System with industrial robot and end effector with power tool and charger

Abstract

The system (1) comprises an industrial robot (2) having a robot arm distal section (3) and a power supply circuit (4) configured to provide electrical current to the robot arm distal section (3), an end effector (5) attached to the robot arm distal section (3) and comprising a power tool (6) and a power storage module (7) (e.g., a battery) configured to power the operation of the power tool (6), the end effector (5) further comprising a charger (8) arranged to draw current from the power supply circuit at the robot arm distal section and provide a charging current to the power storage module (7), facilitating charging of the power storage module (7) for the power tool (6) and increasing the efficiency of the manufacturing process.

Description

[Technical Field]

[0001] The present disclosure relates generally to the field of industrial robots having end effectors for manipulating power tools, and more particularly to charging power storage modules that power such power tools. [Background technology]

[0002] In manufacturing, industrial robots can be used to process objects using power tools. Such industrial robots are equipped with so-called end effectors, which are devices attached to the end of a robot arm and designed to interact with objects and / or the surrounding environment. The end effector is usually referred to as the final link of the robot. The end effector typically includes a power tool and is attached to the distal end of the robot arm. The end effector may also include some kind of (energy) storage module, such as a battery, that powers the operation of the power tool.

[0003] The storage modules must be periodically charged to properly power the power tool. Typically, a robot drops an empty storage module onto a charger stand and picks up another charged storage module from the charger stand. This process is tedious and time-consuming, reducing the efficiency of the manufacturing process. Summary of the Invention [Problem to be solved by the invention]

[0004] It would be advantageous to have a system that solves or at least mitigates the problems discussed above. In particular, it would be desirable to have a system that facilitates charging of power tools operated by industrial robots. [Means for solving the problem]

[0005] To better address one or more of these problems, a system is provided having the features defined in the independent claims. Preferred embodiments are defined in the dependent claims.

[0006] A system is provided, comprising an industrial robot including a robot arm distal section and a power supply circuit configured to provide current to the robot arm distal section. The system further comprises an end effector including a power tool and an (energy) storage module configured to power operation of the power tool. The end effector is attached to the robot arm distal section. The end effector further comprises a charger configured to draw current from the power supply circuit at the robot arm distal section and provide a charging current to the storage module.

[0007] The inventors have recognized that the available current at the end of the robot arm can be utilized to charge a storage module for a power tool. The available current from a standard industrial robot's power circuit is typically not sufficient to supply the power tool with its peak operating current, but can be used to continuously charge the storage module when needed. Thus, the storage module provides peak power to the power tool during operation, but the current from the industrial robot is utilized to recharge the storage module as needed. This reduces the need to replace empty storage modules with charged ones, thereby saving time in the manufacturing process. Furthermore, the need for a separate charging station for the storage module is reduced, thereby saving resources in the manufacturing process. As a result, charging the storage module for the power tool is easier and the manufacturing process is more efficient.

[0008] For example, the system can be configured so that the charging current (available from the industrial robot's power supply circuit) is a fraction of the peak current consumed by the power tool when operating, for example, less than one-third of the peak current consumed by the power tool when operating, for example, less than one-fifth of the peak current consumed by the tool when operating, for example, on the order of one-tenth of the peak current consumed by the power tool when operating.

[0009] For example, the available current from the power supply circuit may be approximately 1-3 A, while the peak current consumed by the power tool may be approximately 15 A-30 A. Thus, the storage module may be utilized to supply the relatively high peak current required to operate the tool, while the relatively low current available from the industrial robot is used to charge the storage module.

[0010] For example, the capacity of the storage module may be adapted to supply the full peak current draw of the power tool when the power tool is in operation, and the main power source for operating the power tool may therefore be the storage module.

[0011] According to one embodiment, the system may further comprise a control device configured to control charging of the storage module by the charger. The control device may thus be utilized to manage the charging of the storage module in various ways, thereby enabling several advantages as further described below.

[0012] The term "control device" is broadly interpreted as any means, decentralized or centralized, configured to control the charging of the storage modules. Alternatively, a control device may be referred to as a control unit, a control system, or a control circuit.

