Robot system

Abstract

To enhance the efficiency of work performed by a robot system.SOLUTION: A controller 24 of a first robot device 2a includes: a terminal block to which group information identifying a group to which the first robot device 2a having the controller 24 belongs is input; and a first notification CPU which determines, when a predetermined abnormality related to any of robot devices 2b-2d other than the first robot device 2a occurs, whether or not to stop a robot body 21 on the basis of whether or not a group identified by the group information output by the any of robot devices 2b-2d and the group identified by the group information input to the terminal block are common.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a robotic system including a plurality of robotic devices. [Background technology]

[0002] Patent Document 1 discloses a robot system including three robot devices, each having a robot body and a controller for controlling the robot body. In this robot system, when an emergency stop switch connected to the controller of one of the robot devices is pressed, the operation of the robot bodies of the three robot devices is prohibited. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6613851 Summary of the Invention [Problem to be solved by the invention]

[0004] However, when an abnormality occurs, such as when an emergency stop switch is pressed, there are cases where it is acceptable to continue the operation of some of the robot bodies. Even in such cases, the robot system of Patent Document 1 stops the operation of all of the robot bodies that make up the robot system when an abnormality occurs, which reduces the efficiency of the work performed by the robot system.

[0005] The present disclosure has been made in view of the above points, and an object thereof is to improve the efficiency of work performed by a robot system. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the present disclosure provides a robot system including a plurality of robot devices, each having a robot body and a controller for controlling the robot body, wherein the controller has an attribute input unit to which group information specifying a group to which the robot device having the controller belongs, and a control unit that, when a predetermined abnormality occurs related to another robot device different from the robot device having the controller, determines whether to stop the robot body based on whether the group specified by the group information output by the other robot device is the same as the group specified by the group information input to the attribute input unit.

[0007] This allows the robot bodies of robot devices in a different group from the robot device in question to continue operating if an abnormality occurs in one of the robot devices, thereby improving the efficiency of work performed by the robot system compared to when all of the robot bodies are stopped. [Effects of the Invention]

[0008] According to the present disclosure, the efficiency of the work performed by the robot system can be increased. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic diagram illustrating a configuration of a robot system according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a block diagram showing the configuration of the robot device. [Figure 3] 10 is a table showing cooperation information, group information, and leader information stored in the controller of each robot device. [Figure 4] FIG. 2 is a block diagram showing the configuration of a notification board. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. The following description of the preferred embodiments is merely exemplary in nature and is not intended to limit the present invention, its applications, or uses in any way.

[0011] 1 shows the configuration of a robot system 1. This robot system 1 includes first to fourth robot devices 2a to 2d and a safety PLC (programmable logic controller) 3. The configuration of the first robot device 2a will be described below. Unless otherwise specified, the second to fourth robot devices 2b to 2d have the same configuration as the first robot device 2a, which will be described below.

[0012] As shown in FIG. 2, the first robot device 2a has a robot body 21, a teach pendant 22 as an input device, an area sensor 23, and a controller 24.

[0013] The robot body 21 has nine motors 211 and nine encoders 212 that detect and output the positions of the rotation axes of the corresponding motors 211. Some of the motors 211 and encoders 212 are not shown in Fig. 2. Each robot body 21 is a six-axis robot having six rotary joints, and six of the nine motors 211 are motors that rotate the rotary joints, and three motors 211 are motors for external axes (not shown).

[0014] The teach pendant 22 has an input unit 221, an operation input board 222, and a TP side communication board 223.

[0015] The input unit 221 accepts input from the user and outputs an input signal in response to the input. The input unit 221 has a plurality of switches, such as a mode switch and a deadman switch. Inputs accepted by the input unit 221 include an emergency stop input, a mode switching input, and an activation input. The mode switching input is an input that switches the mode of the first robotic device 2a or the other robotic devices 2b to 2d that are to be controlled, and is input by a mode switch. The activation input is an input that keeps the robot main body 21 of the first robotic device 2a or the other robotic devices 2b to 2d that are to be controlled in an activated state, and is input by a deadman switch.

