Data monitoring for interchangeable robot end-of-arm tools

Abstract

To monitor the usage of interchangeable end-of-arm tools across multiple robots.SOLUTION: Each tool is assigned a unique identifier maintained in a database. At each facility where robots are installed, a data collection device communicates with all robot controllers and provides centralized storage and monitoring of usage data and maintenance data for each end-of-arm tool. Each time a tool is attached to a robot, the controller downloads the current data for the tool from the data collection device. Likewise, each time a tool is detached from a robot, the controller uploads updated data for the tool to the data collection device. The data collection device maintains cumulative usage data for each tool, provides a user interface to the data to allow monitoring by personnel, and sends notifications of important pending maintenance requirements and any performance issues. The data is also stored on a cloud server for global access.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present disclosure relates generally to the field of industrial robots and end-of-arm tools (EOATs), and more specifically to a method and system for monitoring usage and maintenance data of robotic end-of-arm tools that are interchangeable between different robots, including assigning a unique identifier to each EOAT and transferring EOAT usage and maintenance data from a robot controller to a data collector that centrally manages the data. [Background technology]

[0002] The use of industrial robots to perform a wide range of manufacturing, fabrication, assembly, and material transfer operations is well known. Most operations performed by industrial robots involve the use of an end-of-arm tool, such as a gripper to grasp a part and move it from one position or orientation to another, a material removal tool such as a drill or mill, or a welding laser or torch. Each of these end-of-arm tools comes in many varieties; for example, a gripper can be in the form of a suction cup gripper, a mechanical finger gripper, or a servo-controlled gripper.

[0003] Like other types of mechanical components, end-of-arm tooling is subject to wear and tear, eventually leading to reduced performance and / or complete failure. Additionally, tools require regular maintenance to ensure optimal performance and longevity. For these reasons, it is common to track end-of-arm tooling usage data, including hours in service, number of operation cycles performed, etc. Summary of the Invention [Problem to be solved by the invention]

[0004] It is also common practice for end-of-arm tools to be interchangeable between different robots. That is, a particular gripper may be used on a first 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 line or in the same plant as the first robot. Because each robot has its own controller, only the controller for the individual robot monitors usage data for the particular end-of-arm tool attached to that robot. This situation results in monitoring usage data for interchangeable end-of-arm tools on multiple robots being performed manually, if it is performed at all.

[0005] In view of the foregoing, there is a need for a robot end-of-arm tool monitoring technique that tracks usage and maintenance data for individual tools used interchangeably on different robots. [Means for solving the problem]

[0006] In accordance with the teachings of the present disclosure, a method and system for monitoring the use of interchangeable robot end-of-arm tools across multiple robots is described and illustrated. Each 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 robot controllers within the facility. The data collection device centrally collects data and monitors the use and maintenance of each end-of-arm tool. Each time a tool is attached to a robot, the robot controller downloads current data for that particular tool from the data collection device. Similarly, each time a tool is removed from the robot, the robot controller uploads updated tool data to the data collection device. The data collection device maintains cumulative usage data for each tool and provides a user interface to the data, enabling monitoring by plant maintenance personnel and sending notifications of critical pending maintenance requirements and performance issues. Data from the data collection device is also stored on a cloud server for global access. [Brief explanation of the drawings]

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

[0008] [Figure 2] FIG. 2 shows an industrial robot equipped with a welder's end-of-arm tool as known in the art.

[0009] [Figure 3] FIG. 3 is a block diagram of a system for monitoring usage and maintenance data for an interchangeable robotic end-of-arm tool, according to one embodiment of the present disclosure.

[0010] [Figure 4] FIG. 4 is a flowchart of a method for monitoring usage and maintenance data for an exchangeable robotic end-of-arm tool according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0011] The following description of disclosed embodiments directed to data monitoring for interchangeable robotic end-of-arm tools is merely exemplary in nature and is not intended to limit the disclosed apparatus and techniques, and their applications or uses.

[0012] The use of industrial robots for a variety of manufacturing, assembly, and material transfer operations is well known, and many of the tasks performed by industrial robots involve the use of end-of-arm tools, such as grippers, drills, caulk guns, lasers, or torch welders.

[0013] FIG. 1 is a diagram of an industrial robot and controller equipped with a mechanical gripper-type end-of-arm tooling, as known in the art. The robot 100 is controlled by a controller 110 and performs operations in a manner known in the art. The controller 110 communicates with the robot 100 via a cable 112. In FIG. 1, the robot 100 is equipped with a mechanical finger-style gripper 120 that is used to grasp a part or workpiece 130 from an initial position and pose (e.g., on a conveyor) and place it in a target position and pose (e.g., in a shipping container). The gripper 120 is an example of a type of end-of-arm tooling. In addition to controlling the operation of the robot arm, the controller 110 controls the gripping and release operations of the gripper 120 and monitors and records data related to the gripper 120, such as the number of grip / release cycles and the grip / release response time.

