A HAND-HELD TERMINAL UNIT, AN INDUSTRIAL ROBOT SYSTEM AND A
METHOD FOR CONTROLLING AN INDUSTRIAL ROBOT Technical field of the invention
The present invention relates to a hand-held terminal unit configured to communicate with a robot control unit in order to control an industrial robot. The present invention also relates to an industrial robot system, comprising an industrial robot including a manipulator, a control system and a hand-held terminal unit configured to communicate with the robot control system. Further, the invention relates to a method for controlling an industrial robot, and a computer-readable medium and a computer program product configured to perform the method.
Background of the invention
An industrial robot includes a manipulator, a control unit for automatically operating the manipulator, and a hand-held device for control of the robot, and communicating with the control unit. The hand-held device may also be called teach pendant unit (TPU), portable operating unit, portable controller, etc. In the following description and claims it will be referred to as a hand-held terminal unit. A hand-held terminal unit can, for example, be used by an operator to manually move the robot, to program the robot, monitoring a robot program, change certain variables in the program, starting, stopping and editing the robot program, input process parameters, etc. A handheld terminal unit will usually comprise operator control means such as a joystick device and/or push buttons, a visual display screen which may also be a touch screen, and safety function arrangements such as an enabling device and an emergency stop device.
In WO 2007/039785 is disclosed an example of a hand-held terminal unit including an enabling device called a live handle switch comprising a safety switch having three positions. By means of this the operator controls if the robot is in an enabled mode in which the robot is controllable by means of the hand-held terminal unit, or in a disabled mode in which the robot is not controllable from the hand-held terminal unit. In WO 2007/039785, there are two live handle switches, each one located to be operated by one hand of the operator, and arranged such that the hand-held terminal unit is operable when either one of the live handle switches is activated by the operator.
The switch is described to be of the type disclosed in US 5,444, 203, being a
mechanical safety switch comprising a contact device with a pressure rod displaceable against the action of a return spring, from a first end position, via an operating position, to a second end position, and wherein a safety circuit is closed only in the operating position. During the return movement from the second end position to the first end position, the safety circuit remains open.
The emergency stop device on a hand-held terminal unit is normally a push button device of a traditional type. When the operator pushes or presses down the button, an emergency circuit will be opened and all operations and movements of the robot will stop. Usually, the emergency stop can be reactivated again by turning the button and thus releasing the emergency stop.
Summary of the invention
An object of the present invention is to provide an improved hand-held terminal unit for controlling an industrial robot.
The object is achieved by means of a hand-held terminal unit as defined in patent claim 1 .
Accordingly is defined, a hand-held terminal unit configured to communicate with a robot control unit for controlling a robot, and including a safety function arrangement configured to control the opening and closing of a safety control circuit, characterised in that the safety function arrangement comprises at least one pressure force application area located externally on the hand-held terminal unit and separated from any display screen of the hand-held terminal unit, that the pressure force application area comprises at least one pressure force sensor means arranged to control the closing and opening of the safety control circuit in response to an external pressure force applied to the pressure force application area, that the safety function arrangement further comprises at least one processor or computer communicating with the pressure force sensor means and configured to close or open the safety control circuit when the applied pressure force on the pressure force sensor means exceeds a first threshold value. Thus the pressure force sensor is configured to provide a signal to a processor or computer in response to the external force applied to the pressure force application area.
One of the advantages obtained by the defined invention is that safety function arrangements, such as an enabling device or an emergency stop, can be made much
smaller in size, thinner, less bulky and less heavy when pressure force sensors are used instead of buttons, live handle devices etc. of prior art. For example, a hand-held terminal unit according to the invention may very well be designed small enough to be held in one hand only, thus leaving the other hand free to interact with a display screen of the hand-held terminal unit, for example. Such a small hand-held terminal unit is an advantage from an ergonomic point of view.
Another advantage is that the hand-held terminal unit can be made with a smooth external surface, without any projecting parts, which will make it safer to use. Also the use of pressure force sensors will allow for more freedom when designing those parts of the safety function arrangement that are operated by the user, and the form factor of the safety function arrangement can be tailored to be easy to grasp and operate.
Consequently, there are many advantages to be obtained where the prior art typ of mechanical components may be replaced by the inventive combination of hardware and software.
The use of pressure force sensors also makes it possible to provide for control and adaptation of the required pressure force in accordance with the operator's physical ability or preferences, and consequently is defined, according to another feature, that the first threshold value may be adjustable. For example, if the operator has less strong hands, the threshold value can be set at a lower pressure force level than if the operator has strong hands.
