JP5890988B2 - Industrial robot power consumption monitor - Google Patents

Description

  The present invention relates to a power consumption monitor device for an industrial robot that monitors power consumed by the industrial robot.

Conventionally, there has been proposed a power consumption monitoring device for monitoring by providing power detection means between an AC power supply and a load (Patent Document 1, Patent Document 2).
In the power consumption monitoring device disclosed in Patent Document 1, the AC power flowing into the inverter device is monitored by the AC power detection means with respect to the inverter device provided between the AC power source and the load, and the control device monitors the monitoring power. The power saving amount is calculated based on the result and the initial data, and the power saving amount is displayed.

In the power consumption monitoring device of Patent Document 2, a rectifier circuit that rectifies and smoothes an alternating voltage, a transformer circuit that is supplied with the voltage of the rectifier circuit and generates a predetermined voltage on the secondary side due to current interruption of the primary winding, Switching means for switching on / off of the primary side output voltage of the transformer circuit, and voltage adjusting means for adjusting the primary side voltage of the transformer circuit, and the turn-on of the switching means based on the output of the voltage regulator means Control means for calculating time and measuring power consumption based on the turn-on time, the switching frequency of the switching means, and the inductance of the transformer circuit are provided.

  With the above-described conventional power consumption monitoring device, it is possible to monitor the power consumption that changes from moment to moment. And by using these monitoring results, it becomes possible to save power consumption of the electrical equipment.

Japanese Patent Laid-Open No. 2001-4679 JP 2004-101518 A

  By the way, in an industrial robot, a plurality of electric motors are used to operate actuators such as arms and external shafts constituting a manipulator, and work is performed according to various work programs. It is desired to monitor the power consumption of this industrial robot to save power consumption.

  However, even if it is used as the power consumption monitoring device, the industrial robot controls the electric motor in accordance with a work program, so that power can be saved by simply monitoring the power supplied to the electric motor. However, it is not easy to know.

  An object of the present invention is an industry capable of correcting a work program while balancing tact time and power consumption by storing and notifying the power consumption of an industrial robot for each step of the work program. An object of the present invention is to provide a power consumption monitoring device for a robot.

In order to solve the above problem, the invention according to claim 1 is a power consumption monitoring device for an industrial robot that operates according to a work program, and detects power consumption consumed by a servo motor that drives an actuator. Power detection means; storage means for storing the power consumption detected by the power detection means for each step of the work program; and storing the accumulated power consumption as a cumulative power consumption amount for each step of the work program stored by the storage means. The gist of the power consumption monitoring apparatus for an industrial robot is provided with a notification means for notifying the cumulative power consumption.

  According to a second aspect of the present invention, in the first aspect, the power detection unit further cancels the first servo-off time from when the power supply to the servomotor is started until the servo is turned on, and the servo-on is released. Power consumption in a second servo-off time from when the servo is turned off until power supply to the servomotor is cut off, and the storage means stores the accumulated power consumption in the first servo-off time and the second servo-off time It is characterized by memorizing the quantity.

  According to a third aspect of the present invention, in the first or second aspect, the power detection unit and the storage unit are provided in a robot control device that controls the actuator, and the notification unit can communicate with the robot control device. Display means provided in such a portable operating device, wherein the display means notifies the accumulated power consumption for each step of the work program.

  According to the first aspect of the invention, since the accumulated power consumption of the industrial robot is stored and notified for each step of the work program, the worker can know the accumulated power consumption for each step of the work program. . For this reason, it can be easily understood that the accumulated power consumption amount is large in any step of the work program, so that the worker can correct the work program while balancing the tact time and the power consumption. For example, in a step of a work program, if the manipulator has a sudden acceleration or a sudden deceleration, and that step has a larger cumulative power consumption than other steps, the tact time is not significantly affected. If the degree of sudden acceleration or sudden deceleration of the step is changed, the accumulated power consumption can be suppressed to save power.

  According to the invention of claim 2, the power supply is cut off after the servo-off time (waiting time before the start of daily operation) that is the time from the start of power supply to the servomotor to the servo-on, and the servo-off to cancel the servo-on. Since the worker can grasp the accumulated power consumption during the servo off time (standby time after the end of operation), which is the time to be used, if the accumulated power consumption during these times is large, shorten these times. Thus, it is possible to save power by suppressing the accumulated power consumption.

  According to the invention of claim 3, by displaying the accumulated power consumption of each step of the work program on the display means of the portable operating device, the effects of claims 1 and 2 can be easily realized. it can.

The functional block diagram of the robot control apparatus which comprises the power consumption monitoring apparatus of the industrial robot of 1st Embodiment of this invention. The block diagram of a three-phase alternating current power supply, a servo amplifier, and an electric power detection part. The flowchart of the power consumption calculation program which a power consumption calculating part performs. (A) is a schematic front view of a teach pendant, (b) is explanatory drawing of the program displayed on the display screen. Explanatory drawing which displayed the power consumption totaled for every step of the work program on the display screen with the bar graph. Servo motor power on, servo on, servo off, power off time chart.

