Abstract: A system and methods for automated support for industrial robots. The system includes a data collection device which communicates with all robots at a customer site, and uploads data to a remote diagnostic system. The method is activated either automatically when an alarm occurs, or by the robot operator or a remote support team. Upon activation, particular diagnostic files are captured and sent from the affected robot's controller to the data collection device and on to the remote diagnostic system. The system employs a knowledge base to diagnose the cause of the issue from the diagnostic files, and support team personnel are also involved to reach a diagnosis. Based on the diagnosis, updated software or configuration files are sent to the affected robot to correct the issue and allow the robot to return to service, instructions are provided to the robot operator, or an on-site service technician visit is scheduled.

Abstract: A method and system for monitoring the usage of interchangeable end-of-arm tools across multiple robots. Each tool is assigned a unique identifier maintained in a database. At each facility where robots are installed, a data collection device communicates with all robot controllers and provides centralized storage and monitoring of usage and maintenance data for each end-of-arm tool. Each time a tool is attached to a robot, the controller downloads the current data for the tool from the data collection device. Likewise, each time a tool is detached from a robot, the controller uploads updated data for the tool to the data collection device. The data collection device maintains cumulative usage data for each tool, provides a user interface to the data to allow monitoring by personnel, and sends notifications of important pending maintenance requirements and any performance issues. The data is also stored on a cloud server for global access.

Abstract: A system and method for controlling movement of a robot holding a tool from an end of one tool operation to a beginning of a next tool operation that reduces tool jerk and thus reduces the robot stabilization time. The method includes separating the robot movement into a plurality of segments that have different robot movement accelerations, determining an acceleration of the robot for each segment that optimizes a cycle time of the robot movement, and reducing the optimal acceleration of the robot during a last segment so as to reduce tool jerk when the robot reaches the beginning of the next tool operation. In one non-limiting embodiment, the tool is a laser cutting tool and the number of segments is seven segments.

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 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.