[0013] According to one embodiment, the control device can be configured to control the charging current to be below a (preset) current threshold that is less than the total current available from the power circuit (of the industrial robot). Thus, part of the current from the power circuit can be used for other purposes, such as a vision camera or a gripping tool integrated into the industrial robot. For example, if the total current available from the industrial robot is about 2 A, the charging current can be controlled not to exceed a current threshold of 0.7 A.

[0014] According to one embodiment, the current threshold value may simply be preset to a static value, etc. For example, the current threshold value may be preset by an operator setting up the system or may be preset at a factory setting.

[0015] According to another embodiment, the current threshold can be based on one or more dynamic parameters (such as a control signal), which allows for smarter control of charging. For example, if the robot's control system dictates that the robot and its power tools not be operated for a certain period of time, the current threshold can be increased, resulting in faster charging of the storage module. On the other hand, if more current is required for the industrial robot's operation, the threshold can be decreased.

[0016] According to one embodiment, the control device can be configured to control charging, such that the storage module is charged by the charger during operations performed by the power tool, and optionally when operations are performed by the power tool.

[0017] According to one embodiment, the control device can be located within the industrial robot and / or within the end effector. For example, the control device can be located within a power storage module, within the power tool, or within a holder for the end effector that holds the power tool. Alternatively, the control device can be located separate from, but in communication with, the industrial robot and end effector.

[0018] According to one embodiment, the control device may be configured to control charging such that the charge level of the storage module is maintained below the maximum charge capacity of the storage module, for example below 80% of the maximum charge capacity of the storage module, for example below 70% of the maximum charge capacity of the storage module, for example below 60% of the maximum charge capacity of the storage module. Having an upper charge limit extends the life of the energy storage and is particularly advantageous in the present system since the storage module may be connected to a charger most of the time.

[0019] According to one embodiment, the control device can be configured to control charging such that the charge level of the storage module is maintained above a minimum threshold, e.g., above 20% of the module's maximum charge capacity, e.g., above 30% of the storage module's maximum charge capacity, e.g., above 40% of the storage module's maximum charge capacity. By avoiding complete depletion of the storage module, the life of the storage module is extended and the risk of interruptions in the operation of the power tool is reduced.

[0020] Because the storage modules of the present system are likely to be connected to a charger most of the time, and additionally, the time-consuming task of replacing empty storage modules can be avoided, a relatively small state-of-charge window can be used, which is beneficial to the health of the storage modules.

[0021] According to one embodiment, the control device may be configured to activate a warning signal if the charge level of the storage module is too low and / or too high, to reduce the risk of the storage module being depleted, which may interrupt the manufacturing process as the storage module will not be able to operate the power tool, and / or to reduce the risk of the storage module being charged more than necessary, which may be unhealthy for the storage module.

[0022] For example, a warning signal may be issued if the charge level of the storage module falls below a particular threshold that defines a minimum acceptable charge level and / or if it exceeds another particular threshold that defines a maximum acceptable charge level.

[0023] According to one embodiment, the end effector can include a holder configured to hold a power tool, the holder being attached to a distal portion of the robot arm. This facilitates changing the power tool, for example, to a different type of power tool. Thus, the power tool and the holder can be separate components.

[0024] Alternatively, the power tool may be an integral part of the end effector, so that modifying the power tool may involve modifying the entire end effector.

[0025] According to one embodiment, the charger may be located on the power tool or elsewhere on the end effector, such as in a holder.

[0026] According to one embodiment, the power storage module can be attached and connected to a charger.

[0027] According to one embodiment, the robot arm distal end portion may include electrical contacts (e.g., sockets) adapted to mate with electrical contacts on the end effector to electrically connect the charger of the end effector with a power circuit of the industrial robot.

[0028] It is to be noted that embodiments of the invention relate to all possible combinations of the features recited in the claims.

[0029] The system is described in more detail below in the detailed description of exemplary and non-limiting embodiments with reference to the accompanying drawings. [Brief explanation of the drawings]

[0030] [Figure 1] 1 illustrates a system according to one embodiment. [Figure 2] 1 shows in more detail a portion of the system including the end effector and the distal portion of the robot arm. DETAILED DESCRIPTION OF THE INVENTION

[0031] All drawings are schematic and not necessarily to scale, and generally only parts necessary for clarity of the embodiments are shown, and other parts may be omitted. Like reference numerals refer to like elements throughout the specification.

