Industrial robot system with a portable operator control device

• US 7,933,667 B2
• Filed: 06/23/2005
• Issued: 04/26/2011
• Est. Priority Date: 06/24/2004
• Status: Expired due to Fees

• Current Assignee: ABB AB (ABB Limited)
• Original Assignee: ABB AB (ABB Limited)
• Inventors: Endresen, Jan, Carlson, Erik, Warren, Nick, Sjöberg, Ralph
• Primary Examiner(s): Decady; Albert
• Assistant Examiner(s): CHANG, SUNRAY
• Application Number:
  US11/630,480
• Publication Number:
  US 20070297890A1
• Time in Patent Office: 2,133 Days
• Field of Search: None
• US Class Current: 700/82
• CPC Class Codes: B25J 13/065 comprising joy-sticks
• CPC Class Codes: B25J 19/06 Safety devices
• CPC Class Codes: G01S 13/878 Combination of several spaced transmitters or receivers of known location for determining the position of a transponder or a reflector G01S13/874 takes precedence
• CPC Class Codes: G06Q 10/0639 Performance analysis of employees; Performance analysis of enterprise or organisation operations
• CPC Class Codes: G08C 17/00 Arrangements for transmitting signals characterised by the use of a wireless electrical link

Abstract

An industrial robot including a manipulator, a control unit for controlling the manipulator, a portable operating unit for teaching and manually operating the robot, which operating unit is adapted for wireless communication with the control unit and including an operator control. The transmissions may be made wirelessly with redundant software processes for transmission and/or reception. Safety is increased by ensuring that the operator is within the specified operating area.

Claims

1. An industrial robot system, comprising:

an industrial robot comprising a manipulator;

a control unit for controlling the manipulator;

at least one portable operator control device for teaching and manually operating the robot, which portable operator control device is adapted for communication with the control unit;

a position determining unit configured to determine a position of the at least one portable operator control unit and break a data link between the control unit and the at least one portable operator control device based upon a determined position of the at least one portable operator control device, thereby increasing a safety and security of the system, the position determining unit comprising at least one reference transmitter configured to send a reference signal from at least one reference station or the at least one portable operator control device, at least one reference receiver configured to receive the reference signal, at least one reply transmitter arranged with the at least one reference receiver configured to transmit a reply signal to a reply receiver arranged with the reference transmitter, wherein the position of the at least one portable operator control unit is determined based upon at least one of a timing of the transmission of the reference signal and receipt of the reply signal and a known position of the at least one reference station;

means to provide redundant software programs for control of communications of an emergency stop signal, an enabling status, and/or reset, wherein the software redundancy on any of the transmission and/or receiving sides is carried out by at least two redundant software programs which carry out the same function but are each written in a different computer language and/or formed using a different programming technology, and wherein the at least two redundant software programs are arranged to send duplicate wireless communication to allow an abnormal state to be detected when there is a discrepancy in the communication from the at least two redundant software programs; and

an indicator configured to indicate a failure of a data link between the at least one portable operator control device and the robot.

2. The industrial robot system according claim 1, wherein the transmitted signals are handled by multiple and redundant software program processes.

3. The industrial robot system according to claim 1, wherein the received signals are handled by multiple and redundant software program processes.

4. The industrial robot system according to claim 1, wherein the position determining unit comprises at least one reference station on which the reference transmitter is arranged.

5. The industrial robot system according to claim 4, wherein the at least one reply receiver is arranged with the at least one reference station and is configured to receive a transmitted reply signal from the portable operator control device.

6. The industrial robot system according to claim 5, wherein the at least one reply receiver comprises an antenna.

7. The industrial robot system according to claim 5, wherein the reference receiver is arranged with the at least one portable operator control device.

8. The industrial robot system according to claim 1, wherein the control unit is operable to define a work area.

9. The industrial robot system according to claim 1, wherein the position determining unit comprises a measuring unit configured to measure the time between transmitting the reference signal and receiving the reply signal.

10. The industrial robot system according to claim 1, further comprising:

means arranged to release an enabling state upon reception failure dependent on a predetermined number of time parts.

11. The industrial robot system according to claim 1, wherein the position determining unit comprises a measuring unit configured to measure a direction/angle between the transmitted reference signal and the received reply signal.

12. The industrial robot system according claim 1, further comprising:

an indicator configured to indicate a current mode of the data link.

13. The industrial robot system according to claim 1, wherein the control unit comprises a processor for processing the redundant software programs.

14. The industrial robot system according to claim 1, wherein the indicator is operable to physically indicate a communication failure of the data link through tactile feedback by touch perception to the body of an operator bringing the operator control device during operation.

