Robot Controller Process Data Logging and Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current robot systems lack a systematic method for collecting and storing application process-specific information for each instruction executed by the robot controller, limiting data analysis and reporting capabilities.
Innovation Solution
A system and method for collecting, storing, and reporting application process-specific data, uniquely tagged by program name and process identifier, allowing data access through remote devices and teach pendants, with options for internal and external storage, and providing filtering and reporting features for detailed data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If manual tabulation of process information is used, then simplicity of operation is maintained, but data collection completeness and analysis capability are limited
Solution Approach 1:
The patent segments process information collection by creating separate data structures for different process instructions (e.g., weld instructions, paint instructions, pick/place instructions). Each instruction type has its own dedicated data collection template, allowing comprehensive data gathering without overwhelming system complexity. This segmentation enables targeted collection of relevant parameters for each specific process step.
Solution Approach 2:
The patent implements preliminary action by pre-defining data collection templates and structures before robot program execution. The system is configured with predetermined data collection rules and formats that automatically apply during runtime, eliminating the need for manual setup during operation and enabling automatic comprehensive data capture.
2Loss of information
If comprehensive process data is collected and stored, then data analysis capability is improved, but data storage requirements and system complexity increase
Solution Approach 1:
The patent applies local quality by storing different types of process data in optimized formats suited to their specific characteristics. Critical quality control data (e.g., weld parameters, temperature readings) are stored with high precision, while less critical operational data (e.g., cycle timestamps, basic status flags) use compressed formats. This selective data quality approach maintains analysis capability while reducing overall storage requirements.
Solution Approach 2:
The patent inverts the traditional approach by collecting and storing only the specific process data that is actually needed for analysis, rather than attempting to store all possible robot controller data. The system selectively captures data based on pre-defined relevance criteria, turning the problem around from 'how to store everything' to 'how to store only what matters'.
3Ease of operation
If process information is displayed on status screens only, then ease of operation is maintained, but data accessibility and reporting capability are limited
Solution Approach 1:
The patent implements universality by creating a multi-functional data access architecture. The same collected process data can be accessed and displayed through multiple interfaces: traditional status screens for operators, remote computers for engineers, and external databases for analytics. This single data collection system serves multiple functions and user groups simultaneously, enhancing both ease of operation and data accessibility.
4Measurement precision
If data is stored without unique identifiers, then storage simplicity is maintained, but data traceability and analysis precision are reduced
Solution Approach 1:
The patent applies the nested doll principle by creating hierarchical data structures with unique identifiers at multiple levels. Each process instruction receives a unique ID, and collections of related instructions are grouped with parent identifiers. This nested structure allows precise tracing of individual data points while organizing them within broader contextual groups, achieving high traceability without linear increases in complexity.
Data Source
AI summary
A method for controlling a robot includes the step of controlling operation of the robot with a robot controller executing a control program having a plurality of process instructions. Associated process data for each of predetermined ones of the process instructions executed by the robot controller is then collected. The collected process data is subsequently stored in a form uniquely identified by at least one unique identifier. The at least one unique identifier may include both the program identifier and the process instruction identifier. The collected process data may be stored on the robot controller.