Abstract: Methods and systems include ways to implement change analysis of an automated production line including at least one robot. Monitoring a plurality of operating parameters associated with the automated production line including the at least one robot is followed by recording at least one change to the plurality of operating parameters. A notification is then provided identifying the at least one change to the plurality of operating parameters. The notification can include mapping the at least one change onto a graphical representation of the automated production line, thereby identifying a portion of the automated production line affected by the at least one change. As a result, at least one of the operating parameters can be adjusted in response to the notification. An action can also be performed in response to the notification. In this manner, the change analysis can optimize operation of the automated production line.

Abstract: An augmented reality (AR) system for visualizing and modifying robot operational zones. The system includes an AR device such as a headset in communication with a robot controller. The AR device includes software for the AR display and modification of the operational zones. The AR device is registered with the robot coordinate frame via detection of a visual marker. The AR device displays operational zones overlaid on real world images of the robot and existing fixtures, where the display is updated as the user moves around the robot work cell. Control points on the virtual operational zones are displayed and allow the user to reshape the operational zones. The robot can be operated during the AR session, running the robot's programmed motion and evaluating the operational zones. Zone violations are highlighted in the AR display. When zone definition is complete, the finalized operational zones are uploaded to the robot controller.

Abstract: A system and method for calibrating the position of a machine having a stationary part to a stationary marker. The process first images the machine and the marker, and then identifies a visible part of the machine in the images that has been 3D modeled. The process then calculates a location of the stationary part of the machine using the modeled position of the visible part and the known kinematics and position of the machine. The process then identifies the stationary marker in the images, and establishes a relationship between the stationary marker and the stationary part of the machine, which can be used for calibration purposes. In one embodiment, the machine is a robot and the process is performed by an AR application.

Abstract: A robotic apparatus for painting a workpiece includes a redundant axis robot for use in a robotic painting system. The redundant axis of rotation provides the robot arm additional flexibility in avoiding obstacles and reaching an interior of the workpiece to apply paint thereto. The robotic apparatus could be a seven-axis robot arm or a five-axis parallel link panel opener robot arm for opening and/or closing the panel. The robot arms are mounted on at least one vertically oriented column adjacent a path of travel of the workpiece through a painting booth and the robot arms can be mounted on a common base.

Abstract: 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.

Abstract: 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.

Abstract: A method and system for calibration of an augmented reality (AR) device's position and orientation based on a robot's positional configuration. A conventional visual calibration target is not required for AR device calibration. Instead, the robot itself, in any pose, is used as a three dimensional (3D) calibration target. The AR system is provided with a CAD model of the entire robot to use as a reference frame, and 3D models of the individual robot arms are combined into a single object model based on joint positions known from the robot controller. The 3D surface model of the entire robot in the current pose is then used for visual calibration of the AR system by analyzing images from the AR device camera in comparison to the surface model of the robot in the current pose. The technique is applicable to initial AR device calibration and to ongoing device tracking.

Abstract: A next generation painting robot with advanced fluid delivery system, enhanced kinematics and a service airlock compartment. The painting robot includes a fluid delivery system which places color changing valves and pumping hardware on the back side of the robot's mounting pedestal, where it can be serviced without a technician having to enter the spray booth. Additionally, the robot enables routine cleaning and maintenance to be performed without personnel entering the spray booth and without stopping the vehicle conveyor, due to simplified outer arm design, improved home positioning and an airlock booth adjacent to the robot pedestal. Service personnel can clean and service the applicator and other components on the outer arm from the airlock booth, while other robots continue painting parts moving on the conveyor, without allowing fume-laden vapors into the operator aisle.

Abstract: 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.

Abstract: A smart coolant pump for a robotic or computer-controlled machine. The smart pump uses a servo motor rather than a conventional industrial motor such as an induction motor. The smart pump has inherent torque and speed sensing, and a controller integrated with the computer-controlled machine controller. The motor torque/speed sensing and coolant pressure/flow sensing enable immediate detection of any anomalous conditions such as low coolant level or coolant port blockage. The smart pump can be configured to run at a certain speed and provide a specific coolant pressure and flow rate for each machining operation performed at the station, and to run at a very low speed between machining operations. This speed configurability saves energy and allows the pump and coolant to run at lower temperatures compared to conventional constant-speed coolant pumps.

