Fanuc America Corporation

Fanuc Robotics America Corporation

Fanuc Robotics North America, Inc.

Fanuc Corporation

Jason Tsai

Sai-Kai Cheng

Yi Sun

H Dean McGee

Jianming Tao

Hadi A Akeel

Tien L Chang

Ho Cheung Wong

Rick E Wunderlich

Gordon Geheb

Bradley Q Niederquell

Leo Keselman

Min-Ren Jean

Ganesh Kalbavi

Di Xiao

Isaac Eckert

Eric Wong

Don Kijek

Kenneth W Krause

Judy Evans

Eric C Lee

Peter J Swanson

Randy A Graca

Derek Jung

Akihiro Yanagita

Frank Garza

Ashok Prajapati

Brad Niederquell

Matthew Ray Sikowski

Terry Tupper

Min Ren Jean

Laxmi Musunur

Michael Sharpe

Charles R Strybis

Ken Krause

Genesh Kalbavi

Gerald A Ross

Robert A Bolhouse

James F Huber

A method for monitoring an industrial robot. The method includes configuring the robot to perform a certain task during an integration process and storing integration data in the robot identifying the configuration of the robot for performing the task. The method also includes installing the robot in a manufacturing facility, and uploading the stored integration data to the Cloud when the robot is installed in the manufacturing facility. The method further includes capturing production data generated by the robot during operation of the robot in the manufacturing facility, uploading the production data to the Cloud, and comparing the production data to the integration data.

Golden data for industrial robots

An augmented reality (AR) system for production-tuning of parameters for a visual tracking robotic picking system. The robotic picking system includes one or more robots configured to pick randomly-placed and randomly-oriented parts off a conveyor belt and place the parts in an available position, either on a second moving conveyor belt or on a stationary device such as a pallet. A visual tracking system identifies position and orientation of the parts on the feed conveyor. The AR system allows picking system tuning parameters including upstream, discard and downstream boundary locations to be visualized and controlled, real-time robot pick/place operations to be viewed with virtual boundaries, and system performance parameters such as part throughput rate and part allocation by robot to be viewed. The AR system also allows virtual parts to be used in simulations, either instead of or in addition to real parts.

Augmented reality visualization for robotic picking system

A method and system for programming a path-following robot to perform an operation along a continuous path while accounting for process equipment characteristics. The method eliminates the use of manual teaching cycles. In one example, a dispensing robot is programmed to apply a consistent bead of material, such as adhesive or sealant, along the continuous path. A computer-generated definition of the path, along with a model of dispensing equipment characteristics, are provided to an optimization routine. The optimization routine iteratively calculates robot tool center point path and velocity, and material flow, until an optimum solution is found. The optimized robot motion and dispensing equipment commands are then provided to an augmented reality (AR) system which allows a user to visualize and adjust the operation while viewing an AR simulation of dispensing system actions and a simulated material bead. Other examples include robotic welding or cutting along a continuous path.

Zero teach for robotic continuous path

An augmented reality (AR) system for diagnosis, troubleshooting and repair of industrial robots. The disclosed diagnosis guide system communicates with a controller of an industrial robot and collects data from the robot controller, including a trouble code identifying a problem with the robot. The system then identifies an appropriate diagnosis decision tree based on the collected data, and provides an interactive step-by-step troubleshooting guide to a user on an AR-capable mobile device, including augmented reality for depicting actions to be taken during testing and component replacement. The system includes data collector, tree generator and guide generator modules, and builds the decision tree and the diagnosis guide using a stored library of diagnosis trees, decisions and diagnosis steps, along with the associated AR data.

Automatic dynamic diagnosis guide with augmented reality

A robot is moved along a first continuous programmed path with a robot controller executing a learning path control program without performing an operation on a workpiece. The actual movement of the robot along the first continuous programmed path is recorded. The first continuous programmed path is adjusted to create a second programmed path. The robot is moved along the second continuous programmed with the robot controller executing the learning path control program without performing the operation on the workpiece. The actual movement of the robot along the second continuous programmed path is recorded. Traces of the recorded actual movements of the robot along the first continuous programmed path and the second continuous programmed path are displayed.

Learning path control

A method and a system stream robot tool center point position to external processors at high frequency. The method includes the steps of: reading robot joint encoder data using an Interrupt Service Routine in the robot controller; calculating tool center point position based on the encoder data; and sending the calculated position data to a network socket in a high priority task. The method achieves tool center point and/or joint position communication at fast and consistent time intervals, as compared to much longer times for prior art methods. A downstream device, such as a processor or controller for another machine, reads the communicated tool center point and/or joint position data and uses it to control the operations of its own device. High speed motion command streaming from outside processors can be used in a similar way to control the robot.

