WO2020028750A1 - Extension hardware for physical controller - Google Patents

Abstract

A user-friendly physical extension hardware device/add-on for a physical controller enables a user to control the controller via any microcontroller-friendly input platform. The physical controller may be a KUKA robotics physical controller, such as a 4th generation KRC4 controller which may also be known as a "teaching pendant". The extension hardware/add-on may be used to activate a pre-programmed move of a robot controlled by the physical controller.

Description

EXTENSION HARDWARE FOR PHYSICAL CONTROLLER

[0001] This application claims the priority benefit of U.S. Provisional Application No. 62/713,566 filed August 2, 2018 and titled“EXTENSION HARDWARE FOR PHYSICAL CONTROLLER”, which is incorporated by reference in its entirety.

BACKGROUND

[0001] The present exemplary embodiment relates to extension hardware for a physical controller (e.g., for a KUKA robotics controller).

[0002] In current set-ups using KUKA robotics, there are two primary methods to execute or stop a programmed robotic motion. The first method involves software/digital control using custom KUKA packages to either enable to control or facilitate the real-time communication with the robot. In the second method, the operator directly uses the teaching pendant and pushes stop/play buttons.

[0003] It would be desirable to develop new apparatuses and methods for bridging these two platforms/methods to create a seamless, customizable/open-source way of activating/stopping the KUKA robot program operation through the majority of programming platforms and interactive controllers.

[0004] All of the previous solutions for the real-time controlling of the KUKA robots with KRC4 controllers are limited to custom or KUKA developed software packages. These software solutions need advanced programming and KUKA robotics knowledge.

[0005] It would be desirable to develop knew apparatuses and methods for controlling KUKA robots that do not require advanced programming or knowledge.

[0006] KUKA software packages also typically cost around $3000 and take around 2 hours to set-up.

[0007] It would be desirable to develop new apparatuses and methods for controlling KUKA robots which are relatively inexpensive and plug-and-play. BRIEF DESCRIPTION

[0008] The present disclosure relates to a hardware extension device for a physical controller. Disclosed in some embodiments is a hardware extension device as described herein and/or as illustrated in the accompanying drawings. Disclosed in other embodiments is a method for manufacturing a hardware extension device as described herein and/or as illustrated in the accompanying drawings. Disclosed in further embodiments is a method for controlling a robot using a hardware extension device as described herein and/or as illustrated in the accompanying drawings.

[0009] Disclosed, in some embodiments, is an extension hardware device for a physical controller. The extension hardware device includes a shell comprising a microcontroller pocket, a controller pocket, and a motor pocket.

[0010] The extension hardware device may further include a microcontroller received within the microcontroller pocket.

[0011] In some embodiments, the extension hardware device includes a motor received within the motor pocket. The motor may be a servo motor.

[0012] The microcontroller may be configured to receive a signal wirelessly or via a wired connection. In some embodiments, the extension hardware device further includes a wireless card received within the microcontroller pocket.

[0013] The shell may be in the form of a single piece or a plurality of pieces. One or more fasteners may be included to hold the plurality of pieces together.

[0014] In some embodiments, the shell comprises a first shell component, a second shell component, and at least one fastener connecting the first shell component to the second shell component.

[0015] Connector pins are a non-limiting example of fasteners.

[0016] The first shell component may include the controller pocket, the motor pocket, and a first portion of the microcontroller pocket. In some embodiments, the second shell component comprises a second portion of the microcontroller pocket.

[0017] It is also possible that the controller pocket is formed of a first controller recess in the first shell and a second controller recess in the second shell.

[0018] It is also possible that the motor pocket is formed of a first motor recess in the first shell and a second motor recess in the second shell. [0019] The controller pocket may be configured to receive a KUKA teach pendant.

[0020] In some embodiments, the system further includes a KUKA teach pendant received within the controller pocket.

[0021] The extension hardware device may further include a microcontroller input device.

[0022] In some embodiments, the microcontroller input device comprises at least one of a depth-sensing camera, a gaming controller, a cell phone, and a wearable sensor.

