquisition device in real time, wherein the data transmitted to the first data acquisition device is temporarily stored in the data storage with the ability to save data for a certain duration; Caching the data in the first data acquisition device using a multi-segment queuing mechanism with a retention policy, wherein the retention policy secures the data in the first data acquisition device based on a triggering event, priority, duration, size, transfer rate, and / or data transformation to optimize throughput or data storage requirements, and wherein the first data acquisition device sorts the data into priority segments and interrupts data transmission with a lower priority segment and transmits the data from a higher priority segment to the second data acquisition device or the server; and Transferring the data to a second data collection device based on the retention policy. [2] The method of claim 1, further comprising the step of analyzing the data in the second data acquisition device to determine needs for maintenance or optimization of the robots. [3] The method of claim 1, further comprising the step of generating a report from the second data acquisition device, the report including mechanical readiness, process readiness, system readiness, and / or a maintenance notice. [4] The method of claim 1, wherein the first data acquisition device is a logical device within the controller of the robot. [5] The method of claim 1, wherein the first data acquisition device is a physical storage device external to the controller of the robot. [6] The method of claim 1, wherein the second data acquisition device is a network server, the network server being connected to the first data acquisition device via a functional network. [7] The method of claim 1, wherein the second data acquisition device is configured to be local to the first data acquisition device, the second data acquisition device being in direct communication with the first data acquisition device. [8] Method according to claim 1, comprising the following steps: the data transmitted to the first data acquisition device is temporarily stored in the data storage with the ability to save data for a certain duration; and the first data acquisition device transmits the data in total to the second data acquisition device in response to one of an event from the robot controller or an external device and an internally triggered event on the first data acquisition device. [9] The method of claim 1, wherein the data includes a travel distance of the joints, an operating load of the components, an operating temperature of the components, high-speed emergency stops of the components, and / or a reverse movement state of the joints. [10] Analytical and predictive robot reporting method comprising the following steps: Collecting data in a first data collection device, wherein the data transmitted from at least one robot to the associated first data collection device is cached in the data storage with the ability to save data for a certain duration, wherein the data is stored in the first data collection device using a multi-segment queuing mechanism with a retention policy, wherein the retention policy saves the data in the first data collection device based on a triggering event, priority, duration, size, transfer rate, and / or data transformation to optimize throughput or data storage requirements, and wherein the first data acquisition device sorts the data into priority segments and interrupts data transmission with a lower priority segment and transmits the data from a higher priority segment to the second data acquisition device or the server; transmitting the data and storing the data in a second data acquisition device, the second data acquisition device being remote from or local to the first data acquisition device; analyzing the data in the second data acquisition device; generating a report from the second data acquisition device, the report based on the analysis of the data by the second data acquisition device; Detecting a decision to change the robot control parameters, an abnormal condition, or failure in the report; and Distribute the report to at least one recipient. [11] The method of claim 10, wherein the receiver is a smart device, a server, application software, an email, an office computer and / or a robotic teaching device. [12] The method of claim 10, further comprising the step of generating a work order based on the analysis of the data. [13] The method of claim 10, wherein the data includes a travel distance of the joints, an operating load of the components, an operating temperature of the components, high-speed emergency conditions of the components, and / or a reverse movement condition of the joints. [14] Analytical and optimization reporting system for robots, comprising: at least one robot, the robot having a programmable controller configured to collect dynamic data from the robot; a first data acquisition device in electrical connection with the controller of the at least one robot, wherein the first data acquisition device is designed - to receive the dynamic data from the controller and - to cache the dynamic data for a duration, and - for caching the data using a multi-segment queuing mechanism with a retention policy, wherein the retention policy is configured to secure the data in the first data acquisition device based on a triggering event, priority, duration, size, transfer rate, and / or data transformation to optimize throughput or data storage requirements, and - to classify the data into priority segments, and - to interrupt data transmission with a lower priority segment; a second data acquisition device in communication with the first data acquisition device, wherein the first data acquisition device is further configured to transmit the data from a higher priority segment to the second data acquisition device or the server, and wherein the second data acquisition device is configured to receive the dynamic data from the first data acquisition device and to analyze the dynamic data; and a receiver in communication with the second data acquisition device for receiving the analysis of the dynamic data. [15] The system of claim 14, wherein the first data acquisition device is a logical device within a memory of the controller of the robot. [16] The system of claim 14, wherein the first data acquisition device is a physical storage disk formed separately from the controller. [17] The system of claim 14, wherein each of the controller, the first data acquisition device, the second data acquisition device, and the receiver is in communication with a functional network. [18] The system of claim 14, wherein the second data acquisition device is local to the first data acquisition device.

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