Abstract: An apparatus for providing haptic feedback to a teach pendant including a teach pendant having a housing and a processor disposed therein. The processor is in signal communication with a robot controller and is configured to monitor and control a robot. At least one haptic device is disposed on the teach pendant. The haptic device is in signal communication with the processor and configured for providing haptic feedback through the teach pendant to a user upon the occurrence of a haptic event.

Abstract: A method and an apparatus for displaying three-dimensional workcell data includes a hand-held pendant that is provided with 3-D workcell data representing a model of a machine and associated components in a workcell. The hand-held pendant has a display that generates a 3-D visual representation of the workcell data. The pendant can be operated by a user to manipulate the visual representation to change a user viewpoint and to show motion of the machine with associated process information.

Abstract: 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.

Abstract: 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.

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 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: An apparatus for providing haptic feedback to a teach pendant including a teach pendant having a housing and a processor disposed therein. The processor is in signal communication with a robot controller and is configured to monitor and control a robot. At least one haptic device is disposed on the teach pendant. The haptic device is in signal communication with the processor and configured for providing haptic feedback through the teach pendant to a user upon the occurrence of a haptic event.

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 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 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.

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 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 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 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 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 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 system for performing the method of this invention includes a leader having a robot arm able to articulate about first axes and supporting an end effector. A follower includes a robot arm able to articulate about respective second axes. Servo motors articulate the leader arm about the first axes and the follower arm about the second axes. A user interface allows a user to jog the arm of the leader and to program movement of the arms for automatic execution such that the end effector reaches predetermined positions. A controller, operatively connected to the servo motors and the user interface, controls operation of the servo motors, moves the arm of the leader in accordance with the programmed movement, and moves the arm of the follower such that it tracks or mirrors movement of the leader.

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 system for performing the method of this invention includes a leader having a robot arm able to articulate about first axes and supporting an end effector. A follower includes a robot arm able to articulate about respective second axes. Servo motors articulate the leader arm about the first axes and the follower arm about the second axes. A user interface allows a user to jog the arm of the leader and to program movement of the arms for automatic execution such that the end effector reaches predetermined positions. A controller, operatively connected to the servo motors and the user interface, controls operation of the servo motors, moves the arm of the leader in accordance with the programmed movement, and moves the arm of the follower such that it tracks or mirrors movement of the leader.