Robot Cell Mode Control for Safe Synchronized Robot Switching
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Solution Overview
Problem
Existing industrial robot control systems lack an efficient and safe method for simultaneously changing the operating mode of multiple robots within a manufacturing system, often requiring manual and error-prone mechanical switches or virtual buttons, which can compromise operator safety and introduce data transmission errors.
Innovation Solution
A centralized control system using a master computer with a communication network to synchronize mode changes across robot control devices, incorporating safety controllers and mode switching logic that ensures secure operation mode changes based on sensor inputs and operator confirmation, reducing the risk of errors and ensuring operator safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual mechanical switches or virtual buttons are used to change operating mode for each robot individually, then the operating mode can be changed for each robot, but the process becomes time-consuming and error-prone
Solution Approach 1:
The patent combines multiple individual mode change operations into a single centralized mode change command. The control system allows an operator to issue one mode change command that simultaneously changes the operating mode of multiple robots, eliminating the need to manually change each robot's mode separately and significantly reducing the time and effort required.
Solution Approach 2:
The control system provides a universal mode change function that can simultaneously control multiple robots with different operating modes (automatic, semi-automatic, manual). The system handles various robot types and states through a single interface, making the mode change process efficient and standardized across the entire robotic system.
2Adaptability or versatility
If individual mechanical switches are used for mode changes, then each robot can be controlled independently, but operator safety is compromised due to potential errors and lack of coordination
Solution Approach 1:
The control system incorporates feedback mechanisms that monitor the state of each robot and the overall system configuration. Before executing a mode change, the system checks the current states of all robots and provides feedback to the operator. The system only allows mode changes when safety conditions are met, such as ensuring robots are properly positioned or that no dangerous operations are in progress, thereby maintaining operator safety while enabling coordinated control.
Solution Approach 2:
The system performs preliminary checks and preparations before executing mode changes. It evaluates the current system state, identifies potential safety risks, and prepares appropriate safety measures before allowing the mode change to proceed. This preliminary action ensures that mode changes are only executed when safe, preventing accidents while maintaining the ability to control each robot independently when needed.
3Reliability
If centralized control is implemented for mode changes, then operator safety and coordination are improved, but system complexity increases
Solution Approach 1:
The control system acts as an intermediary between the operator and multiple robots. It provides a simplified user interface that abstracts the complexity of coordinating multiple robots, allowing the operator to issue simple mode change commands without needing to understand or manage the complex underlying coordination logic. The intermediary handles the complex safety checks, state monitoring, and coordinated execution, thereby improving safety while keeping the operator interface simple.
Data Source
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Figure 4~5B
Figure 5C~5D
AI summary
A manufacturing system comprises a plurality of industrial robots (2A) located within one or more robot cells(1),a set of robot control devices(10)and a central computer device (20). Each robot control device (10) is arranged to control a respective subset of the industrial robots (2A),and the central computer device(20) is connected via a communication network (21) to the set of robot control devices (10) and configured to provide, to the set of robot control devices(10), at least one central mode selection signal which defines a request for a switch of operating mode. The respective robot control device (10) comprises a mode controller which is configured to switch, based on the at least one central mode selection signal,the respective robot control device (10) between at least an automatic mode and a manual mode.