According to a further feature, each pressure force sensor means may comprise two pressure force sensors. In order to secure the function and minimize the risk of function failure, the present type of safety function arrangement is recommended to have a built in redundancy. Therefore, each pressure force sensor means may comprise two separate pressure force sensors and it will be sufficient that only one registers a pressure force that exceeds the threshold value in order for the safety control circuit to be closed or, alternatively, opened.
The pressure force sensor means may be located on part or parts of, or around the entire edge side of the hand-held terminal unit. Also other locations are of course possible, and a high flexibility when choosing where to locate the pressure force sensor means is a further advantage of the invention. There may also be provided a feedback function related to the pressure force sensors and there activation of the safety function
arrangement, such as a tactile feedback, audible feedback or visual feedback shown on a display screen of the hand-held terminal unit.
The pressure force sensor means may for example be in the shape of thin strips having a protective cover forming the pressure force application area.
It should be clarified that it is conceivable that the hand-held terminal unit can have more than one pressure force application area comprising pressure force sensor means, for example related to an enabling device, in which case the normal set-up would be that it is sufficient to apply pressure force on only one of these areas in order to activate the enabling device. However, there is nothing to prevent a set-up where pressure force needs to be applied to two or more such areas in order to activate the device. Further, the hand-held terminal unit may have more than one pressure force application area comprising pressure force sensor means, where these different pressure force application areas with their pressure force sensors may be allocated different functions. For example one may have the functions of an enabling device and the other may have the functions of an emergency stop.
According to one embodiment, the safety function arrangement of the hand-held terminal unit may comprise an enabling device configured to control the opening and closing of an enabling circuit forming a safety control circuit, and the enabling device is configured to close the enabling circuit when a pressure force exerted on the pressure force sensor means exceeds a first threshold value, specific for the enabling device, whereby the robot is controllable by means of the hand-held terminal unit only when the enabling circuit is closed. To use a pressure force sensor means in an enabling device makes it possible not only to set the first threshold value at a desired, chosen level. It also makes it possible to configure the enabling device to react to different pressure force levels that can be chosen and preset.
According to a further feature is defined that, when the first threshold value of the pressure force has been exceeded and the enabling circuit is closed, the enabling device may be configured to keep the enabling circuit closed as long as the pressure force exerted on the pressure force sensor means stays above a second threshold value, which is below the first threshold value but above zero. The advantage of this is that the user may relax the pressure force on the pressure force application area, once the enabling device has been activated and the circuit is closed, and the enabling circuit will continue to be closed and the robot will be controllable. However, if the exerted
pressure force falls below the second minimum value, the enabling circuit will be broken, as it should be for safety reasons.
According to another feature, the enabling device of the hand-held terminal unit may be configured to open the enabling circuit when the pressure force exerted on the pressure force sensor means exceeds a third threshold value which is higher than the first threshold value, whereby the robot is not controllable by means of the hand-held terminal unit. This feature is provided as an extra safety feature. When the operator exerts a pressure force that keeps the enabling circuit closed and the robot is operating, and the operator suddenly experiences an emergency situation, he can either release his pressure, i.e. reduce the pressure force to below the second minimum pressure force threshold value, and the enabling device will then open the enabling circuit, or he can increase his pressure force to the third threshold value, which is sometimes an instinctive reaction in a panic situation. In both cases the enabling circuit will be opened/broken.
In accordance with yet a feature of the present invention, when the enabling circuit has been opened due to the pressure force exceeding the third threshold value, the enabling device may be configured to keep the enabling circuit open even if the pressure force diminishes down to zero. This is another safety feature, since normally it is not desirable that the enabling circuit is closed again in a "return path" from the third threshold pressure force value down to zero, when the third threshold value is considered to reflect some kind of emergency situation.
Finally, either one of the first threshold value and the second threshold value related to the enabling device may be adjustable.
According to another embodiment, the safety function arrangement of the hand- held terminal unit may comprise an emergency stop device configured to open an emergency stop circuit forming the safety control circuit, and the emergency stop device is arranged to open the emergency stop circuit when a pressure force exerted on the pressure force sensor means exceeds a first threshold value specific for the emergency stop device. Since prior art emergency stops are physical/mechanical components with a push button contact projecting from the hand-held terminal unit, they make the handheld terminal unit bulky and there is also a risk that the button gets caught up by something. Therefore, in addition to the previously mentioned general advantages, a more secure function of the emergency stop is also achieved by the present invention,
where the prior art type of physical/mechanical components may be replaced by the inventive combination of hardware and software.
