Robot Controller Predicting Machine Tool Processing Time
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Solution Overview
Problem
Existing robot controller systems reduce operation rates by maintaining robots in standby mode during workpiece replacing operations, either by waiting for a replacing request signal or starting preparation operations too late, leading to inefficiencies in machine tool and robot utilization.
Innovation Solution
A processing system with a machine tool controller and a robot controller that predicts processing completion time and preparation operation duration, allowing the robot to initiate preparation and workpiece replacing operations synchronously with processing start, thereby minimizing standby time and optimizing operation rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the robot starts workpiece replacing preparation operation after receiving the replacing request signal from the machine tool, then the machine tool can process the workpiece without interruption, but the robot is set in standby state during the preparation operation and the operation rate is reduced
Solution Approach 1:
The robot controller predicts the processing completion time of the machine tool and determines to start the workpiece replacing preparation operation in advance before the actual completion time, so that the robot completes preparation exactly when the machine tool finishes processing, eliminating standby time while ensuring continuous processing
2Productivity
If the robot starts workpiece replacing preparation operation before the processing operation starts, then the robot operation rate is improved, but the robot is set on standby until the replacing request signal is output and the operation rate is reduced
Solution Approach 1:
The robot controller receives the processing start signal from the machine tool and uses feedback from the predicted processing completion time to dynamically determine the optimal start time for the preparation operation, ensuring the robot operates continuously without unnecessary standby periods
3Ease of operation
If the machine tool is set in standby state during workpiece replacing preparation operation, then the robot can complete preparation, but the machine tool operation rate is reduced
Solution Approach 1:
The robot performs the workpiece replacing preparation operation in advance and completes it exactly when the machine tool finishes processing, so the machine tool can immediately receive the replaced workpiece without entering standby state, maintaining continuous operation for both robot and machine tool
Data Source
AI summary
The robot controller includes an operation command part configured to output an operation command so as to perform a first operation of conveying a workpiece from an initial position to a first position adjacent to the machine tool, a time prediction part configured to predict processing completion time of the workpiece based on a processing start signal output from a machine tool controller, a time length prediction part configured to predict time length necessary for the first operation, and a time determination part configured to determine start time of the first operation so that the first operation is completed at the processing completion time on the basis of the predicted processing completion time and time length necessary for the first operation.