Patents by Inventor Sai-Kai Cheng
Sai-Kai Cheng 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).
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Patent number: 11400594Abstract: 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: GrantFiled: September 10, 2019Date of Patent: August 2, 2022Assignee: FANUC AMERICA CORPORATIONInventors: Yi Sun, Sai-Kai Cheng, Jason Tsai
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Patent number: 11373372Abstract: 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: GrantFiled: June 26, 2019Date of Patent: June 28, 2022Assignee: FANUC AMERICA CORPORATIONInventors: Leo Keselman, Yi Sun, Sai-Kai Cheng, Jason Tsai
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Patent number: 11112776Abstract: 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.Type: GrantFiled: September 26, 2017Date of Patent: September 7, 2021Assignee: FANUC AMERICA CORPORATIONInventors: Leo Keselman, Matthew DeNio, Eric Lee, Ho Cheung Wong, Peter Swanson, Sai-Kai Cheng
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Patent number: 10773383Abstract: 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: GrantFiled: May 21, 2018Date of Patent: September 15, 2020Assignee: FANUC AMERICA CORPORATIONInventors: Yi Sun, Jason Tsai, Sai-Kai Cheng, James F. Huber
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Patent number: 10639791Abstract: 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: GrantFiled: June 5, 2017Date of Patent: May 5, 2020Assignee: FANUC CORPORATIONInventors: Tien L. Chang, Terry Tupper, Ho Cheung Wong, Sai-Kai Cheng, Jason Tsai
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Publication number: 20200078945Abstract: 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: ApplicationFiled: September 10, 2019Publication date: March 12, 2020Inventors: Yi Sun, Sai-Kai Cheng, Jason Tsai
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Publication number: 20200078937Abstract: 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: ApplicationFiled: September 9, 2019Publication date: March 12, 2020Inventors: Yi Sun, Jason Tsai, Sai-Kai Cheng, Don Kijek, Bradley Q. Niederquell
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Publication number: 20190392644Abstract: 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: ApplicationFiled: June 26, 2019Publication date: December 26, 2019Inventors: Leo Keselman, Yi Sun, Sai-Kai Cheng, Jason Tsai
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Patent number: 10414043Abstract: A method for controlling motion of a robot relative to a conveyor flow direction of a moving conveyor includes the steps of: establishing a tracking frame for coordinating a position and movement of the robot relative to an object support surface of the conveyor; setting an upstream boundary perpendicular or skewed to a conveyor flow direction of the conveyor; setting a downstream boundary perpendicular or skewed to the conveyor flow direction; optionally setting a circular boundary partially overlapping the upstream boundary and the downstream boundary, wherein the upstream boundary, the downstream boundary and the circular boundary are positioned to define a picking area relative to the support surface; and operating the robot to pick objects from the picking area.Type: GrantFiled: January 31, 2017Date of Patent: September 17, 2019Assignee: FANUC AMERICA CORPORATIONInventors: Min Ren Jean, Ganesh Kalbavi, Sai-Kai Cheng
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Publication number: 20190227532Abstract: 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.Type: ApplicationFiled: September 26, 2017Publication date: July 25, 2019Inventors: Leo Keselman, Matthew DeNio, Eric Lee, Ho Cheung Wong, Peter Swanson, Sai-Kai Cheng
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Publication number: 20180333852Abstract: 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: ApplicationFiled: May 21, 2018Publication date: November 22, 2018Inventors: Yi Sun, Jason Tsai, Sai-Kai Cheng, James F. Huber
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Publication number: 20180215034Abstract: A method for controlling motion of a robot relative to a conveyor flow direction of a moving conveyor includes the steps of: establishing a tracking frame for coordinating a position and movement of the robot relative to an object support surface of the conveyor; setting an upstream boundary perpendicular or skewed to a conveyor flow direction of the conveyor; setting a downstream boundary perpendicular or skewed to the conveyor flow direction; optionally setting a circular boundary partially overlapping the upstream boundary and the downstream boundary, wherein the upstream boundary, the downstream boundary and the circular boundary are positioned to define a picking area relative to the support surface; and operating the robot to pick objects from the picking area.Type: ApplicationFiled: January 31, 2017Publication date: August 2, 2018Inventors: Min Ren Jean, Ganesh Kalbavi, Sai-Kai Cheng