According to another feature, the hand-held terminal unit may comprise a reset device for the emergency stop device, and the emergency stop circuit is configured to remain open once it has been opened, until the reset device has been activated.
According to an embodiment of the reset device, the hand-held terminal unit may comprise a display and touch screen, and the reset device may be controlled from the display and touch screen by means of a touch control. For example there may be a graphic symbol or button on a touch screen, but it would also be conceivable to have a separate reset button of some suitable type.
According to a further embodiment, the hand-held terminal unit may comprise both an enabling device according to any one of the claims defining such a device, and an emergency stop device according to any one of the claims defining such a device.
According to the present invention is also defined an industrial robot system comprising an industrial robot including a manipulator, a robot control unit and a handheld terminal unit configured to communicate with the robot control unit, characterised in that the hand-held terminal unit is configured in accordance with any one of the claims relating to a hand-held terminal unit.
Another object of the present invention is to provide an improved method for controlling an industrial robot, as well as means for implementing the method. This object is achieved by the method defined in claim 14.
Accordingly is defined a method for controlling an industrial robot, the method comprising,
- Detecting a pressure force exerted on a pressure force sensor means incorporated in a safety function arrangement of a hand-held terminal unit for controlling a robot, and said safety function arrangement being separated from a display screen of the hand-held terminal unit,
- Measuring the pressure force, and
- Determining if the exerted pressure force is above a first threshold value, in which case a safety control circuit of the safety function arrangement is opened or closed.
The advantages of this method correspond to the advantages already discussed above in relation to the hand-held terminal unit, and involve improved safety, ergonomics, flexibility, etc.
According to one embodiment, the method may comprise, when the safety function arrangement comprises an enabling device configured to control the opening and closing of an enabling circuit forming the safety control circuit, closing the enabling circuit when a pressure force exerted on the pressure force sensor means exceeds the first threshold value specific for the enabling device.
Further, the method may comprise, when the first threshold value of the pressure force has been exceeded and the enabling circuit is closed, keeping the enabling circuit closed as long as the pressure force exerted on the pressure force sensor means stays above a second threshold value, which is below the first threshold value but above zero.
According to another feature, the method may comprise opening the enabling circuit when the pressure force exerted on the pressure force sensor means exceeds a third threshold value which is higher than the first threshold value.
The method may also comprise keeping the enabling circuit open even if the pressure force diminishes down to zero.
According to another embodiment, the method may comprise, when the safety function arrangement is an emergency stop device configured to open an emergency stop circuit forming the safety control circuit, opening the emergency stop circuit when a pressure force exerted on the pressure force sensor means exceeds a first threshold value specific for the emergency stop device.
The method may further comprise keeping the emergency stop circuit open once it has been opened, until a reset device is activated.
According to another feature, method may comprise activating an emergency stop reset device controlled from a display and touch screen, by means of a touch control.
The method may also comprise adjusting any one threshold value, used in the method, according to use requirements.
According to the present invention is also defined a computer-readable medium having a computer-readable code executable by at least one processor or computer to perform the method defined in any one of the method claims, and a computer program product comprising a computer-readable code executable by at least one processor or computer to perform the method of any one of the method claims.
Brief description of the drawings
The invention will now be described in more detail, with reference being made to the enclosed schematic drawings illustrating different aspects and embodiments of the invention, given as examples only, and in which:
Fig. 1 shows schematically an industrial robot system,
Fig. 2 shows schematically a hand-held terminal unit according to the present invention,
Fig. 3 shows schematically a variant of a hand-held terminal unit according to the present invention,
Fig. 4 is a side view in cross section along A-A of the hand-held terminal unit illustrated in Fig. 2,
Fig. 5 is a block diagram showing the hand-held terminal unit according to the present invention,
Fig. 6 is a graphical illustration of the functions related to different pressure forces, according to one exemplifying embodiment,
Fig. 7 is a schematic flow chart illustrating one embodiment of the method according to the present invention,
Fig. 8 is a schematic flow chart illustrating another embodiment of the method according to the present invention, and
Fig. 9 is a schematic flow chart illustrating yet another embodiment of the method according to the present invention.
In the drawings, the same elements or corresponding elements in the different embodiments have been given the same reference number. Detailed description of the invention
Fig. 1 shows schematically an industrial robot system comprising an industrial robot including a manipulator 1 , a robot control system comprising a robot control unit 2 communicating with the manipulator, and a hand-held terminal unit 3 configured to communicate with the robot control unit, either by some kind of suitable wireless communicating system of any known type, such as a data link, or by means of communication cabling. The control unit 2 can communicate with the manipulator 1 by means of any known communication system.