[0014] 2 is an illustration of an industrial robot equipped with a welder end-of-arm tool, as known in the art. Robot 200 communicates with and is controlled by controller 210 in the manner previously described. The end-of-arm tool on robot 200 is a welding torch 220. Welding torch 220 is another example of a type of end-of-arm tool. In addition to controlling the operation of robot 200, controller 210 controls the operation of torch 220 (on and off, and possibly the energy level when on) and monitors and records data about torch 220, such as the cumulative amount of time torch 220 has been on.

[0015] 1 and 2 are provided merely to illustrate examples of end-of-arm tools. As previously mentioned, many other types of end-of-arm tools exist. Many of these end-of-arm tools are interchangeable between robots; that is, a particular tool may be installed on one robot for a period of time, removed from that robot, and later installed on another robot.

[0016] As previously mentioned, robot controllers control the operation of end-of-arm tools and also record data related to end-of-arm tool usage (e.g., on-time, grip / un-grip cycles, etc.). Monitoring end-of-arm tool usage, maintenance, and performance data is important for scheduling predictive / preventive maintenance for each tool and detecting early signs of performance degradation. However, current monitoring methods are based on the permanent attachment of a tool to a single robot, and all information related to the tool is associated with that specific robot and stored in the individual robot controller. When a specific tool is removed from one robot and transferred to another, the end-of-arm tool usage and performance data obtained from the controller is not transferred between the robot controllers. Therefore, cumulative usage data for interchangeable end-of-arm tools was previously lost or had to be manually recorded and monitored. Furthermore, current methods allow for maintenance information to be updated or tracked only while the tool is attached to the robot.

[0017] This disclosure provides a method and system that overcomes the limitations of current methods for monitoring end-of-arm tool data. Using the disclosed technology, every interchangeable tool has its vital data stored independently of the robot based on a unique tool identifier. All tool information is stored in a data collection device that communicates with all robot controllers in a facility. Tool vital data can be automatically exchanged between different robots / controllers and the data collection device. Maintenance performed on a tool can be logged while the tool is attached (during inspection) or detached from the robot. Maintenance information can be accessed from the data collection device through a web interface from any controller, human-machine interface (HMI), PC / workstation, etc. Each end-of-arm tool's vital data is sent from the robot controller to the data collection device when the tool is detached from the robot and / or on a set time schedule, such as daily. Each tool's vital data is retrieved from the data collection device by the controller when the tool is attached to the robot. These features and capabilities are further explained with reference to the following diagram.

[0018] Figure 3 is a block diagram of a system for monitoring usage and maintenance data for interchangeable robotic end-of-arm tooling, according to one embodiment of the present disclosure. The robotic system 300 includes a robot 302 and a controller 304 that operate as previously described with respect to Figures 1 and 2. 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 another location.

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

[0020] Each of the aforementioned robotic systems is annotated with shorthand notations that identify the robots and end-of-arm tools within facility 330. For example, robotic system 300 includes robot 1 with tool 1, system 310 includes robot 2 with tool 3, and system 312 includes robot 3 with tool 6, robot 4 with tool 4, robot 5 with tool 9, and robot 6 with tool 5. The random pairing of tool numbers with robot numbers illustrates that end-of-arm tools may be used interchangeably on different robots at different times. In an actual implementation, robot and tool identifiers would be more than one digit. The identifiers would likely include multiple alphanumeric characters, allowing for globally unique identification of each robot and tool within an organization.

[0021] The controller in each of robot systems 300, 310, and 312 is configured to record and monitor usage, maintenance, and performance data for the end-of-arm tool currently attached to the robot, as previously described. This includes recording usage data for a uniquely identified end-of-arm tool, such as the date and time the tool was attached to the robot, and all relevant usage data for the tool (such as the cumulative welding torch operating hours, number of on / off cycles, and number of gripper grip / release cycles). Maintenance data, such as the gripping cycle count at which the last refueling service occurred, is also known to the controller. Performance data may also be monitored to detect early signs of performance degradation in the end-of-arm tool; for a gripper, performance data may include, for example, gripper response time (the time from the grip signal to actual gripper closure). Usage and maintenance data may be tracked locally to the robot controller for the current tool attachment in a manner known in the art.

[0022] All of the robotic systems 300, 310, and 312 communicate with a data collection device 320, which is typically a computer or server with extensive data storage. The data collection device 320 and the controllers of the robotic systems 300, 310, and 312 are typically all connected to a local area network installed at the facility 330. The connection may be wired, wireless, or a combination thereof.

[0023] The robot controllers for each of robotic systems 300, 310, and 312 communicate bidirectionally with data collector 320. Data collector 320 is configured with a database for storing tool usage and maintenance data (usage / maintenance data) for all of the end-of-arm tools in factory 330. When an end-of-arm tool is attached to a particular robot, that robot's controller retrieves current data for the end-of-arm tool from data collector 320. For example, if tool 3 is attached to robot 2, the controller in system 310 retrieves tool 3 data from data collector 320. This data may include tool 3's cumulative usage hours, usage hours since the last maintenance or inspection was performed, individual maintenance / inspection records (e.g., inspection event "ABC" was performed on date MM / DD / YY), cumulative number of on / off cycles, etc. The data retrieved from data collector 320 for the tools may also include "mastering data," as described further below.

