Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J9/00—Programme-controlled manipulators
  • B25J9/16—Programme controls
  • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
  • B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
  • B25J9/1666—Avoiding collision or forbidden zones
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J9/00—Programme-controlled manipulators
  • B25J9/16—Programme controls
  • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
  • B25J9/1671—Programme controls characterised by programming, planning systems for manipulators characterised by simulation, either to verify existing program or to create and verify new program, CAD/CAM oriented, graphic oriented programming systems
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J9/00—Programme-controlled manipulators
  • B25J9/16—Programme controls
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J9/00—Programme-controlled manipulators
  • B25J9/16—Programme controls
  • B25J9/1674—Programme controls characterised by safety, monitoring, diagnostic
  • B25J9/1676—Avoiding collision or forbidden zones
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J9/00—Programme-controlled manipulators
  • B25J9/16—Programme controls
  • B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
• • G—PHYSICS
  • G05—CONTROLLING; REGULATING
  • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
  • G05B2219/00—Program-control systems
  • G05B2219/30—Nc systems
  • G05B2219/35—Nc in input of data, input till input file format
  • G05B2219/35308—Update simulator with actual machine, control parameters before start simulation
• • G—PHYSICS
  • G05—CONTROLLING; REGULATING
  • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
  • G05B2219/00—Program-control systems
  • G05B2219/30—Nc systems
  • G05B2219/40—Robotics, robotics mapping to robotics vision
  • G05B2219/40311—Real time simulation

Definitions

• the invention relates to a method for motion simulation of a manipulator in a processing environment having the features of the preamble of claim 1, a computer program with program code having the features of the preamble of claim 17 and a system for simulating the motion of a manipulator in a processing environment having the features of the preamble of claim 18th
• manipulator In robotics, the movable part of a robot assembly or an industrial robot is referred to as a manipulator.
• manipulators are regularly used today in automated production, for example for the manufacture of aircraft structural components. These are, for example, multi-axis articulated robots that are used in corresponding production cells.
• the axis position of such a manipulator determines the reference position, including the orientation, for the tool or the end effector of the robot, which reference position is also referred to as Tool Center Point.
• a motion sequence determined in this way is also referred to as path planning and such a control device also as a numerical control (NC) or as a computer-aided numerical control (CNC).
• NC numerical control
• CNC computer-aided numerical control
• the need for such an intervention may be due to the fact that a proximity sensor of the manipulator perceives that the minimum distance between the manipulator, in particular its end effector, and the workpiece or another obstacle contour is undershot. Especially if, in such a state, further movement of the manipulator according to the path planning would then further reduce the distance to the obstacle contour concerned, the movement of the manipulator according to the path planning is regularly interrupted because of the risk of collision associated therewith. Such a deviation of the measured distance from the distance previously simulated according to the offline programming can not be precluded in practice. The deviation may occur due to thermal effects or other irregularities on the workpiece or parts of the manufacturing cell.
• the problem underlying the invention is thus to further develop a known from the prior art method for motion simulation of a manipulator in a processing environment so that the elimination of collision risk situations, which occur when processing a path planning by the manipulator is facilitated.
• the proposed method is used for simulating the motion of a manipulator in a processing environment, wherein the manipulator is moved in a working operation by a control device and wherein the processing environment is depicted in an environment model.
• the term "manipulator” is to be interpreted broadly: it does not only include the manipulator in the narrower sense, but also includes an arbitrary end effector and other components arranged on it, which move along with a movement of the manipulator.
• a "control device” in the sense of the proposal which in the present case may consist of one or more, possibly distributed individual devices, it is a device for controlling and regulating machine tools - including manipulators as just defined - in the sense of a numerical
• the control device can not only control the manipulator via its axes according to a path planning determined by the control device by calculation, but also other components of the manipulator such as the end effector and here Accordingly, the movement of the manipulator by the control device, in addition to the actual movement of the manipulator, also includes any movement or activity only performed by the end effector perform computer-based tasks.
• machining environment includes not only the manufacturing cell with its components, but also the workpiece itself and all other objects which are located in the space that can be accessed by the manipulator In this sense, an overlap for the purposes relevant here is expressly not excluded.
• the term “environment model” again refers to a data-technical calculation model for at least parts of the processing environment in the above sense, which calculation model can serve as a basis for modeling in the course of a path planning and for a collision check Partial mapping of the editing environment in the environment model may be that only the essential elements and not necessarily every detail of the editing environment is mapped in the environment model. It is preferred that the editing environment be fully mapped in the environment model.