A hand-held terminal unit 3 according to the invention is illustrated in Fig. 2. The hand-held terminal unit comprises a safety function arrangement 5, 15, configured to
control the opening or closing of a safety control circuit (not shown). The safety function arrangement 5, 15 comprises at least one pressure force application area 7, 17, having pressure force sensor means 1 1 , 21 . The safety function arrangement 5, 15 further comprises at least one processor or computer 10 communicating with the pressure force sensor means 1 1 , 21 and configured to close or open the safety control circuit based on the level of pressure exerted on the pressure force sensor means, see Fig. 5. The pressure force sensor means 1 1 , 21 are configured to provide an output signal to the processor or computer 10 in response to the pressure force applied to the pressure force application area. In the processor/computer 10 the signal is processed and a measurement of the applied pressure force is obtained that is compared to previously stored pressure force threshold values. The processor/computer 10 will then control functions related to the opening or closing of the safety control circuit, depending on if the applied pressure force is found to exceed or not any stored threshold value.
Normally, the applied pressure force will be measured continuously and compared to threshold values in order to perform the required safety function.
The processor/computer 10 communicates with the robot, i.e. the manipulator 1 and the control unit 2. The hand-held terminal unit may also comprise a display screen 9, which may also be a touch screen for interaction with the hand-held terminal unit operator. The hand-held terminal unit may also include other hardware and software for performing the different operations normally done by such a hand-held terminal unit and it may include devices that are often associated with these types of hand-held terminal units, such as joystick, buttons with different functions, etc., if required.
According to one embodiment of the invention, the safety function arrangement is an enabling device 5. The enabling device is configured to control the opening and closing of an enabling circuit, forming a safety control circuit (not shown). When the enabling device closes the enabling circuit, the robot is controllable and operable, but when the enabling circuit is open, the robot is not controllable or operable.
The enabling device 5 comprises a pressure force application area 7 located externally on the hand-held terminal unit 3. In the illustrated embodiment this area is located along one side of the hand-held terminal unit in order to be easy to apply pressure force on when the operator's hand grasps the hand-held terminal unit. The hand-held terminal unit can be rather small, similar or only slightly bigger than a mobile phone or similar electronic device.
The pressure force application area 7 comprises at least one pressure force sensor means 1 1 , which may comprise two pressure force sensors as illustrated in Fig. 4. For security reasons, there is normally a built-in redundancy in relation to the enabling device and therefore the pressure force sensor means 1 1 comprises two pressure force sensors, of which it is sufficient to only influence one in order for the enabling device to close the enabling circuit. The pressure force application area may be configured as a thin membrane or similar, e.g. of silicone or similar material, designed to cover and protect the pressure force sensor means, while at the same time having the capability of transferring any applied pressure force directly to the pressure force sensor means. Preferably, the pressure force application area forms part of the external surface of the hand-held terminal unit without forming any pronounced joint or transition between this area and the surrounding surface of the hand-held terminal unit. At the same time, however, it should be clearly marked and distinguishable from other parts of the hand-held terminal unit. For example, it may have colour marking or a differing surface structure.
According to another embodiment of the invention, the safety function arrangement is an emergency stop device 15, as also illustrated in Fig. 2. The emergency stop device is configured to open an emergency stop circuit forming a safety control circuit (not shown), and when the emergency stop device is activated all movements and operations of the robot will be stopped.
The emergency stop device comprises a pressure force application area 17, located externally on the hand-held terminal unit, for example on a corner of the handheld terminal unit in order to be easily and rapidly accessible by the operator in case of an emergency situation. The pressure force application area 17 comprises a pressure force sensor means 21 , which may comprise two pressure force sensors 21 , in analogy with the described enabling device. The pressure force application area 17 of the emergency stop device may otherwise also be designed in analogy with the
corresponding area 7 of the enabling device 5. It is particularly important the pressure force application area 17 for the emergency stop is clearly marked, for example by colour marking.
The pressure force sensors that are used in the two embodiments may be in the shape of strips but also other available forms of pressure force sensors may be used.
It should be noted that it would of course be possible to provide a hand-held terminal unit with only one of the enabling device 5 and the emergency stop device 15
according to the invention. However, it is foreseen that the most common application would be to provide a hand-held terminal unit 3 with both an enabling device 5 and an emergency stop device 15 according to the present invention.
The processor/computer 10 illustrated in Fig. 5 may be one common
processor/computer for the enabling device and the emergency stop unit and it may also include control functions in relation to the display screen 9, or there may be separate processors/computers.