[0023] Disclosed, in other embodiments, is an extension hardware device for a physical controller comprising: a shell comprising a microcontroller pocket, a controller pocket, and a motor pocket; a microcontroller received within the microcontroller pocket; and a motor received within the motor pocket.

[0024] The microcontroller may be configured to be wirelessly connected to a microcontroller input device and/or connected to the microcontroller input device via a wired connection.

[0025] In some embodiments, the motor is connected to a head configured for pressing one or more buttons on a controller received within the controller pocket.

[0026] The head may be a two-legged head.

[0027] Disclosed, in further embodiments, is a method for operating a controller comprising: adjusting a microcontroller input device. The microcontroller input device is connected to a microcontroller. The microcontroller is part of an extension hardware device comprising: a shell comprising a microcontroller pocket, a controller pocket, and a motor pocket; a microcontroller received within the microcontroller pocket; and a motor received within the motor pocket. The controller is received within the controller pocket.

[0028] The extension hardware device may further include a head connected to the motor, wherein the head is configured to press one or more buttons on the controller based on a signal from the microcontroller input device.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The following is a brief description of the drawings, which are presented for the purposes of illustrating the exemplary embodiments disclosed herein and not for the purposes of limiting the same. The dashed lines illustrates shapes/aspects that are generally hidden from view in the device is not transparent.

[0030] FIG. 1 is an exploded view of the PX01 -Switch in accordance with some embodiments of the present disclosure.

[0031 ] FIG. 2 is a perspective view of a first shell part of the device of FIG. 1.

[0032] FIG. 3 is a perspective view of the first shell part of FIG. 2 receiving a KUKA

KRC4 teach pendant.

[0033] FIG. 4 is a perspective view of the device of FIG. 1 receiving the KUKA KRC4 teaching pendant.

[0034] FIG. 5 is a side view of the system of FIG. 4.

[0035] FIG. 6 is another side view of the system of FIG. 4, taken from the opposing side from the view of FIG. 5.

[0036] FIG. 7 is a top view of the system of FIG. 4.

DETAILED DESCRIPTION

[0037] The present disclosure may be understood more readily by reference to the following detailed description of desired embodiments included therein and the appended materials. In the following specification and the claims which follow, reference will be made to a number of terms which shall be defined to have the following meanings.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent can be used in practice or testing of the present disclosure. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and articles disclosed herein are illustrative only and not intended to be limiting.

[0039] The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0040] As used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.” The terms “comprise(s),”“include(s),”“having,”“has,”“can,”“contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases that require the presence of the named ingredients/steps and permit the presence of other ingredients/steps. However, such description should be construed as also describing compositions, mixtures, or processes as“consisting of” and“consisting essentially of” the enumerated ingredients/steps, which allows the presence of only the named ingredients/steps, along with any impurities that might result therefrom, and excludes other ingredients/steps.

[0041] Unless indicated to the contrary, the numerical values in the specification should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of the conventional measurement technique of the type used to determine the particular value.

[0042] All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of “from 2 to 10” is inclusive of the endpoints, 2 and 10, and all the intermediate values). The endpoints of the ranges and any values disclosed herein are not limited to the precise range or value; they are sufficiently imprecise to include values approximating these ranges and/or values.

[0043] As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and“substantially,” may not be limited to the precise value specified, in some cases. The modifier“about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression“from about 2 to about 4” also discloses the range“from 2 to 4.” The term“about” may refer to plus or minus 10% of the indicated number. For example,“about 10%” may indicate a range of 9% to 1 1 %, and“about 1” may mean from 0.9-1.1 .

[0044] For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1 , 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated. [0045] The present disclosure relates to a new solution for human-machine interaction in both industrial and creative robotic settings (e.g., using KUKA robots). The solution involves extension hardware for a physical controller. In non-limiting embodiments, the extension hardware may be referred to as the PX01 -Switch and may be configured as an add-on to the KUKA controller (also known as the“teach pendant” or“teaching pendant”).