[0024] Data from the robot controllers is also returned to data collection device 320 for centralized storage. The robot controllers of each of robot systems 300, 310, and 312 may transfer their usage data to data collection device 320 in real time, on an event-based basis, or periodically. For example, in a preferred embodiment, the robot controllers transfer their usage data to data collection device 320 each time an end-of-arm tool is detached from the robot, or once a day if the tool will remain attached to the robot for more than a day. The data transferred from each robot controller to data collection device 320 includes usage data for the specific end-of-arm tool that is incrementally updated by the robot controller. That is, if Tool 3 had a total operating time of 87 hours when attached to Robot 2 and had accumulated more than four hours of operating time before being detached from Robot 2, the controller of Robot 2 would transmit a new accumulated operating time of 91 hours to data collection device 320.

[0025] In another embodiment, one of the robot controllers functions as the data collector. That is, data collector 320 does not exist as a separate, independent computing device. Rather, one robot controller from one of robot systems 300, 310, or 312 serves as the data collector and is configured with a database for storing tool usage and maintenance data for all end-of-arm tools in facility 330.

[0026] One or more maintenance stations 340 may exist in facility 330. Maintenance stations 340 are robots dedicated to non-production operations, such as maintenance, inspection, repair, calibration, and testing of end-of-arm tools. Maintenance station 340 is shown as robot M1 with end-of-arm tool 2 attached. Maintenance station 340 also communicates with data collection device 320. For example, tool 2 may have inspection or maintenance operations performed by robot M1 while attached to robot M1, in which case the maintenance operations are uploaded to data collection device 320 as they occur. In this example, when tool 2 is returned to manufacturing operations on another robot, tool 2 will have a total operating time of 134 hours but zero operating time during maintenance.

[0027] The maintenance station 340 can also be used to service new tools, which includes performing calibration operations and uploading "mastering data" to the data collector 320. Mastering data is calibration data about a particular end-of-arm tool that needs to be known by the robot using the tool. In the case of a servo motor driving a gripper, the mastering data defines the relationship between the rotational position of the servo motor (encoder angle data) and the translation distance between two parallel gripper fingers. Other types of end-of-arm tools may require other forms of mastering data. Mastering data is defined for each individual end-of-arm tool as needed and can be defined as tabulated data, one or more parameters such as coefficients or constant terms used in equations, or any other suitable form.

[0028] End-of-arm tool usage and maintenance data present on data collection device 320 may be viewed and analyzed via user interface 350 on any suitable networked device within facility 330. User interface 350 may be provided on personal computers and workstations equipped with displays and keyboards, on tablet devices and cell phones equipped with touch screens, on other human-machine interfaces (HMIs) such as displays on programmable logic controller (PLC) devices, or on any other suitable device. In one embodiment, user interface 350 is a web-based interface. In another embodiment, a mobile device application ("app") is provided.

[0029] User interface 350 inputs and outputs data to data collection device 320. Many users can use user interface 350 to view end-of-arm tool usage and maintenance data, individually or collectively. For example, a graph 352 can be viewed that plots the number of gripping cycles per day for a particular end-of-arm tool as a function of the number of days. Another query can be made to view a table showing the time since the last refueling service for all gripper-type tools. User interface 350 provides flexibility in querying and viewing the data on data collection device 320 in ways that will be understandable to those skilled in database and user interface design.

[0030] The user interface 350 also enables uploading of data to the data collection device 320 for users with appropriate privileges. For example, the user interface 350 can be used to enter a new tool into the database of the data collection device 320, including the tool's type and its maintenance requirements. Also, some types of inspection and maintenance operations do not need to be performed on the maintenance station 340 but can be performed on a simple work bench with the tool completely removed. When such an inspection or maintenance operation is completed on a work bench, the user interface 350 can be used to record such an operation for that particular end-of-arm tool. For example, if a refueling service is performed on a tool at a work bench, the user interface can be used to update the database on the data collection device to indicate that the time since the last refueling service is zero. This type of maintenance operation recording can be performed 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 performance data. The intent of sending alerts and notifications 360 is to immediately notify appropriate individuals that one or more end-of-arm tools require attention. Alerts may include, for example, "push notifications" (e.g., text messages to key plant personnel and / or alarms to affected robotic controllers) of urgently needed maintenance actions or detected performance degradation. Other, less urgent notifications may include email lists regarding forecasts of maintenance actions that may be required on specific tools in the coming weeks. Alerts and notifications 360 may include any suitable combination of media format (e.g., text, email), data triggers and content, recipients, etc., as known to those skilled in the art.

[0032] The preceding discussion of Figure 3 describes distributed management of end-of-arm tool usage and maintenance data using a data collection system 320 and a robot 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 tool, usage or "odometry" data (e.g., gripper grip cycles, rotation angle, travel distance, or welding machine run time), run time, robot attachment history (relative to the robot), time and date of all attachment / detachment events, current tool location (if attached to the robot), maintenance requirements, maintenance history (when and what was performed), required or scheduled next maintenance, mastering (calibration) data, data regarding critical or abnormal events (e.g., end-of-arm tool hitting an object), etc. Tool performance data, such as grip response time, may also be recorded; such data may be periodically analyzed; and performance degradation data may be used as an indicator for maintenance or inspection.