15. The industrial robot system according to claim 14, wherein the indicator is arranged to indicate actively through vibrations.

16. The industrial robot system according to claim 15, wherein the indicator is arranged to indicate passively through resilient means operable to introduce a mechanical resistance to movement of an operator control.

17. The industrial robot system according to claim 1, wherein the data link is a wireless data link.

18. The industrial robot system according to claim 1, wherein the data link is a wireless data link provided with software redundancy on any of the transmission and/or receiving sides.

19. The industrial robot system according to claim 18, wherein the software redundancy on any of the transmission and/or receiving sides is carried out by multiple instances of the same software program.

20. The industrial robot system according to claim 1, wherein the industrial robot system includes any from the list of a:

welding station, painting operation, assembly operation, pick and place operation.

21. A method for controlling an industrial robot system comprising an industrial robot comprising a manipulator, a control unit comprising a processor for controlling the manipulator, at least one portable operator control device for teaching and manually operating the robot, which at least one portable operator control device is adapted for communication with the control unit via a data link, and a position determining unit comprising at least one reference transmitter configured to send a reference signal from at least one reference station or the at least one portable operator control device, at least one reference receiver configured to receive the reference signal, at least one reply transmitter arranged with the at least one reference receiver configured to transmit a reply signal to a reply receiver arranged with the reference transmitter, the method comprising:

defining a working area for the at least one portable operator control device;

determining a position of the at least one portable operator control device, wherein determining the potion comprises transmitting a reference signal with the reference transmitter, receiving the reference signal with the at least one reference receiver, transmitting a reply signal with at least one reply transmitter, and receiving the reply signal with the reply receiver, wherein the position of the at least one portable operator control unit is determined based upon at least one of a timing of the transmission of the reference signal and receipt of the reply signal and a known position of the at least one reference station;

breaking the data link if the at least one portable operator control device is outside the working area, thereby increasing a safety and security of the system;

connecting a data link upon the at least one portable operator control device being inside the working area;

providing at least two redundant software programs for control of communication of an emergency stop signal, an enabling status, or reset on transmission and/or receiving sides, wherein the at least two redundant software programs carry out a same function but are each written in a different computer language and/or formed using a different programming technology;

sending duplicate wireless communications with the at least two redundant software programs;

detecting an abnormal state when there is a discrepancy in the communication from the at least two redundant software programs; and

indicating a failure of a data link between the at least one portable operator control device and the robot.

22. The method according to claim 21, wherein transmissions of a position of the at least one portable operator control device are handled by multiple and redundant software programs on the transmission side or the receiving side.

23. The method according to claim 21, wherein the reference transmitter is arrange with the at least one reference station and the reference receiver is arranged with the at least one portable operator control device.

24. The method according to claim 23, wherein reply receiver is arranged with the at least one reference station and the reply transmitter is arranged with the at least one portable operator control device.

25. The method according to claim 23, further comprising:

measuring with the position determining unit the time between transmitting the reference signal and receiving the transmitted reply signal.

26. The method according to claim 25, further comprising:

measuring with the position determining unit the distance between the at least one portable operator control device and the at least one reference station.

27. The method according to claim 25, further comprising:

measuring with the position determining unit the direction between the at least one portable operator control device and the at least one reference station.

28. The method according to claim 25, further comprising:

measuring with the position determining unit both the direction and the distance between the at least one portable operator control device and the at least one reference station.

29. The method according to claim 21, further comprising:

a release configured to release an enabling state upon reception failure dependent on a predetermined number of time parts.

30. The method according to claim 21, wherein the position of the at least one portable operator control device is determined continuously.

31. The method according to claim 21, wherein breaking the data link is carried out by the control unit.

32. The method according to claim 21, wherein the control unit comprises a processor for processing the redundant software programs.

33. The method according to claim 21, wherein the method maintains safe operation in a workplace including any from the list of a:

welding station, painting operation, assembly operation, pick and place operation.