[0046] As a physical add-on to the KUKA teaching pendant, PX01 -Switch acts an “operator” pushing the stop/play buttons. This stop/play process can be controlled off-site and through almost infinite numbers of ways with any microcontroller-friendly inputs. With PX01 -Switch, it is also possible to control a predefined/preprogrammed motion of the robot in forward or backward mode through either USB or wireless connection.

[0047] Different form KUKA software packages, PX01 -Switch can use open-source software platforms including but not limited to Arduino, Python, Java, C#, C++, Mel and other visual programming platforms such as Grasshopper 3D.

[0048] The significant advantage of the PX01 -Switch over the previous solutions are:

• an easy and intuitive learning process;

• affordable and open source; and

• easy to develop based upon.

[0049] In PX01 -Switch, little or no programming may be required. Instead, an input device (Kinect, gaming controller, etc.) is connected to the PX01 -Switch's microcontroller which is accessible from many programming platforms.

[0050] The connection may be a wired connection (e.g., USB) or a wireless connection.

[0051] Another advantage of PX01 -Switch is the cost and time that it takes to have it set-up in comparison to previous methods. In particular, the PX01 -Switch may reduce costs and time.

[0052] In some embodiments, PX01 -Switch is plug-and-play.

[0053] In some embodiments, the extension hardware of the present disclosure is produced via additive manufacturing (e.g., 3D printing).

[0054] The extension hardware may be added to the KUKA robot KRC4 Controller teaching pendant. Inside the extension hardware, there may be a servo motor controlled by an Arduino board with the limitation of rotation of 45 degrees. Attached to the end of the servo a custom to a two-!egged head, may act as pushing mechanism to activate the stop/play button(s) on the KUKA robot teaching pendant.

[0055] Using the Arduino microcontroller embedded into the PX01 -Switch, the user can control the PXOTs Servo to play or stop the execution of a preprogrammed motion on the KUKA robot. The communication method between the user and the PX01 -Switch can happen through USB or wireless connection.

[0056] In some embodiments, it is possible to activate the PX01 -Switch using any of the following programming platforms: Java, Python, C++, C Sharp, Grasshopper, and Processing, Software platforms like Rhino 3D, Autodesk MAYA, Matlab, Autodesk 3dsMAX, Unity 3D, Touch OSC, and any Arduino friendly sensors.

[0057] In some embodiments, the microcontroller-friendly input platform includes a depth-sensing camera (e.g., Kinect), a gaming controller, color-based image processing, smart gloves, cellphone applications, wearable sensors (e.g., muscle sensors), or any combination thereof.

[0058] FIGS. 1 -7 illustrate various components and angles of a hardware extension device in accordance with some embodiments of the present disclosure. The hardware extension device includes two shell components connected via connector pins that extend into recesses in each shell component. The shell includes pockets for receiving a physical controller, a microcontroller and/or a wireless card, and a motor.

[0059] FIG. 1 is an exploded view of the PX01 -Switch in accordance with some embodiments of the present disclosure.

[0060] FIG. 2 is a perspective view of a first shell part of the device of FIG. 1.

[0061] FIG. 3 is a perspective view of the first shell part of FIG. 2 receiving a KUKA

KRC4 teach pendant.

[0062] FIG. 4 is a perspective view of the device of FIG. 1 receiving the KUKA KRC4 teaching pendant.

[0063] FIG. 5 is a side view of the system of FIG. 4.

[0064] FIG. 6 is another side view of the system of FIG. 4, taken from the opposing side from the view of FIG. 5.