[0032] 1, a system 1 according to one embodiment includes an industrial robot 2 and an end effector 5 operated by the robot 2. The system 1 can be automated and can operate in at least one axis, preferably two or more axes. For example, the system 1 can be used in manufacturing, such as for assembling parts.

[0033] The industrial robot 2 may comprise a robot arm 16, which may have one or more joints 17 that allow movement of the robot arm 16 about one or more axes. A robot arm end section 3 is provided at the distal end of the robot arm 16. The industrial robot 2 further comprises a power supply circuit 4 configured to supply current to the robot arm end section 3. The power supply circuit 4 may, for example, derive current from a mains power supply. The power supply circuit 4 may comprise or be connected to a control device 9 for the industrial robot 2. The control device 9 may be configured to control the power supply circuit 4. For example, the industrial robot 2 may be stationary or may be located along an assembly line.

[0034] The end effector 5 is attached to the robot arm distal section 3 and comprises a power tool 6 and a power storage module 7 configured to provide power for the operation of the power tool 6. The power tool 6 may be, for example, some type of fastening tool, riveting tool, or drill.

[0035] The power storage module 7 may comprise, for example, a battery, a capacitor, or some other type of means for storing energy that is used to power the tool 6 .

[0036] For example, the end effector 5 can include a holder 11 configured to hold a power tool 6. The holder 11 can be a part of the end effector 5 that is attached to the robot arm distal section 3. The power tool 6 can be attached to the holder 11. Alternatively, the holder 11 can be integral with the power tool 6. For example, the power storage module 7 can be attached to / included in the holder 11, as shown in FIGS. 1 and 2, or attached to / included in the power tool 6 (not shown).

[0037] The end effector 5 further comprises a charger 8 configured to draw current from the power circuit 4 at the robot arm distal section 3 and to provide charging current to the storage module 7. An electrical connection may be provided between the power circuit 4 of the robot arm distal section 3 and the charger 8 of the end effector 5 to provide current therebetween to enable charging. The charger 8 may comprise electrical contacts 15 adapted to mate with electrical contacts 14 of the storage module 7 (see FIG. 2 ). During operation, current flows from the power circuit 4 to the end effector 5 and its charger 8, and then from the charger 8 to the storage module 7. Preferably, the storage module 7 may be connected (attached) to the charger 8 during operation of the system 1, including operation of the power tool 6.

[0038] The system 1 may further include a control device 10 configured to control charging of the storage module 7 by the charger 8. The control device 10 may be located within the end effector 5, such as in a holder 11 as shown in FIG. 1 , or may be located within the power tool 6 (not shown). Alternatively, the control device 10 may be located within (or connected to) the industrial robot 2, for example, a control device 9 for the power supply circuit 4.

[0039] 2, embodiments of system 1 are described in more detail below. For example, holder 11 can include a charger portion 18 that includes a charger 8 and is configured to hold a power storage module 7. A cable 12 can provide power to charger portion 18 from a power supply circuit 4 at the robot arm distal end portion 3. Cable 12 can be routed outside or inside (the latter not shown) the robot arm distal end portion 3 and end effector 5. End effector 5 can include circuitry that provides power from the power storage module 7 to a power tool 6. For example, a cable 13 can provide power from charger portion 18 to power tool 6.

[0040] According to one embodiment, the charging current for charging the storage module 7 may be a small fraction of the peak current consumed by the power tool 6 during operation. Typically, the power tool 6 may require a peak current of approximately 15 to 30 A during operation, but the charging current may be limited to approximately 0.5 to 3 A. For example, the charging current may be less than one-third of the peak current consumed by the power tool 6 during operation, such as less than one-fifth of the peak current consumed by the power tool 6 during operation.

[0041] For example, the power storage module 7 may have a capacity capable of supplying peak current during operation to the power tool 6. The power storage module 7 may include, for example, an 18V, 24V, 36V, or 48V battery.