[0016] The operation input board 222 generates operation input information based on the input signal output by the input unit 221, and transmits it to the TP side communication board 223 using a communication method defined in IEC61784-3.

[0017] The TP side communication board 223 receives the operation input information transmitted by the operation input board 222 and transmits it to the controller 24 via the communication medium M.

[0018] The area sensor 23 outputs a detection result indicating whether or not a person is within the working range of the robot body 21.

[0019] The controller 24 controls the robot body 21. The controller 24 includes a sensor input board 241, a monitoring board 242, a notification board 243, a main control board 244, a motor control unit 245, and nine amplifiers 246.

[0020] The sensor input board 241 generates sensor input information indicating the detection result output by the area sensor 23 .

[0021] The monitoring board 242 generates and outputs monitoring information indicating whether or not the safety conditions are met, that is, whether the positions (angles) of the rotation shafts of the nine motors 211 that rotate the rotary joints are within a safety area and the speeds of the rotation shafts of the nine motors 211 are less than the speed limit, based on the outputs of the nine corresponding encoders 212. The monitoring board 242 also references a notification signal (described later) output by a notification board 243, and when the notification signal is at a low level, outputs a stop signal to an amplifier 246 to bring the robot body 21 to an emergency stop.

[0022] The notification board 243 is capable of executing a reception process for receiving operation input information, sensor input information, and monitoring information, and a notification signal output process for generating a notification signal related to the robot main body 21 based on this information and outputting it to the outside. As shown in Fig. 4, the notification board 243 has first and second notification CPUs 243a, 243b as control units, first and second memories 243c, 243d, and a terminal block 243e as an attribute input unit. The notification board 243 is connected to a communication bus B that complies with the CAN (Controller Area Network) communication protocol.

[0023] The first notification CPU 243a can acquire attribute information by referring to the input to the terminal block 243e and terminal designation information stored in the first memory 243c, which will be described later. Here, the attribute information includes cooperation information, group information, and leader information shown in FIG. 3. Cooperation information is information indicating whether the operation of the first robot apparatus 2a is to be coordinated with the operations of the other robot apparatuses 2b to 2d. Group information is information specifying the group to which the first robot apparatus 2a belongs. Leader information is information indicating whether the first robot apparatus 2a is a leader or a follower. The cooperation information, group information, and leader information of the first to fourth robot apparatuses 2a to 2d are set, for example, as shown in FIG. 3.

[0024] Similarly, the second notification CPU 243b can also acquire attribute information by referring to the input to the terminal block 243e and the terminal designation information stored in the second memory 243d, which will be described later.

[0025] The first and second notification CPUs 243a, 243b each determine whether or not to stop the robot body 21 by determining whether at least one of the following first to eighth conditions is satisfied or whether none of the first to eighth conditions is satisfied.

[0026] The first condition is that the safety condition is not met.

[0027] The second condition is that the area sensor 23 detects that a person has entered the working range of the robot body 21.

[0028] The third condition is that the input unit 221 of the first robot device 2a has received an emergency stop input.

[0029] The fourth condition is that a request to stop the robot body 21 has been received from the safety PLC 3.

[0030] The fifth condition is that a predetermined abnormality occurs in one of the robot devices 2b-2d other than the first robot device 2a, the coordination information input to the terminal block 243e of the first robot device 2a indicates that the operation of the first robot device 2a should be coordinated with the operation of the other robot devices 2b-2d, and the group to which the other robot device 2b-2d in which the abnormality occurred belongs is the same as the group identified by the group information input to the terminal block 243e of the first robot device 2a. The occurrence of a predetermined abnormality in the other robot devices 2b-2d is determined based on emergency stop information output to the bus B from the notification boards 243 of the other robot devices 2b-2d. The emergency stop information indicates the presence or absence of an abnormality for each type of abnormality. For example, the emergency stop information includes an emergency stop signal indicating the presence or absence of an abnormality, such as an emergency stop input received by the teach pendant 22, and an abnormality notification signal indicating the presence or absence of other abnormalities, such as an excess or shortage of welding current or a collision of the robot main body 21 with a foreign object. If the emergency stop information output to bus B indicates the presence of at least one abnormality, the first and second notification CPUs 243a and 243b determine that a predetermined abnormality related to the other robot devices 2b to 2d has occurred. The determination of the fifth condition is performed by further referencing the attribute information of the other robot devices 2b to 2d output to bus B by the other robot devices 2b to 2d. That is, the determination of the fifth condition is performed based on whether the group identified by the group information output to bus B by the other robot devices 2b to 2d is the same as the group identified by the group information input to the terminal block 243e of the first robot device 2a. The predetermined abnormality includes abnormalities such as the teach pendant 22 of the other robot devices 2b to 2d receiving an emergency stop input, excessive or insufficient welding current, or collision of the robot main body 21 with a foreign object. Abnormalities such as excessive or insufficient welding current or collision of the robot main body 21 with a foreign object are detected by detection means (not shown) provided in each robot device 2a to 2d.