[0065] FIG. 7 is a top view of the system of FIG. 4. [0066] The extension hardware device 100 includes a shell 110 including a first shell part 112 and a second shell part 114. The device 100 further includes a plurality of connecting pins 116 for securing the first shell part 112 and the second shell part 114 together. The first shell part includes first shell part openings 113 and the second shell part 114 includes second shell part openings 115. The shell 110 includes controller recess or pocket 120 for receiving a controller, a microcontroller pocket or recess 130 for receiving a microcontroller, and a motor pocket 140 for receiving a motor. In some embodiments, the device 100 further includes a motor 145 received within the motor pocket 140 and a microcontroller 135 received within the microcontroller pocket 130. The microcontroller 135 may be connected to an input device (not shown) via a wireless connection (e.g., wireless card 150) and/or a wired connection (e.g., a cable 137 such as a USB cable). A controller 125 (e.g., a KUKA controller) may be received within the controller pocket 120. The controller 125 may be connected to a robot (not shown) via a wired connected 127 or a wireless connection. The controller 125, microcontroller 135, and motor 145 may be powered from the same or different sources. The power source or sources may be portable (e.g., batteries) and/or hardwired (e.g., a power cord plugged into an electrical outlet) and/or wireless. In some embodiments, the microcontroller 135 and the motor 145 share a common power source. In some embodiments, the controller 125, microcontroller 135, and motor 145 share a common power source. In other embodiments, the controller 125 does not share a common power source with the microcontroller 135 and the motor 145.

[0067] In some embodiments, the extension hardware is powered via one or more USB ports (e.g., from a computer such as a laptop or a desktop, a power bank, or an outlet).

[0068] The extension hardware device 100 is generally configured such that a signal form an input device is received at the microcontroller 135 which is connected to the motor 145 (e.g., via a wired or wireless connection). The signal may lead to a moving part 146 connected to the motor 145 to contact at least one button on the controller 125, thereby generating a signal from the controller 125 to the robot to perform a pre-designed movement pattern. [0069] In some embodiments, the controller 125 includes a single button controlling on/off or forward/reverse that the moving part can contact.

[0070] In other embodiments, the controller 125 includes a plurality of buttons that the moving part connected to the motor 145 can contact. For example, the controller may include separate on and off buttons and/or separate forward and reverse buttons. In some embodiments, the buttons include an on/off button, a forward button, and a reverse button.

[0071] The moving part 146 may include a single contactor (e.g., leg) for contacting the one or more buttons. In other embodiments, the moving part may include a plurality of contactors. For example, the moving part 146 may include a distinct contactor associated with each button of the controller 125 (e.g., two contactors for two buttons on the controller, three contactors for three buttons on the controller, etc.). In some embodiments, the moving part 146 is the same or similar to the four leg configuration of FIGS. 2 and 3. In other embodiments, the two upper legs may be omitted.

[0072] It is also contemplated that a plurality of moving parts may be included. The plurality may be associated with a common motor or a plurality of motors.

[0073] In particular embodiments, the moving part associated with the motor 145 includes two contactors (e.g., legs).

[0074] Methods of making and using the hardware extension device of the present disclosure are also disclosed. The methods generally include providing a signal from an input device to the hardware extension device. The signal may be provided wirelessly or via a wired connection. The signal may be provided via an automated process and/or from a user. In some embodiments,

[0075] The shell optionally includes one or more additional openings extending therethrough. These openings may be used to secure the hardware extension device (e.g., to hold the hardware extension device in a human hand or to hang the hardware extension device from a hook).

[0076] In some embodiments, the openings serve an aesthetic function.

[0077] In some embodiments, the openings can be used to move the device.

[0078] The shell may contain at least one material selected from PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), PET (polyethylene terephthalate), PETT (polyethylene trimethylene terephthalate), nylon, PVA (polyvinyl alcohol), sandstone, PS (polystyrene, e.g., high impact polystyrene), TPE (thermoplastic elastomer), and TPU (thermoplastic polyurethane).

[0079] The shell may be optically transparent, translucent, or opaque.

[0080] The plastic material optionally includes one or more additives. Non-limiting examples of additives include carbon fibers, carbon nanotubes, graphene, antioxidants, stabilizers, and metals.

[0081] In some embodiments, the bounding box of the PX01 -Switch in millimeter is 193.5 w X 342.5 L x 213.5 H.

[0082] In other embodiments, the extension hardware is configured to receive controllers from other companies (e.g., ABB, Fanuc and Staubli).