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Publication number: 20170348853Abstract: 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: ApplicationFiled: June 5, 2017Publication date: December 7, 2017Inventors: Tien L. Chang, Terry Tupper, Ho Cheung Wong, Sai-Kai Cheng, Jason Tsai
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Patent number: 9415512Abstract: A system and method for enhancing a visualization of coordinate points within a robot's working envelope is disclosed. Part data associated with a position of a part, which may include part offset from a known position, is read using a teach pendant program. The part data is automatically stored within a hidden program instruction of the teach pendant program. The part data may be stored within the part program in a motion instruction associated with a motion line of the teach pendant program.Type: GrantFiled: August 28, 2014Date of Patent: August 16, 2016Assignee: Fanuc America CorporationInventors: Sai-Kai Cheng, Gordon Geheb, Nivedhitha Giri, Randy A. Graca, David J. O'Toole
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Patent number: 9327401Abstract: 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: GrantFiled: September 9, 2013Date of Patent: May 3, 2016Assignee: Fanuc America CorporationInventors: Di Xiao, Sai-Kai Cheng, Randy A. Graca, Matthew R. Sikowski, Jason Tsai
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Publication number: 20160059414Abstract: A system and method for enhancing a visualization of coordinate points within a robot's working envelope is disclosed. Part data associated with a position of a part, which may include part offset from a known position, is read using a teach pendant program. The part data is automatically stored within a hidden program instruction of the teach pendant program. The part data may be stored within the part program in a motion instruction associated with a motion line of the teach pendant program.Type: ApplicationFiled: August 28, 2014Publication date: March 3, 2016Inventors: Sai-Kai Cheng, Gordon Geheb, Nivedhitha Giri, Randy A. Graca, David J. O'Toole
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Patent number: 9227322Abstract: Painting robots processing a part moving on a conveyor are synchronized by creating for each of the robots a master sequence of computer program instructions for a collision-free movement of robots along associated master sequence paths relative to the moving part, each of the master sequence paths including positions of the associated robot and the conveyor at pre-defined synchronization points, and running each of the master sequences on a controller connected to the associated robot to move the associated robot and comparing a current path of the associated robot and the conveyor against the master sequence path. The method further includes operating the controllers to adjust the current paths based on the comparison between the master sequence path and the current path, and operating the controllers to request a conveyor motion hold as necessary to facilitate synchronization between movement of the robots and the conveyor.Type: GrantFiled: November 30, 2012Date of Patent: January 5, 2016Assignee: Fanuc Robotics America CorporationInventors: Randy A. Graca, Di Xiao, Sai-Kai Cheng
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Patent number: 9144904Abstract: 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: GrantFiled: May 2, 2012Date of Patent: September 29, 2015Assignee: Fanuc Robotics America CorporationInventors: H. Dean McGee, Tien L. Chang, Peter Swanson, Jianming Tao, Di Xiao, Ho Cheung Wong, Sai-Kai Cheng, Jason Tsai
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Publication number: 20140156068Abstract: Painting robots processing a part moving on a conveyor are synchronized by creating for each of the robots a master sequence of computer program instructions for a collision-free movement of robots along associated master sequence paths relative to the moving part, each of the master sequence paths including positions of the associated robot and the conveyor at pre-defined synchronization points, and running each of the master sequences on a controller connected to the associated robot to move the associated robot and comparing a current path of the associated robot and the conveyor against the master sequence path. The method further includes operating the controllers to adjust the current paths based on the comparison between the master sequence path and the current path, and operating the controllers to request a conveyor motion hold as necessary to facilitate synchronization between movement of the robots and the conveyor.Type: ApplicationFiled: November 30, 2012Publication date: June 5, 2014Applicant: FANUC ROBOTICS AMERICA CORPORATIONInventors: Randy A. Graca, Di Xiao, Sai-Kai Cheng
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Publication number: 20140074289Abstract: 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: ApplicationFiled: September 9, 2013Publication date: March 13, 2014Inventors: Di Xiao, Sai-Kai Cheng, Randy A. Graca, Matthew R. Sikowski, Jason Tsai