[0031] The sixth condition is that the coordination information input to the terminal block 243e indicates that the operation of the first robot apparatus 2a is to be coordinated with the operation of the other robot apparatuses 2b to 2d, and an abnormality has occurred in communication via the bus B with the other robot apparatuses 2b to 2d different from the first robot apparatus 2a.

[0032] The seventh condition is that the leader information input to the terminal block 243e of the first robot apparatus 2a indicates a follower, and the mode switching input and operation input input to the teach pendants 22 of the other robot apparatuses 2b to 2d that are leaders and belong to the same group as the first robot apparatus 2a satisfy a predetermined condition. The seventh condition is determined by referring to the attribute information input to the terminal block 243e of the first robot apparatus 2a, the attribute information of the other robot apparatuses 2b to 2d, and control signals that indicate operation input information corresponding to the mode switching input and operation input of the other robot apparatuses 2b to 2d. The attribute information of the other robot apparatuses 2b to 2d and the control signals of the other robot apparatuses 2b to 2d are output to the bus B by the other robot apparatuses 2b to 2d.

[0033] The eighth condition is that the reader information input to the terminal block 243e of the first robot device 2a indicates a reader, and the mode switching input and operation input input to the teach pendant 22 of the first robot device 2a satisfy predetermined conditions.

[0034] When at least one of the first to eighth conditions is satisfied, each of the notification CPUs 243a and 243b sets the notification signal to low level. On the other hand, when none of the first to eighth conditions is satisfied, each of the notification CPUs 243a and 243b sets the notification signal to high level.

[0035] Each of the notification CPUs 243a, 243b determines whether the value (level) of the notification signal matches the value of the notification signal output by the other notification CPU 243a, 243b. If the value of the notification signal obtained by the notification CPU 243a, 243b matches the value of the notification signal obtained by the other notification CPU 243a, 243b, the notification CPU 243a, 243b continues processing as is, but if they do not match a predetermined number of times, the robot main body 21 is stopped.

[0036] When both notification CPUs 243a, 243b set the notification signal to low level, the notification board 243 outputs a low level notification signal to the monitoring board 242, thereby stopping the robot main body 21. Also, when both notification CPUs 243a, 243b set the notification signal to low level, the notification board 243 outputs emergency stop information indicating the presence of an abnormality and the attribute information input to the terminal block 243e to bus B. When both notification CPUs 243a, 243b set the notification signal to high level, the notification board 243 outputs emergency stop information indicating no abnormality to bus B.

[0037] Furthermore, when the leader information input to the terminal block 243e indicates the leader, the first and second notification CPUs 243a, 243b each control the controllers 24 of the other robot devices 2b to 2d belonging to the same group by outputting a control signal based on the mode switching input and operation input received by the input unit 221 of the teach pendant 22 and the attribute information input to the terminal block 243e to the bus B. Then, the notification boards 243 of the other robot devices 2b to 2d belonging to the same group receive the control signal via the bus B, and the robot bodies 21 of the other robot devices 2b to 2d are controlled based on this control signal.