[0033] Data collection device 320 periodically communicates all end-of-arm tooling 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” having one or more server computers and data storage capabilities. Data collection device 320 can communicate end-of-arm tooling usage and maintenance data to cloud server 370 as it is received, on a daily basis, or any other suitable period. Typically, data flows one way, from data collection device 320 in facility 330 (and other data collection devices in other facilities) to cloud server 370, which serves as a global repository of data for the organization. Cloud server 370 may be a data storage, analysis, and display system that manages all of an enterprise's robotic system data, including data other than end-of-arm tooling data.

[0034] Cloud server 370 provides the ability to view and analyze end-of-arm tool usage and maintenance data via user interface 380. User interface 380 is typically a web-based interface available over the internet, but may also be available via a mobile device application (“app”). User interface 380 allows a user to view, sort, filter, analyze, and download data in any manner desired. Cloud server 370 may also be configured to send alerts and notifications 390 in the same manner as described above. For alerts and notifications 390, the data analyzed includes end-of-arm tool usage data from all locations of a global enterprise.

[0035] FIG. 4 is a flowchart 400 of a method for monitoring usage and maintenance data for interchangeable robotic end-of-arm tools according to one embodiment of the present disclosure. In box 402, a data collection device is provided in communication with all robotic controllers in a facility. The data collection device includes a database configured to store usage and maintenance data for each of a plurality of uniquely identified end-of-arm tools. The end-of-arm tool data includes the items previously described. The data collection device also includes application software configured to manage the sharing of end-of-arm tool data with individual robotic controllers, and software that allows for viewing and analysis of the data via a user interface. Arrows in flowchart 400 indicate the direction of data flow to and from the database provided in box 402.

[0036] In box 404, when an individual end-of-arms tool is attached to a robot in the facility, the robot controller downloads the individual end-of-arms tool data from the data collector. This data includes the data previously described about the tool (usage, maintenance, mastering, etc.) based on the tool's unique identifier. The data collector's database also records the attachment event (tool ID, date, time, and ID of the robot the tool is attached to). From this moment on, the robot controller continues to track the incremental and cumulative usage data for each individual end-of-arms tool until the tool is removed from the robot.

[0037] In box 406, the robot controller updates usage data for each end-of-arm tool while the tool is attached to the robot. This includes updating "odometry" values ​​(such as number of grip / release cycles, rotation angle, travel distance, and welder run time), as well as updating data such as service time. While each end-of-arm tool is attached to the robot, the robot controller is responsible for recording and monitoring the current usage data for that particular tool.

[0038] In box 408, when an individual end-of-arm tool is removed from the robot, the robot controller uploads the end-of-arm tool data for that tool to the data collector. This can include all of the data listed above (use, maintenance, mastering, etc.). However, in many cases, only cumulative usage data (e.g., inspection hours, welder run hours, number of grip / release cycles) needs to be updated in the data collector database; most other data about the tool (e.g., maintenance requirements and history, mastering data) does not change frequently and is already recorded in the data collector database. Only data values ​​updated on the robot controller need to be uploaded to the data collector database. Additionally, the removal event (tool ID, date, time, robot ID) is recorded in the data collector database. After removal, the tool can be used on another robot or maintained at a maintenance robot station. In either case, the robot controller downloads the latest tool data from the data collector when the tool is installed. The removed tool is also available for maintenance at the work bench, in which case inspection or maintenance actions performed can be logged in the data collection device database via the user interface.

[0039] Uploading usage data from the robot controller to the data collector in box 408 may also be defined to occur on a regular schedule, such as daily. The regular (e.g., daily) transfer of usage data back to the data collector ensures that the data collector has current data when a 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 taken in any particular order; in fact, many different method steps may be occurring at the same time, on different robots or other devices, by different users. In box 410, a robot 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 tool data uploaded to the data collection device will typically relate to inspection or maintenance operations performed on the tool while on the maintenance robot, or mastering (calibration) data for the tool. A new end-of-arm tool can also be put into service via the maintenance robot in box 410, in which case all data for the new tool (tool ID, odometry values ​​to be set to zero, maintenance requirements, and mastering data, if appropriate) is uploaded to the data collection device's database.

[0041] In box 412, end-of-arm tool data is viewed and / or analyzed by a user. Tool data is viewed and analyzed through a user interface that communicates with a database on the data collection device, as described above with respect to FIG. 3. The user interface may run on a PC with a keyboard and monitor, on a touchscreen device such as a tablet or cell phone, or on any other suitable device. The data collection device is configured with data viewing and analysis software that allows predefined queries and reports to be run against the database, as well as ad hoc queries and analyses. A user may request detailed data about a specific end-of-arm tool (e.g., odometry / usage data, maintenance history), aggregate data about all tools of a particular type in a facility or about tools (e.g., a list of upcoming maintenance due dates for each tool sorted by shortest and highest), plots of performance metrics (e.g., grip response time vs. time), or a report listing all tools with important usage and maintenance data. The data viewing and analysis in box 412 may be performed on any device or at any location on the user interface described above, by any authorized user, at any time.

