Patents by Inventor Jason Tsai

Jason Tsai has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11472035
    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.
    Type: Grant
    Filed: June 26, 2019
    Date of Patent: October 18, 2022
    Assignee: FANUC AMERICA CORPORATION
    Inventors: Ganesh Kalbavi, Derek Jung, Leo Keselman, Min-Ren Jean, Kenneth W. Krause, Jason Tsai
  • Patent number: 11400594
    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.
    Type: Grant
    Filed: September 10, 2019
    Date of Patent: August 2, 2022
    Assignee: FANUC AMERICA CORPORATION
    Inventors: Yi Sun, Sai-Kai Cheng, Jason Tsai
  • Patent number: 11373372
    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.
    Type: Grant
    Filed: June 26, 2019
    Date of Patent: June 28, 2022
    Assignee: FANUC AMERICA CORPORATION
    Inventors: Leo Keselman, Yi Sun, Sai-Kai Cheng, Jason Tsai
  • Patent number: 10836038
    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.
    Type: Grant
    Filed: May 21, 2014
    Date of Patent: November 17, 2020
    Assignee: FANUC AMERICA CORPORATION
    Inventors: Yi Sun, Jason Tsai, Laxmi Musunur, Michael Sharpe
  • Patent number: 10773383
    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.
    Type: Grant
    Filed: May 21, 2018
    Date of Patent: September 15, 2020
    Assignee: FANUC AMERICA CORPORATION
    Inventors: Yi Sun, Jason Tsai, Sai-Kai Cheng, James F. Huber
  • Patent number: 10639791
    Abstract: 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.
    Type: Grant
    Filed: June 5, 2017
    Date of Patent: May 5, 2020
    Assignee: FANUC CORPORATION
    Inventors: Tien L. Chang, Terry Tupper, Ho Cheung Wong, Sai-Kai Cheng, Jason Tsai
  • Patent number: 10616080
    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.
    Type: Grant
    Filed: November 25, 2015
    Date of Patent: April 7, 2020
    Assignee: FANUC AMERICA CORPORATION
    Inventors: Isaac Eckert, Gordon Geheb, Bradley Q. Niederquell, Yi Sun, Jason Tsai, Rick E. Wunderlich
  • Publication number: 20200078937
    Abstract: 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.
    Type: Application
    Filed: September 9, 2019
    Publication date: March 12, 2020
    Inventors: Yi Sun, Jason Tsai, Sai-Kai Cheng, Don Kijek, Bradley Q. Niederquell
  • Publication number: 20200078945
    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 CAD-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.
    Type: Application
    Filed: September 10, 2019
    Publication date: March 12, 2020
    Inventors: Yi Sun, Sai-Kai Cheng, Jason Tsai
  • Publication number: 20190389069
    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.
    Type: Application
    Filed: June 26, 2019
    Publication date: December 26, 2019
    Inventors: Ganesh Kalbavi, Derek Jung, Leo Keselman, Min-Ren Jean, Kenneth W. Krause, Jason Tsai
  • Publication number: 20190392644
    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.
    Type: Application
    Filed: June 26, 2019
    Publication date: December 26, 2019
    Inventors: Leo Keselman, Yi Sun, Sai-Kai Cheng, Jason Tsai
  • Publication number: 20180333852
    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.
    Type: Application
    Filed: May 21, 2018
    Publication date: November 22, 2018
    Inventors: Yi Sun, Jason Tsai, Sai-Kai Cheng, James F. Huber
  • Patent number: 10094052
    Abstract: This invention is directed to a light weight fire resistant material. The material is constructed of a plurality of oxidized polyacrylonitrile (OPAN) fibers. The fire resistant material having a weight in the range of less than about 9.0 oz/yd2, an Arc Thermal Performance Value of greater than about 8.0 and a Thermal Protection Performance of greater than about 13.0.
    Type: Grant
    Filed: August 26, 2010
    Date of Patent: October 9, 2018
    Assignee: National Safety Apparel, Inc.
    Inventors: Jung-Huang (Jason) Tsai, Elizabeth Clagg, Mitchael C. Freeman, Andrew M. Allen, Paige Johnson, William D. Townsend
  • Patent number: 10052759
    Abstract: 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.
    Type: Grant
    Filed: March 28, 2014
    Date of Patent: August 21, 2018
    Assignee: FANUC AMERICA CORPORATION
    Inventors: Jianming Tao, Charles R. Strybis, Bradley Niederquell, Jason Tsai
  • Publication number: 20170348853
    Abstract: 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.
    Type: Application
    Filed: June 5, 2017
    Publication date: December 7, 2017
    Inventors: Tien L. Chang, Terry Tupper, Ho Cheung Wong, Sai-Kai Cheng, Jason Tsai
  • Patent number: 9415514
    Abstract: 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.
    Type: Grant
    Filed: September 9, 2013
    Date of Patent: August 16, 2016
    Assignee: Fanuc America Corporation
    Inventors: Gordon Geheb, Jason Tsai, Rick E. Wunderlich, Yi Sun, Don Kijek, Isaac Eckert, Ganesh Kalbavi, Ken Krause, Judy Evans, Ashok Prajapati
  • Publication number: 20160149996
    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.
    Type: Application
    Filed: November 25, 2015
    Publication date: May 26, 2016
    Inventors: Isaac Eckert, Gordon Geheb, Bradley Q. Niederquell, Yi Sun, Jason Tsai, Rick E. Wunderlich
  • Patent number: 9327401
    Abstract: 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.
    Type: Grant
    Filed: September 9, 2013
    Date of Patent: May 3, 2016
    Assignee: Fanuc America Corporation
    Inventors: Di Xiao, Sai-Kai Cheng, Randy A. Graca, Matthew R. Sikowski, Jason Tsai
  • Publication number: 20150336267
    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.
    Type: Application
    Filed: May 21, 2014
    Publication date: November 26, 2015
    Inventors: Yi Sun, Jason Tsai, Laxmi Musunur, Michael Sharpe
  • Patent number: 9144904
    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.
    Type: Grant
    Filed: May 2, 2012
    Date of Patent: September 29, 2015
    Assignee: Fanuc Robotics America Corporation
    Inventors: H. Dean McGee, Tien L. Chang, Peter Swanson, Jianming Tao, Di Xiao, Ho Cheung Wong, Sai-Kai Cheng, Jason Tsai