Abstract: A robot control system includes a line tracking encoder that measures a reference position of a conveyor line and transmits a tracking signal representing tracking data including the reference position of the conveyor line. A master controller is in communication with the encoder to receive the tracking signal, process the tracking data represented by the tracking signal, and generate a data packet in response to processing of the tracking data. A slave controller is in communication with the master controller and at least one robot for receiving the data packet and controlling the movement of the at least one robot in response to the data packet. A communications network directly interconnects the master controller and the slave controller and transmits the data packet from the master controller to the slave controller.

Abstract: 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.

Abstract: A method of controlling a robot system includes the steps of providing a tool supported by a moveable mechanism of the robot system, providing a workpiece supported by a holder, generating an image of the workpiece, extracting a data from the image, the data relating to a feature of the workpiece, generating a continuous three-dimensional path along the workpiece using data extracted from the image, and moving the tool along the path.

Abstract: A magnetic tool to enable a robot arm to grip a metallic workpiece includes a hollow housing having a coupling member adapted to attach the tool to the robotic arm. A sleeve depends from the housing having a shaft slidably received therein. The shaft has a first end disposed in the housing and a second end extending axially outwardly from an open end of the sleeve. A magnetic member is disposed on the second end of the shaft. The magnetic member includes a main body having a cavity formed therein. A magnet is slidably disposed within the cavity and attached to an actuator adapted to adjust the distance between the magnet and an inner surface of a magnetic face of the main body of the magnetic member to vary the magnetic attraction force at the magnetic face.

Abstract: A robotic painting system includes an applicator, a first paint metering device in fluid communication with the applicator, a second paint metering device in fluid communication with the paint applicator, and a paint supply in fluid communication with each the paint metering devices to fill at least one of the paint metering devices with a desired amount of paint, wherein each of the paint metering devices is electrostatically isolated from the paint supply, and wherein a color change time and a paint waste are minimized and a cleaning operation of the system is optimized.

Abstract: 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.

Abstract: A conveyor system and a method for dynamically switching an active work associated with a motion device, the system including a plurality of conveyors for moving at least one part, at least one production machine associated with at least one of the conveyors, at least one motion device to move the at least one part, a controller associated with the at least one motion device, wherein the controller is in data communication with the at least one production machine to receive a feedback data therefrom, the feedback data representing a state of the production machine, and a software system executed by the controller to dynamically and selectively control the at least one motion device in response to the feedback data.

Abstract: A system for calibrating a robotic tool includes a housing including an aperture for receiving the robotic tool, an image generating device disposed in the housing and positioned to generate an image of the robotic tool received through the aperture of the housing, wherein the image generating device generates an image signal representing the image of the robotic tool, a light source disposed in the housing to backlight the robotic tool received through the aperture of the housing, and a processor responsive to the image signal for calculating and monitoring a configuration of the robotic tool.

Abstract: A system for picking and packing applications is provided. The system includes a plurality of robots and a plurality of robot controllers. Each robot controller includes a load re-balance subsystem, a load balance subsystem, a robot state change detector subsystem, a communicator subsystem, and a motion control subsystem. Each of the robot controllers is interconnected and in communication with one another via the communicator subsystems. Each of the robots has a workload that may be selectively balanced. A method for balancing the workloads of the robots using built-in processors which run motion control is also provided.

Abstract: A system and method for controlling avoiding collisions in a workcell containing multiple robots is provided. The system includes a sequence of instructions residing on a controller for execution thereon to perform an interference check automatic zone method. The interference check automatic zone method includes the steps of: determining a first portion of a common space that is occupied during a movement of a first robot along a first programmed path; determining a second portion of the common space that is occupied during a movement of a second robot along a second programmed path; comparing the first portion and the second portion to determine if an overlap exists therebetween; and moving the first robot and the second robot in response to whether or not the overlap exists.

Abstract: A method and system for handling a swing metal panel using a robot's drive axis servo motor feedback to eliminate the need for the sensors and breakaway devices is provided. Using the servo motor feedback for this function reduces cost and improves reliability. The method also applies the servo motor feedback to hold a panel in position and exchange the panel between robots during the painting or coating process.

Abstract: A robotic painting system includes a device for generating a vacuum and a dump line disposed upstream from a connection between an isolation line and a canister, wherein the device for generating a vacuum and the dump line are employed for filling and cleaning the robotic painting system.

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: An apparatus provides selective communication between multiple programmable robot controllers and one or more teaching devices connected by a network. The network controls communication between the teaching devices and the controllers including active tasks and passive tasks for preventing communication of active tasks between any of the controllers and more than one of any of the teaching devices. The network permits communication of the passive tasks between any of the controllers and one of the teaching devices communicating active tasks with another one of the controllers.

Abstract: A mixed size product end of arm tooling is used in conjunction with a robot to pick mixed size product and place the product onto a pallet or layers resting on top of a pallet. The end of arm tooling includes two center rails/forks mounted to a base. Two outer rails/forks are mounted to linear bearings that guide the outer rails/forks when moving inwardly or outwardly from the center rails for pre-sizing to the product. Pusher arms are formed of two outer pusher arms and one center pusher arm. These pusher arms are attached to linear bushings that guide the pusher arms forward and backward. The pusher arms push off the product simultaneously as the robot is withdrawing the rails.

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: An apparatus and a method for optimizing robot performance includes a computer connected to the robot controller for receiving performance data of the robot as the controller executes a path program. The computer uses the performance data, user specified optimization objectives and constraints and a kinematic/dynamic simulator to generate a new set of control system parameters to replace the default set in the controller. The computer repeats the process until the new set of control system parameters is optimized.

Abstract: An electrostatic rotary atomizer apparatus includes a housing encasing a turbine assembly, a shaping air assembly disposed radially outwardly from the turbine assembly for fluid communication with a shaping air supply, and a charge ring mounted to the housing and adapted to be connected to an electrical power supply. The charge ring has a plurality of electrodes within the housing. Ions emitted by the charge ring are directed through shaping air passages to intersect paint droplets leaving a rotating bell cup.

Abstract: An apparatus for processing objects includes an elevated tubular frame rail mounting a four axis robot arm with a tool such as a painting applicator. The robot is attached to a mounting base that moves along the rail permitting painting of the top and/or side of a vehicle body. Electrical power and fluid lines can be routed through the rail to the robot. Two such rails and multiple robots can be combined as a module for installation in a new or an existing painting booth.

Abstract: A painting robot outer arm includes a non-conductive housing mounting a color changer on the outside and a paint canister on the inside connected by an isolating paint transfer line. The paint canister is releasably attached to a piston ram and drive motor by a quick disconnect coupling. The paint supply is isolated from the applied high voltage by cleaning and drying the transfer line. The rate of filling of the canister can be controlled in response to sensed torque applied by a drive motor moving a piston in the paint canister.