[0042] In box 414, the user uploads the relevant end-of-arm tool data to the data collection device from one of the user interfaces. In the case of data upload via the user interface, the tool data uploaded to the data collection device typically relates to inspection or maintenance operations performed on the tool at a work bench (i.e., a location other than where it is attached to the maintenance robot). New end-of-arm tools can also be put into service via the user interface, in which case all data for the new tool (tool ID, odometry values ​​set to zero, maintenance requirements) will be uploaded to the data collection device. For end-of-arm tools that require mastering data, this requires the use of a maintenance robot station and is not uploaded from the user interface.

[0043] In box 416, alerts and notifications are sent from the data collection device to designated users (based on the user's role, such as a maintenance manager or plant manager) and / or designated stations (such as a robot with a tool currently experiencing performance degradation or requiring maintenance). Alerts and notifications can include push notifications, such as text messages or pop-up alerts, or alarms intended for immediate acknowledgement and action. Additionally, alerts and notifications may include acknowledgement messages, such as emails, that can be acknowledged by the user on a less urgent basis. In most cases, alerts and notifications are triggered by a tool that has exceeded a usage threshold or is approaching a calendared event for a maintenance requirement (such as exceeding 95% of grip / release cycles before refueling is required or an inspection event scheduled in seven days), or a tool that is experiencing performance degradation (such as a rapid increase in grip response time). The configuration of alerts and notifications on the data collection device (including defining the event type, trigger threshold, notification type, recipients, etc.) can be performed by a system administrator.

[0044] In box 418, end-of-arm tool data is uploaded from the data collection device to a cloud server. The data collection device manages tool data for a specific site or facility. By uploading data to the cloud periodically (e.g., daily), end-of-arm tool data for all company facilities can be monitored and analyzed. The cloud server can be a repository system for not just end-of-arm tool data, but also data for all company robots. The cloud server is accessible to users via the internet. All data on the cloud server can be viewed and analyzed via a web-based user interface or app, and alerts and notifications can be automatically sent as previously described.

[0045] It should be understood that the above-described system includes defined user roles, role-based security, and privileges, as provided in state-of-the-art database systems. For example, an individual user may be assigned a role such as plant manager, which means that the individual will receive certain alerts and notifications. Similarly, other roles, such as tool maintenance manager, may be assigned. Similarly, only users / roles with certain privileges can update tool maintenance records or add new tools to the database. Typically, most users within an organization are assigned general roles, allowing them to view any data in the database on the data collection device through the user interface.

[0046] As previously mentioned, robot end-of-arm tools require regular maintenance to enhance performance and lifespan, and existing methods for monitoring tool usage do not address tool interchangeability across different robots. The previously described technology for monitoring robot end-of-arm tool usage enables end-of-arm tool interchange across different robots while continuously and automatically maintaining critical usage data for each tool. End-of-arm tool data is kept up to date through the use of a centralized data collector accessed by all robots, where data is stored and monitored based on the specific tool (rather than the robot controller) using a unique tool identifier. Tool maintenance is logged while the tool is attached to the robot or while the tool is detached from the robot, and calendar-based maintenance items can be tracked even while the tool is detached. These capabilities provide significant benefits to any robot customer who swaps end-of-arm tools across different robots in their facility.

[0047] Throughout the preceding discussion, various computers and controllers have been described and suggested in connection with the disclosed methods and systems. It should be understood that the software applications and modules of these computers and controllers execute on one or more computing devices having processors and memory modules. This includes, among other things, the processors of the robotic controllers (e.g., 304), the data collection device 320, and the computers of the cloud server 370. Specifically, the processors in the controllers and data collection device 320 are configured to collect, update, and share end-of-arm tool usage and maintenance data, as previously described.

[0048] While many exemplary aspects and embodiments of techniques for monitoring data for interchangeable robotic end-of-arm tools have been described above, those skilled in the art will recognize modifications, permutations, additions, and subcombinations thereof. Accordingly, the appended claims, and any claims hereafter introduced, are intended to be construed as including all such variations, permutations, additions, and subcombinations as fall within their true spirit and scope.