[0042] According to one embodiment, the control device 9 can be configured to control the charging of the storage module 7 such that the charging current is maintained below a (preset or dynamic) threshold that is lower than the total current available from the power supply circuit 4. Thus, charging of the power tool 6 can utilize only a portion of the available current from the industrial robot 2, which in turn can be used for other purposes.

[0043] The power tool 6 may be charged only while the power tool 6 is in operation, or may simply be charged continuously as long as the charge level of the storage module 7 is below a certain (pre-set) threshold.

[0044] The control device 10 can be configured to control the charge level of the storage module 7 to be below a (preset) maximum threshold and, optionally, above a (preset) minimum threshold. This can be referred to as the state-of-charge window of the storage module 7. The state-of-charge window can have a lower threshold, for example, comprised within a range of 20 to 40% of the maximum charge capacity. The upper threshold can be comprised within a range of 60 to 80% of the maximum charge capacity. Because the storage module 7 can be continuously charged by the end effector 5, the state-of-charge window can be kept relatively small, which is beneficial for the health of the storage module 7.

[0045] According to one embodiment, the control device 10 may be configured to provide a warning signal in response to the charge level of the storage module 7 falling below a minimum threshold and / or exceeding a maximum threshold. An operator of the system 1 may then be notified that charging of the storage module 7 is not occurring as expected. The warning signal may be, for example, a visual and / or audio signal.

[0046] Those skilled in the art will recognize that the invention is not limited to the embodiments described above: on the contrary, many modifications and variations are possible within the scope of the appended claims.

[0047] In addition, variations of the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite articles "a" or "an" do not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. [Explanation of symbols]

[0048] 1 System 2. Industrial robots 3. End of robot arm 4 Power circuit 5 End Effector 6 Power tools 7 Energy storage module 8 charger

Claims

1. an industrial robot (2) comprising a robot arm end portion (3) and a power supply circuit (4) configured to supply current to said robot arm end portion (3); an end effector (5) attached to the robot arm distal section (3), the end effector comprising a power tool (6) and a storage module (7) configured to provide power for operation of the power tool (6); A system comprising: The end effector (5) further comprises a charger (8) configured to draw current from the power supply circuit (4) at the robot arm distal end (3) and provide a charging current to the storage module (7); The system further comprises a control device (10) configured to control charging of the storage module (7) by the charger (8); The system is configured to control the charging current to be below a current threshold set based on one or more dynamic parameters of the industrial robot (2) and the power tool (6).

2. the charging current is a fraction of the peak current consumed by the power tool (6) during operation; For example, less than one-third of the peak current consumed by the power tool (6) during operation; For example, the system (1) according to claim 1, wherein the peak current consumed by the power tool (6) during operation is less than 1 / 5.

3. 2. The system (1) according to claim 1, wherein the capacity of the storage module (7) is adapted to provide the full peak current draw of the power tool (6) when the power tool (6) is in operation.

4. A system (1) as described in claim 1, wherein the current threshold is set to be less than the total current available from the power supply circuit (4).

5. 2. The system (1) of claim 1, wherein the control device (10) is configured to control charging, and the storage module (7) is charged by the charger (8) during operations performed by the power tool (6), optionally at the time of operations performed by the power tool (6).

6. The system (1) according to claim 1, wherein the control device (10) is arranged in an industrial robot (2) and / or in the end effector (5).

7. The control device (10) is configured to: For example, less than 80% of the maximum charge capacity of the storage module (7), For example, less than 70% of the maximum charging capacity of the storage module (7), For example, less than 60% of the maximum charge capacity of the storage module (7), 2. The system (1) according to claim 1, configured to control charging so that the charging is maintained.

8. The control device (10) is configured to: For example, exceeding 20% ​​of the maximum charge capacity of the storage module (7), For example, exceeding 30% of the maximum charging capacity of the storage module (7), For example, exceeding 40% of the maximum charging capacity of the storage module (7), 2. The system (1) according to claim 1, configured to control charging so that the charging is maintained.

9. 2. The system (1) according to claim 1, wherein the control device (10) is configured to activate a warning signal if the charge level of the storage module (7) is too low and / or too high.

10. 2. The system (1) of claim 1, wherein the end effector (5) comprises a holder (11) configured to hold the power tool (6), the holder (11) being attached to the robot arm end portion (3).

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