Robot high frequency position streaming

Methods and systems for touch-sensing to provide an updated user frame are provided. These include the provision of a user frame and the touch-sensing of a workpiece, where the touch-sensing includes performing a touch-sensing schedule. The touch-sensing schedule includes one of a laser touch-sensing event and a wire touch-sensing event, where one of the laser touch-sensing event and the wire touch-sensing event is switched to the other of the laser touch-sensing event and the wire touch-sensing event while performing the touch-sensing schedule. An offset of the workpiece relative to the user frame is determined based on the touch-sensing of the workpiece and the offset is applied to the user frame to provide the updated user frame. The unique dynamic user frame feature enables same touch sensing program to be cloned and applied on multiple robot controllers.

Dynamic laser touch-sensing with multiple robot dynamic user frame

A robot data transfer method includes the step of collecting data from each of a plurality of robots in a multi-robot production facility in real-time. The data collected from the robots is then transferred in real-time from a controller of each of the robots to a first data collection device. Within the first data collection device, the data is buffered using a multi-segment queueing mechanism. The queueing mechanism is configured with a retention policy. The data is then transferred to a second data collection device based on the retention policy of the queueing mechanism of the first data collection device. The second data collection device analyzes the data and determines whether maintenance or optimization is necessary for any of the robots.

System for diagnosis of robot state

A method for adaptive control of a robotic operation of a robot includes providing a software program to generate process signals executable during the robotic operation, including one or more execution commands. A first Signal Value channel is provided to control at least one control process parameter of the robot, where the first Signal Value channel is subject to a first time latency. The execution timing of the first Signal Value channel is synchronized with the one or more execution commands by accounting for the first time latency in relation to the one or more execution commands. The software program is run to generate the process signals and the robot is operated in response to the synchronized execution timing of the execution commands.

Adaptive control of robotic laser braze/weld operation

A robot monitoring system for monitoring and analyzing robot related data and displaying the data on a smart device is provided. The robot monitoring system comprises at least one robot in local communication with at least one robot controller. The at least one robot controller has local processing power for monitoring, gathering, and analyzing data related to the at least one robot. The data analysis results are formatted into a message file that is communicated to a storage system. The message file may then be retrieved by a smart device having software running thereon for displaying the results of the data analysis.

System to monitor/analyze robot related information and display on a smart device

A method for controlling a redundant robot arm includes the steps of selecting an application for performing a robotic process on a workpiece with the arm and defining at least one constraint on motion of the arm. Then an instruction set is generated based upon the selected application representing a path for a robot tool attached to the arm by operating the arm in one of a teaching mode and a programmed mode to perform the robotic process on the workpiece and movement of the arm is controlled during the robotic process. A constraint algorithm is generated to maintain a predetermined point on the arm to at least one of be on, be near and avoid a specified constraint in a robot envelope during movement of the arm, and a singularity algorithm is generated to avoid a singularity encountered during the movement of the arm.

Method of controlling a redundant robot

A system and method for controlling avoiding collisions and deadlocks in a workcell containing multiple robots automatically determines the potential deadlock conditions and identifies a way to avoid these conditions. Deadlock conditions are eliminated by determining the deadlock-free motion statements prior to execution of the motions that have potential deadlock conditions. This determination of deadlock-free motion statements can be done offline, outside normal execution, or it can be done during normal production execution. If there is sufficient CPU processing time available, the determination during normal production execution provides the most flexibility to respond to dynamic conditions such as changes in I/O timing or the timing of external events or sequences. For minimal CPU impact the determination is done offline where many permutations of programming sequences can be analyzed and an optimized sequence of execution may be found.

Method and system for automatically preventing deadlock in multi-robot systems

A system and a method for converting a machine tool program in NC programming language to permit a robot controller to execute the program. A robot controller converts the NC program into robot language according to a conversion configuration table, and uses the converted language as pseudo program data internally stored in a data memory within the robot controller. Each M-code (Miscellaneous code) in the NC program is executed as a sub-program call using the robot language. The content of the sub-programs can be freely defined and programmed by the user and, therefore, can be customized for the specific application.

Numerical control program execution by robot

A method of controlling robot motion for small shape generation is provided. The method includes the steps of: a) providing a robot having a plurality of interconnected distal links with a respective plurality major axes and a respective plurality of minor axes, the robot having a controller for moving the robot to a starting position and along a path including a series of interpolated positions to be followed relative a workpiece; b) moving the robot to the starting position; c) determining a next interpolated position on the path, wherein the robot remains fixed in position about at least one of the major axes and a location and an approach vector of the next interpolated position can be achieved; and d) moving the robot to the next interpolated position. A method where the robot remains fixed in position about all major axes is also provided.

Method of controlling a robot for small shape generation

A method of and apparatus for achieving dynamic robot accuracy includes a control system utilizing a dual position loop control. An outer position loop uses secondary encoders on the output side of the gear train of a robot joint axis, while the inner position loop uses the primary encoder attached to the motor. Both single and dual loop control can be used on the same robot and tooling axes.

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Bloomfield Hills, MI, United States of America

Jason Tsai