[0049] The following additional notes are provided regarding the above embodiments and modifications. (Appendix 1) 1. A method for monitoring data of an exchangeable end-of-arm tool for a robot, the method comprising: providing a data collection device having a processor and memory and in communication with a plurality of robot controllers at the facility, the data collection device configured with a database storing usage and maintenance data for a plurality of uniquely identified replaceable end-of-arm tools; moreover, copying the usage data and maintenance data for a particular end-of-arm tool to a controller of the robot when the particular end-of-arm tool is attached to the robot; updating the usage data and the maintenance data for the particular end-of-arm tool while the particular tool is attached to a robot; and copying updates to the usage and maintenance data for the particular end-of-arm tool from the robot's controller to the data collection device when the tool is removed from the robot. (Appendix 2) 2. The monitoring method of claim 1, wherein the usage data and maintenance data includes, for each tool, a unique identifier for the tool, usage or odometry data tracking distance traveled or cycles and cumulative time of work performed by the tool, cumulative hours of service, date and time of all attachment / detachment events including identification of the robot, identification of the robot to which the tool is currently attached, maintenance requirements, a maintenance history indicating what maintenance has been performed, and the next maintenance required or scheduled. (Appendix 3) 3. The monitoring method of claim 2, wherein the usage data and maintenance data further include at least one of tool mastering or calibration data, data regarding significant or abnormal events including tool collisions with objects, and tool performance data. (Appendix 4) 10. The monitoring method of claim 1, further comprising copying updated usage and maintenance data for the particular end-of-arm tool from the controller of the robot to the data collection device on a regular time schedule. (Appendix 5) further comprising uploading certain values ​​of end-of-arm tool usage and maintenance data from a maintenance robot controller to the data collection device, said uploading including uploading all values ​​of the usage and maintenance data for a new end-of-arm tool; or uploading updated maintenance event and schedule data for the end-of-arm tool including maintenance that has been performed while installed on the maintenance robot. (Appendix 6) 6. The monitoring method of claim 5, wherein the particular values ​​of the usage data and maintenance data include tool mastering data, the mastering data being determined using the maintenance robot and including calibration information for the end-of-arm tool necessary for using the end-of-arm tool on other robots. (Appendix 7) 2. The monitoring method of claim 1, further comprising: viewing the 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, the viewing including viewing predefined reports; and performing ad hoc queries and analyses on the end-of-arm tool data in the database. (Appendix 8) and uploading, by a user via a user interface on a device in communication with the data collection device, specific values ​​of usage and maintenance data relating to the end-of-arm tool to the data collection device; 2. The monitoring method of claim 1, wherein the uploading includes uploading all values ​​of usage and maintenance data for a new end-of-arm tool or uploading updated maintenance event and schedule data for an end-of-arm tool that has had maintenance performed. (Appendix 9) further comprising sending alerts and notifications from said data collection device indicating end-of-arm tool maintenance or performance conditions requiring attention; 10. The monitoring method of claim 1, wherein the alerts and notifications include one or more alerts sent to a specific robot controller, and emails, text messages, and push notifications sent to designated users or roles. (Appendix 10) 10. The monitoring method of claim 1, further comprising periodically uploading the usage and maintenance data in a database from the data collection device to a cloud server for storage, along with end-of-arm tool usage and maintenance data from other facilities. (Appendix 11) 1. A method for monitoring data of an exchangeable end-of-arm tool for a robot, the method comprising: providing a data collection device having a processor and memory and in communication with all robotic controllers in the facility, the data collection device configured with a database storing usage and maintenance data for a plurality of uniquely identified interchangeable end-of-arm tools; moreover, copying the usage data and maintenance data for a particular end-of-arm tool to a robot controller when the particular end-of-arm tool is attached to the robot; updating the usage data and the maintenance data for the particular end-of-arm tool while the particular tool is attached to a robot; copying updates to the usage and maintenance data for the particular end-of-arm tool from the robot controller to the data collection device when the tool is removed from the robot or on a regular time schedule; uploading certain values ​​of the usage data and maintenance data of the end-of-arm tool to the data collection device from a user interface of a maintenance robot controller or a device in communication with the data collection device; uploading includes uploading all usage and maintenance data for a new end-of-arm tool or uploading updated maintenance event and schedule data for an end-of-arm tool that has had maintenance performed; moreover, A method of monitoring wherein the end-of-arm tool data in the database is viewed via the user interface. (Appendix 12) the usage data and the maintenance data includes, for each tool, a unique identifier for the tool, usage or odometry data tracking distance traveled or cycles and cumulative time of work performed by the tool, cumulative hours of service, date and time of all attachment / detachment events including identification of the robot, identification of the robot to which the tool is currently attached, maintenance requirements, a maintenance history indicating what maintenance has been performed, and the next maintenance required or scheduled; 12. The monitoring method of claim 11, wherein the usage data and maintenance data further include at least one of tool mastering or calibration data, data regarding significant or abnormal events including tool collisions with objects, and tool performance data. (Appendix 13) 1. A monitoring system for an interchangeable end-of-arm tool of an industrial robot, Several robots and a plurality of uniquely identified end-of-arm tools, each of which is interchangeable between one or more of said robots; a dedicated robot controller communicating with each of the plurality of robots, each robot controller having a processor and a memory; moreover, a data collection device configured to communicate with the robot controller and to include a database storing usage and maintenance data for the end-of-arm tool; the usage data and the maintenance data relating to the particular one of the end-of-arm tools is copied from the data collection device to a robot controller when the particular one of the end-of-arm tools is attached to the robot; the usage data and the maintenance data for a particular one of the end-of-arm tools is updated by the controller of the robot while the tool is attached to the robot; A monitoring system wherein updates to the usage and maintenance data for the particular end-of-arm tool are copied from the robot's controller to the data collection device when the tool is removed from the robot. (Appendix 14) 14. The monitoring system of claim 13, wherein the usage data and maintenance data includes, for each tool, a unique identifier for the tool, usage or odometry data tracking distance traveled or cycles and cumulative time of work performed by the tool, cumulative time of service, date and time of all attachment / detachment events including identification of the robot, identification of the robot to which the tool is currently attached, maintenance requirements, a maintenance history indicating what maintenance has been performed, and the next maintenance required or scheduled. (Appendix 15) 15. The monitoring system of claim 14, wherein the usage data and maintenance data further include at least one of tool mastering or calibration data, data regarding significant or abnormal events including tool collisions with objects, and tool performance data. (Appendix 16) 14. The monitoring system of claim 13, wherein the usage data and maintenance data for the particular end-of-arm tool is copied from the controller of the robot to the data collection device on a regular time schedule. (Appendix 17) further comprising a maintenance robot in communication with the data collection device; certain values ​​of end-of-arm tool usage data and maintenance data are uploaded from a controller of the maintenance robot to the data collection device; uploading includes uploading all values ​​of the usage and maintenance data for the new end-of-arm tool; or uploading updated maintenance event and schedule data for the end-of-arm tool including maintenance that has been performed while installed on the maintenance robot. (Appendix 18) 18. The monitoring system of claim 17, wherein the particular values ​​of the usage data and maintenance data include tool mastering data, the mastering data being determined using the maintenance robot and including calibration information for the end-of-arm tool necessary for using the end-of-arm tool on other robots. (Appendix 19) 14. The monitoring system of claim 13, wherein the data collection device is configured to provide viewing of the 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, the viewing including viewing predefined reports, and further including performing ad hoc queries and analyses on the end-of-arm tool data in the database. (Appendix 20) the data collection device is configured to allow a user to upload certain values ​​of end-of-arm tool usage and maintenance data to a database via a user interface on a device in communication with the data collection device; 14. The monitoring system of claim 13, wherein the uploading includes uploading all values ​​of the usage data and the maintenance data for a new end-of-arm tool or uploading updated maintenance event and schedule data for an end-of-arm tool that has had maintenance performed. (Appendix 21) the data collection device is configured to send alerts and notifications indicating end-of-arm tool maintenance or performance conditions requiring attention; 14. The monitoring system of claim 13, wherein the alerts and notifications include one or more alerts sent to a specific robot, and emails, text messages, and push notifications sent to designated users or roles. (Appendix 22) 14. The monitoring system of claim 13, wherein the data collection device is configured to periodically upload the usage data and the maintenance data in the database to a cloud server. (Appendix 23) 14. The monitoring system of claim 13, wherein the data collection device is one of the designated robot controllers. [Explanation of symbols]