34. A computer program product, comprising:

a computer readable medium; and

computer program instructions recorded on the computer readable medium and executable by a processor to control an industrial robot system comprising an industrial robot comprising a manipulator, a control unit comprising a processor for controlling the manipulator, at least one portable operator control device for teaching and manually operating the robot, which at least one portable operator control device is adapted for communication with the control unit via a data link, and a position determining unit comprising at least one reference transmitter configured to send a reference signal from at least one reference station or the at least one portable operator control device, at least one reference receiver configured to receive the reference signal, at least one reply transmitter arranged with the at least one reference receiver configured to transmit a reply signal to a reply receiver arranged with the reference transmitter, the method comprising;

defining a working area for the at least one portable operator control device;

determining a position of the at least one portable operator control device, wherein determining the potion comprises transmitting a reference signal with the reference transmitter, receiving the reference signal with the at least one reference receiver, transmitting a reply signal with at least one reply transmitter, and receiving the reply signal with the reply receiver, wherein the position of the at least one portable operator control unit is determined based upon at least one of a timing of the transmission of the reference signal and receipt of the reply signal and a known position of the at least one reference station;

breaking the data link if the at least one portable operator control device is outside the working area, thereby increasing a safety and security of the system;

connecting a data link upon the at least one portable operator control device being inside the working area;

providing at least two redundant software programs for control of communication of an emergency stop signal, an enabling status, or reset on transmission and/or receiving sides, wherein the at least two redundant software programs carry out a same function but are each written in a different computer language and/or formed using a different programming technology;

sending duplicate wireless communications with the at least two redundant software programs;

detecting an abnormal state when there is a discrepancy in the communication from the at least two redundant software programs; and

indicating a failure of a data link between the at least one portable operator control device and the robot.

35. The computer program product according to claim 34, wherein the computer program instructions are further for carrying out at least partly supplying the computer program instructions over a network.

36. The computer program product according to claim 35, wherein the network comprises at least one of the Internet or a data network.

37. The computer program product according to claim 35, wherein the data network comprises a wireless local area network.

38. A robot controller for an industrial robot system comprising an industrial robot comprising a manipulator, the robot controller comprising:

a control unit for controlling the manipulator,

at least one portable operator control device for teaching and manually operating the robot, which at least one portable operator control device is adapted for communication with the control unit, and which at least one portable operator control device comprises a manually operated enabling device, which when continuously activated, permits motion of the robot and/or the associated equipment,

at least two redundant software processes wherein the software redundancy on any of the transmission and/or receiving sides is carried out by at least two redundant software programs which carry out the same function but are each written in a different computer language and/or formed using a different programming technology or communication data generating circuits, which respectively generate communications data expressing an enabling device status command based on operation of said enabling device, and which respectively generate communications data expressing an enabling status command based on operations for said robot controller, wherein the at least two redundant software programs are arranged to send duplicate wireless communication to allow an abnormal state to be detected when there is a discrepancy in the communication from the at least two redundant software programs;

a transmitter configured to transmit communications data expressing said enabling status command and communications data expressing said enabling status command to said control part by wireless network communication; and

which permits motion alternatively emergency stop of the robot or associated equipment when receiving even a single set of communications data expressing an enabling status command generated by said multiple and redundant software or communications data generating circuits;

a position determining unit configured to determine a position of the at least one portable operator control unit and break a data link between the control unit and the at least one portable operator control device based upon a determined position of the at least one portable operator control device, thereby increasing a safety and security of the system, the position determining unit comprising at least one reference transmitter configured to send a reference signal from at least one reference station or the at least one portable operator control device, at least one reference receiver configured to receive the reference signal, at least one reply transmitter arranged with the at least one reference receiver configured to transmit a reply signal to a reply receiver arranged with the reference transmitter, wherein the position of the at least one portable operator control unit is determined based upon at least one of a timing of the transmission of the reference signal and receipt of the reply signal and a known position of the at least one reference station; and

an indicator configured to indicate a failure of a data link between the at least one portable operator control device and the robot.

39. The robot controller according to claim 38, wherein said control device comprises a receiver configured to receive communications data comprising a plurality of communications data receiving software processes or communication data receiving circuits.

40. The robot controller according to claim 38, wherein said robot controller comprises a control part for controlling at least one industrial robot or associated equipment, and a portable operating device arranged to communicate with each other by at least one wireless network wherein said portable operating device comprises a manually operated enabling device, which when continuously activated, permits motion of the robot and/or the associated equipment.

41. The robot controller according to claim 38, wherein the control unit comprises a processor configured to process the redundant software programs.

42. The robot controller according to claim 38, further comprising:

a plurality of communications data generating software processes or communication data generating circuits, which comprises a receiver configured to receive communications data expressing enabling status command from said transmitter;

wherein said receiver is configured to place said robot or associated equipment in the enabling state according to the received enabling status command, and which permits motion of the robot or associated equipment as long as correct information has been received within a watch-time comprising a number of time parts just exceeding a full time slot.

43. The robot controller according to claim 38, said receiver is arranged to release said enabling state upon reception failure dependent on a predetermined number of time parts.

44. The robot controller according to claim 38, further comprising:

a release configured to release the emergency stop state of the robot and/or associated equipment.