Abstract: A method and system for dynamic collision avoidance motion planning for industrial robots. An obstacle avoidance motion optimization routine receives a planned path and obstacle detection data as inputs, and computes a commanded robot path which avoids any detected obstacles. Robot joint motions to follow the tool center point path are used by a robot controller to command robot motion. The planning and optimization calculations are performed in a feedback loop which is decoupled from the controller feedback loop which computes robot commands based on actual robot position. The two feedback loops perform planning, command and control calculations in real time, including responding to dynamic obstacles which may be present in the robot workspace. The optimization calculations include a safety function which efficiently incorporates both relative position and relative velocity of the obstacles with respect to the robot.

Abstract: A method and system for motion planning for robots with a redundant degree of freedom. The technique computes a collision avoidance motion plan for a robot with a redundant degree of freedom, without artificially constraining the extra degree of freedom. The motion planning is formulated as a quadratic programming optimization calculation having a multi-component objective function and a collision avoidance constraint function. The formulation is efficient enough to compute the motion plan in real time at every robot control cycle. The collision avoidance constraint ensures clearance of all parts of the robot from both static and dynamic obstacles. Objective function terms include minimizing path deviation, joint velocity regularization and robot configuration or pose regularization. Weighting factors on the terms of the objective function are changeable for each control cycle calculation based on obstacle proximity conditions at the time.

Abstract: A region-based robotic grasp generation technique for machine tending or bin picking applications. Part and gripper geometry are provided as inputs, typically from CAD files, along with gripper kinematics. A human user defines one or more target grasp regions on the part, using a graphical user interface displaying the part geometry. The target grasp regions are identified by the user based on the user's knowledge of how the part may be grasped to ensure that the part can be subsequently placed in a proper destination pose. For each of the target grasp regions, an optimization solver is used to compute a plurality of quality grasps with stable surface contact between the part and the gripper, and no part-gripper interference. The computed grasps for each target grasp region are placed in a grasp database which is used by a robot in actual bin picking operations.

Abstract: A deadlock avoidance motion planning technique for a multi-robot system. The technique includes online calculation of swept volumes for upcoming robot motion segments, and uses the swept volumes to compute one or more overlap zones, which are published to all robot controllers. Swept volume calculation is based on actual upcoming tool path, including adaptive conditions such as jumps and offsets. Robot controllers check at each time step whether an overlap zone will be entered and whether another robot is already in the zone. When a robot determines that it is about to enter a zone that is occupied, the robot holds position until the zone is vacated. Robots publish zone entry and exit for other robots’ awareness. Additional logic is added to establish priority for automatically resolving a deadlock condition, and for prioritizing completion of motion segments for a robot which is performing a continuous processing operation.

Abstract: A method and system for dynamic collision avoidance motion planning for industrial robots. An obstacle avoidance motion optimization routine receives a planned path and obstacle detection data as inputs, and computes a commanded robot path which avoids any detected obstacles. Robot joint motions to follow the tool center point path are used by a robot controller to command robot motion. The planning and optimization calculations are performed in a feedback loop which is decoupled from the controller feedback loop which computes robot commands based on actual robot position. The two feedback loops perform planning, command and control calculations in real time, including responding to dynamic obstacles which may be present in the robot workspace. The optimization calculations include a safety function which efficiently incorporates both relative position and relative velocity of the obstacles with respect to the robot.

Abstract: A method for determining a position of an object moving along a conveyor belt. The method includes measuring the position of the conveyor belt while the conveyor belt is moving using a motor encoder and providing a measured position signal of the position of the object based on the measured position of the conveyor belt. The method also includes determining that the conveyor belt has stopped, providing a CAD model of the object and generating a point cloud representation of the object using a 3D vision system. The method then matches the model and the point cloud to determine the position of the object, provides a model position signal of the position of the object based on the matched model and point cloud, and uses the model position signal to correct an error in the measured position signal that occurs as a result of the conveyor belt being stopped.

Abstract: A system and method for controlling motion interference avoidance for a plurality of robots are disclosed, the system and method including a dynamic space check system wherein an efficiency of operation is maximized and a potential for interference or collision is minimized.

Abstract: A synchronous high speed motion stop for a series of multi-top loaders residing on “n” controllers on one rail achieves effective detection of the servo-error status and shut off of the trailing controller's servo power within 3 ITP time. The control method reduces the unnecessary error recovery because it only shuts off its immediate trailing controller without aborting its leading controller, allowing the leading controller to complete the cycle tasks. The cascade control method produces a synchronous high-speed motion stop for the robots across the controllers and effectively prevents the collision between the robots.