• a path planning by the control device from a target movement of the manipulator starting from a starting position and based on a kinematics model of Manipulator is calculated. Furthermore, a kinematic collision check based on the path planning, the kinematics model and the environment model is performed and a prediction result is generated based on the kinematic collision check.
• the "target movement" of the manipulator means any specification, in particular by the operator, of a movement to be carried out by the manipulator Such a predefinition can be from a specific target point or a specific target coordinate of the manipulator and especially its Tool Center Point (TCP ) or from specifying a desired direction of movement of the manipulator or the tool center point with or without simultaneous determination of the length or the duration of the movement or of the desired end point
• TCP Tool Center Point
• the target movement may also comprise a plurality of movement sections with respective intermediate positions.
• initial position in the present case means any mechanical or electrical state property of the manipulator which this manipulator can assume, for example its geometric position, the configuration of the axes, the position of each actuator on the manipulator or on the end effector etc. instead “Initial situation” could thus also be formulated in more detail "starting position of the manipulator”.
• kinematics model designates a kinematic manipulator model with data which are suitable for an electronic mapping of the kinematic of the manipulator and its starting position in the above sense, in particular for the purpose of calculating the motion of the manipulator For example, the future course of movement generated by the control device for all parts of the manipulator that can be controlled by the control device, including the end effector, and in particular comprising the axes of the manipulator.
• the term "kinematic collision check” is to be understood as a calculation which provides information as to whether and to what extent, when executing the path planning by the manipulator, a collision of the manipulator or one of its components with a part of the processing environment, insofar as this is in the environment model
• the result of a such a collision check can be both binary, ie affirm or deny only a collision or a certain risk of collision, as well as a percentage or otherwise described probability for the path planning as a whole or for each section or point of the movement path according to the path planning provide another yardstick for the occurrence of a collision.
• the collision check can also include checking for the occurrence of singularities.
• the prediction result based on this kinematic collision check provides information as to whether the desired movement of the manipulator is permitted or not.
• the prediction result may also include the statement that the target movement is only under certain circumstances, e.g. with a simultaneous movement of the component carrier is allowed. In other words, the result of the possibly complex kinematic collision check generates the prediction result.
• the starting position corresponds to the current manipulator state.
• the starting position underlying the calculation of the path planning from the target movement does not correspond to a fictitious or projected, past or future situation or situation or to such a state of the manipulator, but rather to the actual situation and situation and the situation actual state of the manipulator.
• the determination of the actual state can in principle be based both on sensory detection of the nipulators as well as based on a calculation of the actual state of the manipulator according to a known previous state and a known executed movement or on a combination of both approaches.
• the prediction result is based on a collision check, which is based on the current, actual state of the manipulator and a path planning based on this actual state.
• a collision check which is based on the current, actual state of the manipulator and a path planning based on this actual state.
• the prediction result is also output, so that the operator can be informed thereof.
• a particularly clear output can be achieved through visualization.
• the desired movement of the manipulator can be described in any manner, such as by data in a computer file.
• the claim 5 relates to an ergonomically particularly interesting input of the desired movement by an operating device, such as a control stick or the like.
• a particularly suitable tool for collision checking is to map the path planning of the manipulator and the environment model into a virtual state, as proposed by claim 6 and further developed by claims 7 and 8.
• virtual states of the manipulator projected into the future in accordance with the path planning can also be presented to the operator in a particularly meaningful manner.
• the preferred embodiment according to claim 9, in turn, also provides for a repeated provision of the actual starting position by the checking device, so that the kinematic interference check is always based on the actual manipulator state with a possibly negligible time delay.
• the preferred embodiment according to claim 10 makes use of the possibility of running a computer program on a computing device separate from the control device, which computer program maps the path planning of the control device completely and identically. In this way, the kinematic interference test can be carried out independently but simultaneously with the path planning of the control device. It is precisely this, the conventional way of thinking contradictory approach, which provides the parallel and thus seemingly redundant flow of two identical path planning, facilitates the realization of a Kollisions tenudiktion in real time.
• the preferred embodiment according to claim 11 proposes a prevention of the activation of the manipulator if this activation leads to a collision or to an unacceptable one according to the prediction result high risk of collision would result. In this way, even unconscious operating errors can be prevented.