[0038] On the other hand, when the leader information input to the terminal block 243e indicates a follower, the first and second notification CPUs 243a, 243b are each controlled by a control signal output to the bus B by the controllers 24 of the other robot devices 2b to 2d that belong to the same group. By referring to the group information and leader information input to the terminal block 243e and the group information and leader information output to the bus B from the other robot devices 2b to 2d, the first and second notification CPUs 243a, 243b can determine whether the other robot devices 2b to 2d belong to the same group as the first robot device 2a and whether the other robot devices 2b to 2d are leaders or followers.

[0039] The first and second memories 243c and 243d store terminal designation information that designates the terminal of the terminal block 243e to which attribute information of the first robot device 2a is input. Specifically, the terminal designation information stores first terminal information that designates the terminal to which cooperation information is input, second terminal information that designates the terminal to which group information is input, and third terminal information that designates the terminal to which leader information is input.

[0040] The first notification CPU 243a identifies, among the inputs to the terminal block 243e, the input to the terminal designated by the first terminal information stored in the first memory 243c as cooperation information. Furthermore, the first notification CPU 243a identifies, among the inputs to the terminal block 243e, the input to the terminal designated by the second terminal information stored in the first memory 243c as group information. Furthermore, the first notification CPU 243a identifies, among the inputs to the terminal block 243e, the input to the terminal designated by the third terminal information stored in the first memory 243c as leader information.

[0041] Similarly, the second notification CPU 243b identifies, among the inputs to the terminal block 243e, the input to the terminal designated by the first terminal information stored in the second memory 243d as cooperation information. Furthermore, the second notification CPU 243b identifies, among the inputs to the terminal block 243e, the input to the terminal designated by the second terminal information stored in the second memory 243d as group information. Furthermore, the second notification CPU 243b identifies, among the inputs to the terminal block 243e, the input to the terminal designated by the third terminal information stored in the second memory 243d as leader information.

[0042] The terminal block 243e has, for example, a plurality of input terminals to which signals specifying attribute information are input.

[0043] The main control board 244 transmits the operation input information transmitted from the TP side communication board 223 to the notification board 243 .

[0044] The motor control unit 245 controls the nine motors 211 by controlling the nine amplifiers 246 .

[0045] The amplifier 246 stops the motor 211 when a stop signal is output from the monitoring board 242. When a stop signal is not output from the monitoring board 242, the amplifier 246 can rotate the motor 211 under the control of the motor control unit 245.

[0046] The transmission and reception of signals (information) between the operation input board 222 and the notification board 243 is performed using a communication method defined in IEC61784-3 (black channel communication protocol). The TP side communication board 223, the main control board 244, and the wiring M connecting both boards 223, 244 form a so-called black channel. The transmission and reception of signals (information) between the monitoring board 242 and the notification board 243, and between the sensor input board 241 and the notification board 243, is also performed using a communication method defined in IEC61784-3.

[0047] When a low-level notification signal is output by the first and second notification CPUs 243a, 243b of at least one of the robot devices 2a to 2d, the safety PLC 3 requests, for example, some of the robot devices 2a to 2d to stop the robot body 21.

[0048] In the robot system 1 configured as described above, a case will be described in which attribute information specifying cooperation information, group information, and leader information as shown in Fig. 3 is input to the terminal block 243e of the notification board 243 of the first to fourth robot devices 2a to 2d. In Fig. 3, cooperation information ON indicates that the operations of the robot devices 2a to 2d are coordinated with the operations of the other robot devices 2a to 2d, and cooperation information OFF indicates that the operations of the robot devices 2a to 2d are not coordinated with the operations of the other robot devices 2a to 2d. Furthermore, the numbers in the group information indicate the groups to which the robot devices 2a to 2d belong. Furthermore, leader information ON indicates that the robot devices 2a to 2d are leaders, and leader information OFF indicates that the robot devices 2a to 2d are followers.

[0049] In the example of FIG. 3, in the first robotic device 2a, cooperation information of ON, group information of 0, and leader information of ON are input to the terminal block 243e.

[0050] In the second robotic device 2b, cooperation information of ON, group information of 0, and leader information of OFF are input to the terminal block 243e.