Abstract: A method and apparatus for controlling a continuous machining process includes a robot, a machining tool, a table, and a raw parts supply mounted inside a machining cell enclosure. The table has first and second vises for holding parts. The machining tool is operated to machine a raw part in one of the vises while the robot is operated to pick a machined part from the other vise and then place another raw part into the other vise. The table can be fixed or rotatable. The robot places the picked machined parts on an exit conveyor to remove the machined parts from the enclosure.

Abstract: A next generation painting robot with advanced fluid delivery system, enhanced kinematics and a service airlock compartment. The painting robot includes a fluid delivery system which places color changing valves and pumping hardware on the back side of the robot's mounting pedestal, where it can be serviced without a technician having to enter the spray booth. The fluid delivery system also allows smaller and lighter robot arms, and is designed to minimize paint waste and wait time during color changes. The robot also features kinematics providing redundant inner arm rotation. The arm kinematics, along with the smaller arms, a paint supply line routed through the center of first and third arm joints, and optimized motor conductor routing, dramatically improve near reach flexibility. The improved near reach flexibility in turn allows a smaller spray booth than possible with previous robot architectures.

Abstract: Methods and systems include ways to synchronize a press machine and tending robots, including a pick robot and a drop robot, where the press machine includes an operating area for pressing a blank into a part. The pick robot and the part are moved out of the operating area while the drop robot carrying the blank is moved into the operating area. At least a portion of the pick robot and/or the part resides within the operating area at the same time at least a portion of the drop robot and/or the blank resides within the operating area. The pick robot is in communication with the drop robot and the movement of the pick robot is synchronized with the movement of the drop robot to prevent the pick robot or part from colliding with the drop robot or the blank.

Abstract: Methods and systems include ways to implement change analysis of an automated production line including at least one robot. Monitoring a plurality of operating parameters associated with the automated production line including the at least one robot followed by recording at least one change to the plurality of operating parameters. A notification is then provided identifying the at least one change to the plurality of operating parameters. The notification can include mapping the at least one change onto a graphical representation of the automated production line, thereby identifying a portion of the automated production line affected by the at least one change. As a result, at least one of the operating parameters can be adjusted in response to the notification. An action can also be performed in response to the notification. In this manner, the change analysis can optimize operation of the automated production line.

Abstract: 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.

Abstract: 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.

Abstract: A robotic electrostatic painting system includes a barrier formed from an electrical insulating material and disposed between adjacent reservoirs for holding a conductive paint used in an electrostatic painting operation. The barrier is shaped and dimensioned with a central plate and upper and lower flanges to block every straight line path between the reservoirs to electrostatically separate the reservoirs and prevent the formation of a ground path or short circuit when there is a voltage difference between the reservoirs. The electrostatic separation of the reservoirs further prevents deterioration of conductive components of the robotic electrostatic painting system.

Abstract: Methods and systems for installing a plug into an aperture of an article are provided, such as drain hole in an electrocoated vehicle floor pan. A robot system used herein includes a robot and a tool, where the tool includes a plug reservoir, a sensor, and an actuator. The sensor is configured to detect the aperture of the article and the actuator is configured to place one of the plugs from the plug reservoir into the aperture. The robot system can include a tool change nest, where the plug reservoir can be received with the tool change nest and the removed from a remainder of the tool. Quick change of plug reservoirs using the present technology improves operation speed and use of one or more tool change nests can reload and/or reconfigure the robot system for plugging various apertures with minimized input or interaction.

Abstract: A method and an apparatus detects pressure changes at servo gun tips of a robotic welding system having a servo gun with a movable tip and an opposed fixed tip configured to weld a part. The method and apparatus observe a tip deflection value and convert the value to a current pressure value using a pressure estimator. The current pressure value is compared to a benchmark pressure value to detect any difference.

Abstract: 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.