[0050] 300, 310, 312 Robot Systems 302 Robot 304 Control device 306 Arm End Tool 320 Data Collection Device 330 facilities 340 Maintenance Station 350 User Interface 352 graphs 360 Alerts and Notifications 370 Cloud Server 380 User Interface 390 Alerts and Notifications

Claims

1. 1. A method for monitoring data of an exchangeable end-of-arm tool for a robot, the method comprising: providing a data collection device having a processor and memory and in communication with a plurality of robot controllers at the facility, the data collection device configured with a database storing usage and maintenance data for a plurality of uniquely identified replaceable end-of-arm tools; moreover, copying the usage data and maintenance data for a particular end-of-arm tool to a controller of the robot when the particular end-of-arm tool is attached to the robot; updating the usage data and the maintenance data for the particular end-of-arm tool while the particular tool is attached to a robot; and copying updates to the usage and maintenance data for the particular end-of-arm tool from the robot's controller to the data collection device when the tool is removed from the robot.

2. 2. The monitoring method of claim 1, wherein the usage data and the maintenance data includes, for each tool, a unique identifier for the tool, usage or odometry data tracking distance traveled or cycles and cumulative time of work performed by the tool, cumulative hours of service, date and time of all attachment / detachment events including identification of the robot, identification of the robot to which the tool is currently attached, maintenance requirements, a maintenance history indicating what maintenance has been performed, and the next maintenance required or scheduled.

3. 3. The monitoring method of claim 2, wherein the usage data and the maintenance data further include at least one of tool mastering or calibration data, data regarding significant or abnormal events including tool collisions with objects, and tool performance data.

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

5. further comprising uploading certain values ​​of end-of-arm tool usage and maintenance data from a maintenance robot controller to the data collection device, said uploading including uploading all values ​​of the usage and maintenance data for a new end-of-arm tool; or uploading updated maintenance event and schedule data for the end-of-arm tool including maintenance that has been performed while installed on the maintenance robot.

6. 6. The monitoring method of claim 5, wherein the particular values ​​of the usage and maintenance data include tool mastering data, the mastering data being determined using the maintenance robot and including calibration information for the end-of-arm tool necessary for using the end-of-arm tool on other robots.

7. 2. The monitoring method of claim 1, further comprising viewing the 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, the viewing including viewing predefined reports, and further comprising performing ad hoc queries and analyses on the end-of-arm tool data in the database.

8. and uploading, by a user via a user interface on a device in communication with the data collection device, specific values ​​of usage and maintenance data relating to the end-of-arm tool to the data collection device; 10. The monitoring method of claim 1, wherein the uploading includes uploading all values ​​of usage and maintenance data for a new end-of-arm tool or uploading updated maintenance event and schedule data for an end-of-arm tool that has had maintenance performed.