[0051] In addition, in the third robot device 2c, the ON cooperation information, the 1 group information, and the ON leader information are input to the terminal block 243e.

[0052] In the fourth robot device 2d, cooperation information of ON, group information of 1, and leader information of OFF are input to the terminal block 243e.

[0053] Thereafter, in the first robot device 2a, when the input unit 221 of the teach pendant 22 receives an emergency stop input, operation input information based on the emergency stop input is transmitted from the operation input board 222 to the notification board 243 via the TP-side communication board 223 and the main control board 244. The notification board 243 receives this operation input information. At this time, the third condition that the input unit 221 has received the emergency stop input is satisfied, so the first and second notification CPUs 243a, 243b output low-level notification signals to the monitoring board 242, thereby stopping the corresponding robot main body 21. In addition, the notification board 243 outputs emergency stop information indicating the presence of an abnormality and the attribute information input to the terminal block 243e to the bus B. At this time, the cooperation information input to the terminal block 243e of the second robotic apparatus 2b is ON, and the group to which the first robotic apparatus 2a belongs (the group identified by the group information output to bus B by the first robotic apparatus 2a) is the same as the group identified by the group information input to the terminal block 243e of the second robotic apparatus 2b. Therefore, the first notification CPU 243a of the second robotic apparatus 2b determines that the fifth condition is met and outputs a low-level notification signal to the monitoring board 242. Similarly, the second notification CPU 243b of the second robotic apparatus 2b also references the cooperation information and group information input to the terminal block 243e, determines that the fifth condition is met, and outputs a low-level notification signal to the monitoring board 242. Meanwhile, in the third and fourth robot devices 2c and 2d, the notification board 243 also receives the emergency stop information and attribute information indicating an abnormality output to the bus B by the first robot device 2a, but the group to which the first robot device 2a belongs is not the same as the group identified by the group information input to the terminal blocks 243e of the third and fourth robot devices 2c and 2d. Therefore, in the third and fourth robot devices 2c and 2d, the first and second notification CPUs 243a and 243b determine that the fifth condition is not satisfied and do not stop the robot main body 21.

[0054] In this way, when an abnormality occurs in one of the robot devices 2a to 2d, the operation of the robot bodies 21 of the robot devices 2a to 2d in a group different from that of the robot device 2a to 2d can be continued, thereby improving the efficiency of the work performed by the robot system 1 compared to when all the robot bodies 21 are stopped.

[0055] Furthermore, when an abnormality occurs in communication via bus B between the notification board 243 of the first robotic device 2a and the notification board 243 of the second robotic device 2b, the cooperation information input to the terminal block 243e of the first robotic device 2a is ON, so the first and second notification CPUs 243a, 243b of the first robotic device 2a determine that the sixth condition is satisfied. Then, the first and second notification CPUs 243a, 243b of the first robotic device 2a output a low-level notification signal to the monitoring board 242, thereby stopping the robot body 21 of the first robotic device 2a.

[0056] Furthermore, in the first robot device 2a, when the input unit 221 of the teach pendant 22 receives a mode switching input or an operation input from the user, operation input information corresponding to this input is transmitted from the operation input board 222 to the notification board 243. In the first robot device 2a, since the reader information input to the terminal block 243e is ON, the first and second notification CPUs 243a, 243b transmit a control signal based on the operation input information corresponding to the mode switching input or operation input, and the attribute information input to the terminal block 243e, to the bus B. In the second robot device 2b, which belongs to the same group, the first and second notification CPUs 243a, 243b receive the control signal and the attribute information from the first robot device 2a via the bus B. The first and second notification CPUs 243a, 243b of the second robotic device 2b refer to the attribute information input to the terminal block 243e of the second robotic device 2b and the attribute information from the first robotic device 2a to determine that the first robotic device 2a is a leader belonging to the same group as the second robotic device 2b, and are controlled based on a control signal from the first robotic device 2a. Note that the second robotic device 2b, which is the follower, is controlled as described above by input to the teach pendant 22 of the first robotic device 2a, which is the leader belonging to the same group. However, it may also be controlled by input to the teach pendant 22 of the second robotic device 2b itself. In more detail, for example, the second robotic device 2b, which is the follower, may be controlled based on the logical sum of a mode switching input input to the second robotic device 2b itself and a mode switching input from the first robotic device 2a. In other words, when at least one of the mode switching input input to the second robot device 2b itself and the mode switching input from the first robot device 2a commands a mode switch, the first and second notification CPUs 243a, 243b of the second robot device 2b may switch modes.