In Fig. 3 is shown a variant of the hand-held terminal unit 3, where the enabling device 5 comprises two pressure force application areas 7. It is of course possible to design the pressure force application areas for the enabling device and the emergency stop device in any suitable way when it comes to form, shape, number etc.
There may also be provided a feedback function related to the pressure force sensors 1 1 , 21 and the activation of the safety function arrangement, such as a tactile feedback, audible feedback or visual feedback, e.g. shown on a display screen of the hand-held terminal unit.
The method according to the present invention will now be described, with reference being made to the flow charts of Figs. 7-9. The safety function arrangement 5, 15 according to the invention, is configured in such a way that the closing/opening of the safety control circuit is made only when the applied pressure force on the pressure force sensor 1 1 , 21 means exceeds a first threshold value. If the pressure force is below the first threshold value, the safety control circuit is not affected.
Referring now to Fig. 6, for an enabling device 5, the default position
corresponds to an open enabling circuit, and there is no pressure applied on the pressure force sensor 1 1 . The enabling device is "off. When the pressure force exerted on the pressure force sensor 1 1 exceeds a first threshold value, at point A, specific for the enabling device, the enabling device is "turned on", i.e. the enabling circuit is closed. The robot is now operable and movable by means of the hand-held terminal unit 3. The pressure force exerted on the pressure force sensor 1 1 is continuously measured. In the illustrated exemplifying embodiment, the enabling circuit continues to be closed, and the robot continues to be controllable and movable, even if the exerted pressure force is reduced, as long as the exerted pressure force exceeds a second, minimum threshold value, which is lower than the first threshold value, but above zero. This is illustrated by the continuous line in Fig. 3. This is optional, since it would of course also be feasible to exclude this last feature, in which case it would be necessary to continuously keep the
pressure force above the first threshold value in order for the enabling circuit to be closed. In both of theses cases, the enabling circuit will be opened as soon as the pressure force falls below the second minimum threshold value, as also illustrated in Fig. 6 at point C, or below the first threshold value when there is no minimum value.
The enabling circuit may also be configured to continue to be closed as long as the exerted pressure force on the pressure force sensor means 1 1 does not exceed a third threshold value, which is higher than the first threshold value. If the exerted pressure force exceeds the third threshold value, as illustrated at point B in Fig. 6, then the enabling circuit will be opened, and the operations and movements of the robot will be stopped. The enabling device will be turned off again. After this has occurred, the enabling device 5 is configured not to close the enabling circuit again, i.e. to keep it open, even when the pressure force drops back into the pressure force interval where the circuit would normally be closed, before it reaches zero. Once the pressure force has reached zero, the enabling device 5 may be configured either to resume its regular enabling functions, or it may be configured to stay in the circuit open condition until a reset function has been activated.
When the safety function arrangement is configured as an emergency stop device 15, an emergency stop circuit forming the safety control circuit is closed when the emergency stop is in its default position. The emergency stop device is activated when a pressure force exerted on the pressure force sensor means 21 exceeds a first threshold value, which is specific for the emergency stop device, and the emergency stop circuit is opened. This first threshold value specific for the emergency stop device is independent of the previously mentioned first threshold value related to the enabling device, and would normally differ from that value. When the emergency stop circuit is opened, all movements and operations of the robot will immediately stop. Once the emergency stop circuit has been opened, it will be kept open until a reset device is activated.
The next step comprises activating the emergency stop reset device 20. This reset device may be configured as shown in Fig. 3, but also other types of reset devices may be combined with an emergency stop 15 according to the present invention, such as a button on the hand-held terminal unit. The reset device illustrated in Fig. 3 comprises a graphical symbol 20 shown on a display screen 9 of the hand-held terminal unit. The graphical symbol may also be regular button symbol. In this case, the display screen is also a touch screen, and the reset device can be controlled by performing
some kind of action on the screen by touch control. For example, a turning movement by touching on the symbol 20 may perform the reset function. There may also be provided instructions appearing on the screen 9 on how to operate the reset device.
When the emergency stop is reset, the emergency stop circuit is closed again.
The method may also comprise a step of adjusting any one of the mentioned threshold values, mainly depending on the physical abilities and preferences of the operator, as has been previously discussed.
In order to implement the method, there is also provided a computer-readable medium having a computer-readable code executable by at least one processor or computer to perform the method, and a computer program product comprising a computer-readable code executable by at least one processor or computer to perform the method, in the processor/computer 10 of the terminal 3 or in the control unit 2.
The present invention is not limited to the disclosed examples, but may be modified in many ways that would be apparent to the skilled person, within the scope of the appended claims.