[0083] The motor or motor attachment may be configured to press one or more buttons on the controller depending on a signal provided by the microcontroller input device. The one or more buttons may lead to the execution of one or more pre-programmed moves for the robot.

[0084] For example, pressing the button or buttons may lead to forward or backward performance of the moves. In some embodiments, forward and backward movements are controlled by a single button. In other embodiments, forward and backward movements are controlled by two or more buttons. As used herein,“button(s)” may also refer to a touch-screen.

[0085] The button or buttons may also represent start/stop. Start and stop may be controlled by a single button. In other embodiments, start and stop are controlled by two or more buttons.

[0086] In particular embodiments, the extension hardware device utilizes a single motor (e.g., servo motor) to manipulate two buttons (e.g., play forward and play backward).

[0087] The extension hardware device may trigger/control a single pre-designed motion that is a combination of all of the axes and motion parameters of the robot.

[0088] The extension hardware device may be designed to trigger (play forward, stop, play backward) a pre-designed motion that is uploaded to the robot. [0089] The extension hardware device may be used in a set-up where safety is critical. Non-limiting examples include robotic performance with a heat gun or welding tool and in a limited space/room. The extension hardware device may be particularly suitable for such applications with its ability to play a pre-programmed code forward and backward and with the possibility of doing so wirelessly.

[0090] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims

CLAIMS:

1 . An extension hardware device for a physical controller comprising:

a shell comprising a microcontroller pocket, a controller pocket, and a motor pocket.

2. The extension hardware device of claim 1 , further comprising:

a microcontroller received within the microcontroller pocket.

3. The extension hardware device of any one of claims 1 and 2, further comprising:

a motor received within the motor pocket.

4. The extension hardware device of claim 3, wherein the motor is a servo motor.

5. The extension hardware device of any one of claims 1 -4, further comprising: a wireless card received within the microcontroller pocket.

6. The extension hardware device of any one of claims 1 -5, wherein the shell comprises a first shell component, a second shell component, and at least one fastener connecting the first shell component to the second shell component.

7. The extension hardware device of claim 6, wherein the at least one fastener comprises a plurality of connector pins.

8. The extension hardware device of any one of claims 6 and 7, wherein the first shell component comprises the controller pocket, the motor pocket, and a first portion of the microcontroller pocket.

9. The extension hardware device of claim 8, wherein the second shell component comprises a second portion of the microcontroller pocket.

10. The extension hardware device of any one of claims 1-9, wherein the controller pocket is configured to receive a KUKA teach pendant.

11. The extension hardware device of any one of claims 1-10, further comprising:

a KUKA teach pendant received within the controller pocket.

12. The extension hardware device of any one of claims 1 -11 , further comprising:

a microcontroller input device.

13. The extension hardware device of claim 12, wherein the microcontroller input device comprises at least one of a depth-sensing camera, a gaming controller, a cell phone, and a wearable sensor.

14. An extension hardware device for a physical controller comprising:

a shell comprising a microcontroller pocket, a controller pocket, and a motor pocket;

a microcontroller received within the microcontroller pocket; and

a motor received within the motor pocket.

15. The extension hardware device of claim 14, wherein the microcontroller is configured to be wirelessly connected to a microcontroller input device.

16. The extension hardware device of claim 14, wherein the microcontroller is configured to be connected to a microcontroller device via a wired connection.

17. The extension hardware device of any one of claims 14-16, wherein the motor is connected to a head configured for pressing one or more buttons on a controller received within the controller pocket.

18. The extension hardware device of claim 17, wherein the head is a two- legged head.

19. A method for operating a controller comprising:

adjusting a microcontroller input device;

wherein the microcontroller input device is connected to a microcontroller; wherein the microcontroller is part of an extension hardware device comprising:

a shell comprising a microcontroller pocket, a controller pocket, and a motor pocket;

a microcontroller received within the microcontroller pocket; and a motor received within the motor pocket; and

wherein the controller is received within the controller pocket.

20. The method of claim 19, wherein the extension hardware device further comprises a head connected to the motor, wherein the head is configured to press one or more buttons on the controller based on a signal from the microcontroller input device.