[0057] Similarly, in the above embodiment, the second robot device 2b, which is the follower, is controlled based on an actuation input (control signal) from the first robot device 2a, which is the leader, but it may be controlled based on the logical sum of an actuation input input to the second robot device 2b itself and an actuation input from the first robot device 2a. In other words, when at least one of the actuation input input to the second robot device 2b itself and the actuation input from the first robot device 2a instructs the second robot device 2b to maintain an actuation state, the first and second notification CPUs 243a, 243b of the second robot device 2b may be configured to maintain an actuation state.

[0058] Furthermore, in the above embodiment, when the first robot device 2a is a follower, the notification CPUs 243a, 243b of the first robot device 2a determine the notification signal by referring to the mode switching input and operation input input to the teach pendants 22 of the other robot devices 2b to 2d that are leaders and belong to the same group as the first robot device 2a. However, when the first robot device 2a is a follower, the notification signal determination in the first robot device 2a (determination of whether to stop the robot main body 21) may be performed by further referring to the mode switching input and operation input input to the teach pendant 22 of the other robot devices 2b to 2d that are leaders, as well as the mode switching input and operation input input to the teach pendant 22 of the first robot device 2a itself.

[0059] Furthermore, in the above embodiment, the present invention is applied to the robot system 1 having the safety PLC 3, but the present invention can also be applied to a robot system 1 that does not have the safety PLC 3.

[0060] In addition, in the above embodiment, the terminal block 243e to which the attribute information is input is provided on the notification board 243, but it may be provided on the sensor input board 241. Also, the input unit of the safety PLC 3 may be used for inputting the attribute information instead of the terminal block 243e to which the attribute information is input. [Industrial Applicability]

[0061] The robot system of the present disclosure can increase the efficiency of work performed by the robot system, and is useful as a robot system including multiple robot devices. [Explanation of symbols]

[0062] 1. Robot System 2a First robot device 2b Second robotic device 2c Third robotic device 2d Fourth Robot Device 21 Robot body 22 Teach pendant (input device) 23 Area Sensor 24 Controller 243a First notification CPU (control unit) 243b Second notification CPU (control unit) 243e Terminal block (attribute input section)

Claims

1. A robot system including a plurality of robot devices, each having a robot body and a controller for controlling the robot body, The controller an attribute input unit to which group information specifying a group to which the robot device having the controller belongs is input; a control unit that, when a predetermined abnormality occurs in another robot device different from the robot device having the controller, determines whether to stop the robot main body based on whether a group identified by group information output by the other robot device is the same as a group identified by group information input to the attribute input unit.

2. 2. The robot system according to claim 1, Each of the robotic devices further includes an input device that receives an emergency stop input; The robot system is characterized in that the abnormality occurs when the input device of the other robot device receives the emergency stop input.

3. 2. The robot system according to claim 1, each of the robotic devices further includes an input device that accepts input from a user; In each of the controllers, leader information indicating whether the robot device having the controller is a leader or a follower is further input to the attribute input unit; The control unit controls the controller of the other robot devices belonging to a common group based on the group information and the leader information input to the attribute input unit when the leader information indicates a leader, based on the input to the input device of the robot device having the controller, while when the leader information indicates a follower, the robot system is controlled by the controller of the other robot devices belonging to the common group.

4. 4. The robot system according to claim 3, In each of the controllers, a control unit that refers to the leader information input to the attribute input unit, and when the leader information indicates a follower, determines whether or not to stop the robot main body having the controller based on the input to the input device of the robot device having the controller and the input to the input device of another robot device that belongs to a common group.

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