• the preferred embodiment according to claim 12 enables a particularly accurate kinematics model or environmental model, namely, by being based on model data in electronic form, such as those provided by design programs.
• claims 13 to 15 relate to the possibility of making an adaptation of the kinematic model during path planning in order to compensate environmental influences such as temperature effects, which may justify a deviation between a desired position and an actual position of the manipulator , Such compensation is then preferably also taken into account in the kinematic collision check and in the generation of the prediction result.
• Fig. 1 is an overall view of an arrangement of a manufacturing cell with
• FIG. 2 shows a schematic representation of components of the control device from the arrangement of FIG. 1, FIG.
• the presently described embodiments relate to a manipulator 1 a, b in a manufacturing cell, in which manufacturing cell parts of the aircraft structural components rivet are set by a riveting machine.
• the manipulator la, b is NC-controlled.
• the exemplary embodiment is an integrated section assembly cell for processing 360 ° aircraft fuselage sections.
• the riveting machine forms the end effector 2a of the manipulator la, which in the present case is a 12-axis positioner.
• the manufacturing cell of both embodiments with all their associated components each forms a processing environment 3a, b in the sense of the above definition of the term.
• the end effector 2a can be moved on the inner surface of a production sheet 5 which can be displaced along floor rails 4, and consequently the floor rails 4 and the production sheet 5 each form both a part of the processing environment 3a and of the manipulator 1a.
• a movable component carrier 6 the workpiece 7a is fixed, which is an aircraft structural component here.
• an access frame 8 for personnel is provided in the production cell. According to the definition of definition already described, the component carrier 6, the workpiece 7a and the access frame 8 also belong to the processing environment 3a.
• a control device 10th belongs to the manufacturing cell, a control device 10th
• FIGS. 3a-c which will also be referred to below, illustrate a second, simplified embodiment with a six-axis manipulator 1b with end effector 2b, whose processing environment 3b comprises a workpiece 7b with two projections 9.
• the initial state of the second embodiment is shown in FIG. 3a.
• the proposed method is, as already stated, the motion simulation of a manipulator la, b in a processing environment 3a, b.
• the manipulator 1a.b is moved in a working mode by a control device 10 (not shown for the embodiment of FIGS. 3a-c), wherein the processing environment 3a, b is at least partially depicted in an environment model.
• working mode is understood to mean a mode of operation for the purpose of processing of workpieces by the manipulator as intended: a calibration or trial operation is not included.
• the proposed method comprises calculating a path planning 12a, b by the control device 10 from a desired movement of the manipulator 1 a, b starting from a starting position 11 a, b of the manipulator 1 a, b and based on a kinematics model of the manipulator model 1 a b.
• path plans 12a, b are shown only for the second exemplary embodiment.
• FIGS. 3b and 3c relate to a respective path planning 12a, b, both of which start from the starting position 11b of the manipulator 1b according to FIG. 3a.
• the proposed method comprises performing a kinematic collision check based on the path planning 12a, b, the kinematics model and the environment model and generating a prediction result based on the kinematic collision check.
• the proposed method is characterized in that the starting position 11 a, b corresponds to the current manipulator state.
• the generated prediction result provides a statement as to whether and to what extent an actual execution of a movement of the manipulator 1a, b along the path planning 12a, b determined by the control device 10 constitutes a collision risk.
• the method comprises the output of the prediction result by an output device 13 in which it is preferred and, as in the present case, is a visualization device 13a, b.
• a visualization device 13a is formed by the screen 14 of a computer arrangement 15 having a computing device 16 and an operating device 17 in the form of a keyboard.
• the computer arrangement 15 as a whole and in particular the computing device 16 are connected to the control device 10 via a communication network 18.
• the control device 10 is the modular system SINUMERIK® 840D sl 19, which includes a SINAMICS® S 120 as the drive system 20 and an NCU 720.3ON as the numerical control unit 21 and a PCU 50.5-P as computer unit 22 summarized.
• a SINUMERIK® Operator Panel OP 019 23 can also form a visualization device 13b for outputting the prediction result.
• the SINUMERIK® Operator Panel OP 019 23 can also have a user interface 24 in the form of a touchpad.
• the operator is to be given a feedback about his input, which is perceived as quasi-immediate, ie the desired movement required by him.
• This is preferably achieved by carrying out the kinematic collision check and generating the prediction result within a predetermined computing time after a change and / or input of the desired movement.