Abstract: A robot multi-arm control system includes robot controllers that communicate via a network to transmit synchronization information from a master controller to one or more slave controllers in order to coordinate manufacturing processes. The system accounts for the network communication delay when synchronizing the event timing for process and motion synchronization.

Abstract: A system and method for controlling motion interference avoidance for a plurality of robots are disclosed, the system and method including a dynamic space check system wherein an efficiency of operation is maximized and a potential for interference or collision is minimized.

Abstract: A synchronous high speed motion stop for a series of multi-top loaders residing on “n” controllers on one rail achieves effective detection of the servo-error status and shut off of the trailing controller's servo power within 3 ITP time. The control method reduces the unnecessary error recovery because it only shuts off its immediate trailing controller without aborting its leading controller, allowing the leading controller to complete the cycle tasks. The cascade control method produces a synchronous high-speed motion stop for the robots across the controllers and effectively prevents the collision between the robots.

Abstract: A robot multi-arm control system includes robot controllers that communicate via a network to transmit synchronization information from a master controller to one or more slave controllers in order to coordinate manufacturing processes. The system accounts for the network communication delay when synchronizing the event timing for process and motion synchronization.

Abstract: A method of controlling a robot (32) includes the steps of selecting an initial configuration from at least one of a first, second, and third sets to position a TCP at a starting point (44) along a path (33) and selecting a final configuration different than the initial configuration to position the TCP at an ending point (46). Next, the TCP moves from the starting point (44) while maintaining the initial configuration, approaches the singularity between a first point (48) and a second point (50), and selects one of the axes in response to reaching the first point (48). The angle for the selected axis is interpolated from the first point (48) to the second point (50). After the interpolation, the angles about the remaining axes are determined and positions the arms in the final configuration when the TCP reaches the second point (50) and moves to the ending point (46) while maintaining the final configuration.

Abstract: A method of controlling a robot (32) includes the steps of selecting an initial configuration from at least one of a first, second, and third sets to position a TCP at a starting point (44) along a path (33) and selecting a final configuration different than the initial configuration to position the TCP at an ending point (46). Next, the TCP moves from the starting point (44) while maintaining the initial configuration, approaches the singularity between a first point (48) and a second point (50), and selects one of the axes in response to reaching the first point (48). The angle for the selected axis is interpolated from the first point (48) to the second point (50). After the interpolation, the angles about the remaining axes are determined and positions the arms in the final configuration when the TCP reaches the second point (50) and moves to the ending point (46) while maintaining the final configuration.

Abstract: A method of teaching a robot a desired operating path and a lead-through teach handle assembly are disclosed. A mounting mechanism mounts the entire handle assembly to an arm of the robot. The handle assembly also includes a handle that is supported by the mounting mechanism. A robot operator utilizes the handle assembly and grasps the handle to apply an external force to move the robot arm, or the operator, without the handle assembly, directly holds a tool connected to the robot arm to apply the external force at the tool. The handle assembly is characterized by a universal joint that interconnects the handle and the mounting mechanism and that accommodates orientation changes of the handle relative to the mounting mechanism that result from translational and rotational movement of the robot arm as the user is teaching the robot. The external force applied at the tool is estimated with either a force sensor disposed on the handle assembly or by monitoring the torque of motors used to move the robot.

Abstract: A robot calibration system includes a calibration sensor that provides an indication of when a first reference point that remains fixed relative to a robot base is a fixed distance from a second reference point that is located on the robot arm. The robot arm is moved through a plurality of orientations and each time that the fixed distance between the two reference points is achieved, robot joint position information is determined. The preferred calibration sensor includes a string that extends between the two reference points and activates a signal generator each time that the string is taut as caused by the orientation of the robot arm. The generated signal indicates that the two reference points are separated by the fixed distance. The determined robot joint positions are then used to determine a calibration factor which varies depending on the needs of a particular situation.

Abstract: Method and system for trajectory or path planning to move a device such as a robot along a Cartesian path to achieve high path accuracy and ease of programming. Cascaded linear filters are utilized to perform acceleration/deceleration control in Cartesian space having six Cartesian components. Generally, six sets of such linear filters are used, three for location components and three for orientation components. Cartesian path blending is also provided. First and second path segments are planned and blended together and a corner distance is formed at a transition between the first and second path segments. A method is also provided for adjusting the corner distance. The corner distance is adjusted by corner distance variables which are independent of program speed so that the resultant Cartesian path can be maintained regardless of program speed changes.