Robot Controller Local Error Replay for Injection Molding
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Solution Overview
Problem
Current methods for data recording and analysis in robotic systems require extended downtime for error analysis, as data must be transferred to external devices for analysis, making immediate error detection and correction difficult and resource-intensive.
Innovation Solution
The robot controller records and stores data such as state changes, positions, and timestamps, allowing for immediate error analysis through a virtual model simulation on the controller, enabling fast and reliable error detection and correction without the need for external data transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data are transferred to external devices (laptop/computer) for analysis, then comprehensive error analysis can be performed, but system downtime is extended and productivity is reduced
Solution Approach 1:
The patent merges the data analysis capability directly into the robot controller by integrating a visualizer that can process and display recorded operation data locally. This eliminates the need to transfer data to external devices, allowing error analysis to be performed on-site without extending system downtime, thus resolving the contradiction between comprehensive error analysis capability and productivity maintenance.
2Loss of information
If all data are recorded over the entire working period, then complete operation history is available for analysis, but data volume increases resulting in considerable analysis effort
Solution Approach 1:
The patent extracts and highlights only the relevant portions of recorded data surrounding error occurrences. The visualizer automatically identifies and displays the time period before and after errors, extracting critical information from the complete operation history. This reduces the data analysis complexity while maintaining operation history completeness, as users only need to examine the extracted relevant segments rather than the entire data set.
Solution Approach 2:
Instead of analyzing the entire working period data, the system applies partial action by focusing only on the necessary time window around error events. The visualizer configures itself to display only the relevant portion of recorded data (before and after errors), which is sufficient for error analysis without requiring processing of excessive data, thus reducing analysis effort while maintaining completeness of critical information.
3Quantity of substance
If data are stored externally on laptop or computer, then data storage capacity is sufficient, but immediate error analysis on the system is not possible
Solution Approach 1:
The robot controller performs error analysis independently without requiring external devices. The integrated visualizer processes recorded data locally within the controller, enabling the system to serve itself for diagnostic purposes. This eliminates the time loss associated with data transfer and external analysis, as error detection can be performed immediately on the system itself using the controller's own storage and processing capabilities.
Data Source
AI summary
A method for the continuous storage of internal operating states and visualization of past sequences of operations, as well as to a robot and/or robot controller, wherein the robot is preferably mounted on or next to a processing machine, in particular an injection molding machine and serves for the removal, handling, manipulation or further processing of injection molded parts which have just been produced. The robot controller records data, in particular changes of state, positions, internal parameters, time stamps, etc., and in case of occurrence of an error this most recently recorded information is linked to the error and stored, whereby the changes of state until the occurrence of the respective error are simulated and visually displayed for an analysis on the basis of a virtual model of the physical robot.