• a real-time output of the prediction result is to be provided by the output device 13, in the present case specifically by the visualization device 13a, b.
• real-time output is to be understood in a first, general sense as described above, that is, a maximum computing time is predetermined, within which the prediction result is provided by the output device 13 or the visualization device 13a, b an output responsive to an input is perceived subjectively as occurring in real time if the output occurs within 50 milliseconds of the input, and this perceived response in real time is particularly noticeable if the output is even within 10 milliseconds of the input Consequently, it is particularly preferred for the output of the prediction result to be output by the output device 13 or by the visualization device 13a, b within 50 milliseconds and in particular within 10 milliseconds after a change and / or input of the desired movement.
• the prediction result can be used by the control device 10 itself as a release signal for a moving control of the manipulator 1a, b. Accordingly, such a control preferably takes place only when the prediction result for a control in accordance with the path planning does not predict a collision. In other words, the prediction result is preferably generated before the manipulator 1a, b is moved by the control device 10 in accordance with the path planning 12a, b.
• the method comprises the acceptance of an input - and in particular an input by manual operation - of the desired movement by an operating device 17.
• the operating device 17 is the aforementioned keyboard of the computer arrangement 19, but also the user interface 24 of the SINUMERIK® operator panel OP 019 23 or a control stick of the computer arrangement 15 or not shown here the control device 10.
• the proposed method comprises the output of a virtual state 25a, b based on the path planning 12a, b and the environment model.
• the concept of the virtual state 25a, b is the electronic mapping on the one hand of the manipulator 1a, b based on the kinematics model after execution of the path planning 12a, b starting from the starting position 11a, b and on the other hand the processing environment 3a, b based on the environment - Model, also after execution of the movement of the manipulator la, b to understand.
• the virtual state 25a, b designates a comprehensive mathematical model of the manipulator 1a, b and the processing environment 3a, b after a movement of the manipulator 1a, b along the path planning 12a, b.
• the virtual state 25a, b can also take into account any movement of the processing environment 3a, b in its entirety or individual parts of it that takes place during the relevant time. Such a movement could, for example in the embodiment of FIG. 1, consist of a rotation of the component carrier 6 with the workpiece 7a.
• the output of the virtual state 25a, b comprises the output of a view 26a, b of an SD model of the manipulator 1a, b and the processing environment 3a, b.
• This 3D model is representative of the representation of the virtual state 25a, b and thus of the state of the manipulator 1a, b and of the processing environment 3a, b after movement according to the path planning 12a, b.
• the view 26a, b is again the two-dimensional representation, which is made up of this 3D model and the angle of an - imaginary Observer and which is thus suitable for reproduction on a conventional visualization device 13a, b.
• FIGS. 3b and 3c respectively exemplify such a view 26a, b, which could possibly also be reproduced on the screen 14 of the computer arrangement 15 of FIG. 1, wherein for the sake of simplicity of illustration in FIGS. 3b and 3c a distinction is not made graphically between the view 26a, b and the virtual state 25a, b on which the view is based.
• the viewing angle on which the representation is based is adjustable so that the view 26a, b of the 3D model of the manipulator 1a, b and the processing environment 3a, b is based on an adjustable viewing angle. This allows the operator to choose a perspective for the view 26a, b which is particularly suitable for detecting the present collision situation.
• the output of the virtual state 25a, b can also be designed in such a way that it is particularly graphically easily identifiable whether the prediction result indicates a collision situation or a collision risk or whether it indicates the absence of such a collision situation or collision risk ,
• the view 26a shows a virus state 25a, in which - according to the prediction result - the path planning 12a has led to a projected collision of the manipulator 1b with a projection 9 of the workpiece 7b from the view 26a for the operator through the collision icon 27 is made clear. The operator is thus warned clearly that this path planning 12a should not be executed.
• the view 26a could also be colored in a warning color, for example in red, for the purpose of warning.
• a movement according to the path planning 12b can be carried out without a collision risk.
• this is done by a representation of the path planning 12b without a collision icon, wherein also here a reproduction of the view 26a in a release color - may be provided - as in green.
• a real-time output in the sense already defined above is also advantageous for the operator when outputting the virtual state 25a, b.
• the output of the virtual state 25a, b by the visualization device 13a, b takes place within a predetermined visualization time after a change and / or input of the desired movement, so that a real-time output of the virtual state 25a, b the visualization device 13a, b is provided.