9. further comprising sending alerts and notifications from said data collection device indicating end-of-arm tool maintenance or performance conditions requiring attention; 10. The monitoring method of claim 1, wherein the alerts and notifications include one or more alerts sent to a controller for a particular robot, and emails, text messages, and push notifications sent to designated users or roles.

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

11. 1. A method for monitoring data of an exchangeable end-of-arm tool for a robot, the method comprising: providing a data collection device having a processor and memory and in communication with all robotic controllers in the facility, the data collection device configured with a database storing usage and maintenance data for a plurality of uniquely identified interchangeable end-of-arm tools; moreover, copying the usage data and maintenance data for a particular end-of-arm tool to a robot controller when the particular end-of-arm tool is attached to the robot; updating the usage data and the maintenance data for the particular end-of-arm tool while the particular tool is attached to a robot; copying updates to the usage and maintenance data for the particular end-of-arm tool from the robot controller to the data collection device when the tool is removed from the robot or on a regular time schedule; uploading certain values ​​of the usage data and maintenance data of the end-of-arm tool to the data collection device from a user interface of a maintenance robot controller or a device in communication with the data collection device; uploading includes uploading all usage and maintenance data for a new end-of-arm tool or uploading updated maintenance event and schedule data for an end-of-arm tool that has had maintenance performed; moreover, A method of monitoring wherein the end-of-arm tool data in the database is viewed via the user interface.

12. the usage data and the maintenance data include, for each tool, a unique identifier for the tool, usage or odometry data tracking distance traveled or cycles and cumulative time of work performed by the tool, cumulative hours of service, date and time of all attachment / detachment events including identification of the robot, identification of the robot to which the tool is currently attached, maintenance requirements, a maintenance history indicating what maintenance has been performed, and the next maintenance required or scheduled; 12. The monitoring method of claim 11, wherein the usage data and the maintenance data further include at least one of tool mastering or calibration data, data regarding significant or abnormal events including tool collisions with objects, and tool performance data.

13. 1. A monitoring system for an interchangeable end-of-arm tool of an industrial robot, Several robots and a plurality of uniquely identified end-of-arm tools, each of which is interchangeable between one or more of said robots; a dedicated robot controller communicating with each of the plurality of robots, each robot controller having a processor and a memory; moreover, a data collection device configured to communicate with the robot controller and to include a database storing usage and maintenance data for the end-of-arm tool; the usage data and the maintenance data relating to the particular one of the end-of-arm tools is copied from the data collection device to a robot controller when the particular one of the end-of-arm tools is attached to the robot; the usage data and the maintenance data for a particular one of the end-of-arm tools is updated by the controller of the robot while the tool is attached to the robot; A monitoring system wherein updates to the usage and maintenance data for the particular end-of-arm tool are copied from the robot's controller to the data collection device when the tool is removed from the robot.

14. 14. The monitoring system of claim 13, wherein the usage data and the maintenance data includes, for each tool, a unique identifier for the tool, usage or odometry data tracking distance traveled or cycles and cumulative time of work performed by the tool, cumulative hours of service, date and time of all attachment / detachment events including identification of the robot, identification of the robot to which the tool is currently attached, maintenance requirements, a maintenance history indicating what maintenance has been performed, and the next maintenance required or scheduled.

15. 15. The monitoring system of claim 14, wherein the usage data and the maintenance data further include at least one of tool mastering or calibration data, data regarding significant or abnormal events including tool collisions with objects, and tool performance data.

16. 14. The monitoring system of claim 13, wherein the usage data and the maintenance data relating to the particular end-of-arm tool are copied from the controller of the robot to the data collection device on a regular time schedule.

17. further comprising a maintenance robot in communication with the data collection device; certain values ​​of end-of-arm tool usage data and maintenance data are uploaded from a controller of the maintenance robot to the data collection device; uploading includes uploading all values ​​of the usage and maintenance data for the new end-of-arm tool; or uploading updated maintenance event and schedule data for the end-of-arm tool including maintenance that has been performed while installed on the maintenance robot.

18. 20. The monitoring system of claim 17, wherein the particular values ​​of the usage and maintenance data include tool mastering data, the mastering data being determined using the maintenance robot and including calibration information for the end-of-arm tool necessary for using the end-of-arm tool on other robots.

19. 14. The monitoring system of claim 13, wherein the data collection device is adapted to provide viewing of the 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, the viewing including viewing predefined reports, and further including performing ad hoc queries and analyses on the end-of-arm tool data in the database.

20. the data collection device is configured to allow a user to upload certain values ​​of end-of-arm tool usage and maintenance data to a database via a user interface on a device in communication with the data collection device; 14. The monitoring system of claim 13, wherein the uploading includes uploading all values ​​of the usage data and the maintenance data for a new end-of-arm tool or uploading updated maintenance event and schedule data for an end-of-arm tool that has had maintenance performed.

21. the data collection device is configured to send alerts and notifications indicating end-of-arm tool maintenance or performance conditions requiring attention; The monitoring system of claim 13 , wherein the alerts and notifications include one or more alerts sent to a specific robot, and emails, text messages, and push notifications sent to designated users or roles.

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

23. 14. The monitoring system of claim 13, wherein the data collection device is one of the designated controllers for the robot.

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