• the real-time output is particularly perceived as being "in real time” if the predetermined visualization time is 50 milliseconds or even 10 milliseconds In the case of the preferred output of the view 26a, b of the 3D model of the manipulator 1a , b as just described, this applies accordingly to this output of the view 26a, b.
• the initial position 1 ia, b updated within the predetermined updating interval is preferably also based on the virtual state 25 a, b and also the view 26 a, b, so that these can always be updated in a timely manner to the operator. It is also useful to update the environment model accordingly within the predetermined update interval.
• the possibility of the external simulation of the path planning 12a, b by the control device 10 can be usefully employed in that, according to a preferred embodiment, calculating a further path planning by a computing device 16 from the desired movement of the manipulator Ia, b starting from a starting position 1 la, b and based on the kinematic model of the manipulator la, b is performed, wherein the computing device 16 by means of a communication network 18 is in communication with the control device 10 and wherein the performing of the kinematic collision check and the generation of the prediction result in the computing device 16 is performed.
• the target movement is thus either input directly to the computing device 16, for example by the operating device 17, or input to the control device 10 and transmitted via the communication network 18 to the computing device 16 which controls the desired movement of the manipulator 1a , b maps into the further path planning and thus simulates the path planning 12a, b of the control device 10 in the sense of a replication or replica.
• the corresponding functionality of the control device 10 - including the processing of the environment model and the kinematics model - can be completely simulated as software code on the computing device 16. Accordingly, the kinematic collision check and the generation of the prediction result are performed either in addition to the respective operation on the control device 10 in the computing device 16 or take place exclusively on the computing device 16.
• the kinematics model and the environment model can also be transmitted from the control device 10 to the computing device 16 via the communication network 18.
• a particularly suitable interface between the control device 10 and the computing device 16 can be provided by selecting an Ethernet connection as the communication network 18 on which TCP / IP (Transmission Control Protocol / Internet Protocol) as the protocol stack or part of the protocol stack is used.
• TCP / IP Transmission Control Protocol / Internet Protocol
• COM Component Object Model
• DCOM Distributed Component Object Model
• RPC Remote Procedure Call
• OCX Object Linking and Embedding Control eXtension
• the creation of the kinematics model and the environment model is simplified if, as is preferred, the kinematics model and / or the environment model are based on model data in electronic form. This can also be model data. These can come from corresponding computer programs such as CATIA® or from the files generated by these computer programs.
• This adaptation preferably takes place before the kinematic interference test is carried out. In that regard, it is then taken into account both when performing the kinematic collision check and when generating the prediction result.
• the adaptation can also be carried out before the path planning 12a, b is calculated and then preferably taken into account in the calculation of the path planning I2a, b.
• the starting position 11 a, b of the manipulator 1 a, b can either be determined by a known previous position of the manipulator 1 a, b and known subsequent movements or, as is preferred, be detected by a sensor device 28.
• the processing environment 3a, b for imaging in the environment model may also be detected by a sensor device 28.
• Such a sensor device 28 may comprise a multiplicity of separate sensors which also function according to different physical principles and, if necessary, communicate with one another as well as with the control device 10 and the computing device 16, for example via the communication network 18.
• the proposed computer program comprises program code for carrying out the following steps for simulating the movement of a manipulator 1a, b when the computer program is executed in a computer: calculating a path planning 12a, b from a desired movement of the manipulator 1a, b in one Processing environment 3a, b, which is at least partially imaged in an environment model, starting from a starting position 1 la, b and based on a kinematic model of the manipulator la, b, performing a kinematic collision check based on the path planning 12a, b , the kinematics model and the environment model, and generating a prediction result based on the kinematic collision check.
• the proposed computer program is characterized in that the initial position 1 la, b corresponds to the current manipulator state.
• a corresponding computer program product that can be loaded directly into the internal memory of a digital computer and includes software code sections that perform the following steps when the product is running on a computer: calculating a path planning 12a, b from a target Movement of the manipulator 1a, b in a working environment 3a, b, which is at least partially imaged in an environment model, starting from a starting position 11a, b and based on a kinematics model of the manipulator 1a, b, performing a kinematic collision check based on the path planning 12a, b, the kinematics model and the environment model and generating a prediction result based on the kinematic collision check.
• This proposed computer program product is characterized in that the starting position 1 la, b corresponds to the current manipulator state
• Preferred embodiments of the proposed computer program and the proposed system for motion simulation arise in each case from the preferred embodiments of the proposed method.

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