Hereinafter, an embodiment in which the power consumption monitoring device for an industrial robot of the present invention is embodied in a robot control device 10 will be described with reference to FIGS.
As shown in FIG. 1, the robot control device that controls the industrial robot of the present embodiment is a robot control device 10 that controls an arc welding robot, for example. The robot control device that controls the industrial robot is not limited to the robot control device that controls the arc welding robot, but other industrial robots such as a robot control device such as a handling robot, a painting robot, and a transfer robot. It is good.

  The arc welding robot is a six-axis welding robot manipulator (hereinafter simply referred to as a manipulator) 30 having a welding torch (not shown). The manipulator 30 corresponds to an actuator. As shown in FIG. 1, the robot control device 10 is for a main control unit 11, a motor control unit 20 connected to the main control unit 11, and a control device for supplying power to the main control unit 11 and the motor control unit 20. A power supply unit 25 is provided.

  The main control unit 11 includes a computer, and includes a system control unit 12, a motion control unit 13, a power consumption calculation unit 14, a work program for the manipulator 30, a power consumption calculation program, and the like. / F (interfaces) 16, 17, etc. are connected via a bus 18.

  The main control unit 11 can communicate with the teach pendant TP as a portable operation device via the communication I / F 16. Teaching data such as welding conditions (that is, welding current, welding voltage, etc.) are input via the teach pendant TP. Then, the system control unit 12 stores the input teaching data in the storage unit 15. As shown in FIGS. 1 and 4A, the teach pendant TP includes a monitor display unit 41 as a notification unit and a display unit, an input unit 42 such as a key and a push button, and a communication I / O of the main control unit 11. A communication I / F 43 that communicates with F16 is provided.

  When the work program for the manipulator 30 stored in the storage unit 15 is activated, the motion control unit 13 controls the motor control unit 20 to control the manipulator 30 via the communication I / F 17 according to the work program. Is output.

  The power consumption calculation unit 14 calculates the power consumption of the servo motor M included in the manipulator 30 based on the motor voltage value and the motor current value transmitted from the power detection unit 23 as a power detection unit described later according to the power consumption calculation program. The calculated cumulative result is stored in the storage unit 15 as the cumulative power consumption. The storage unit 15 is configured by a storage device capable of writing and reading, such as a hard disk.

  As shown in FIG. 1, the motor control unit 20 includes a servo I / F 21 that communicates with the communication I / F 17 and a servo motor M (provided on each arm of the manipulator 30 based on a control command from the motion control unit 13. 2), and a power detection unit 23 that detects power supplied from the three-phase AC power supply 51 to the servo motor M.

  In FIG. 2, for convenience of explanation, only a servo amplifier of one servo motor M among a plurality of servo motors provided on each axis of the manipulator 30 is illustrated, but other servo motors of the manipulator 30 are also illustrated. A similar servo amplifier is provided.

  The servo amplifier 22 includes a rectifier circuit 52 that rectifies the three-phase alternating current output from the three-phase alternating current power supply 51, a large-capacity smoothing capacitor 53 that smoothes the rectified output of the rectifier circuit 52, and a direct current that is smoothed by the smoothing capacitor 53. And an inverter 54 that outputs a three-phase alternating current obtained by PWM conversion of the direct current based on the control command to the servo motor M. As shown in FIG. 2, the three-phase AC power source 51 and the rectifier circuit 52 are connected via a contact MCa of an electromagnetic contactor MC. The magnetic contactor MC is connected to a power operation box (not shown) and can be turned on or off by inputting an on signal or an off signal of a power switch provided in the power operation box.

  The power detection unit 23 is proportional to the current detection unit 56 that detects current values of the U-phase, V-phase, and W-phase flowing from the inverter 54 to the servo motor M by the shunt resistor 55, and the current value detected by the current detection unit 56. An A / D converter 57 for converting the analog voltage signal thus converted into a digital signal is provided.

The A / D converter 57 outputs a digital signal indicating a current value converted into a digital signal (hereinafter referred to as a current value signal) to the communication I / F 21 at a predetermined sampling period.
The power detection unit 23 includes voltage detection circuits 58a, 58b, and 58c that detect voltages between the phases between the inverter 54 of the servo amplifier 22 and the servo motor M. The voltage detection circuits 58a, 58b, and 58c divide the voltage between the U-phase, V-phase, and W-phase, and output a voltage proportional to the voltage between the phases to the A / D converter 57. The A / D converter 57 converts the voltage detected by the voltage detection circuits 58a, 58b, and 58c into a digital value, and the digital signal (hereinafter referred to as a voltage value signal) is sent to the communication I / F 21 by the predetermined sampling. Output in cycles.

  Further, the motion control unit 13 takes in the input current value signal as a current feedback value via the communication I / F 21 and the communication I / F 17, and based on the current feedback value and various commands described in the work program. Then, a predetermined calculation process is performed and the control command is output to the inverter 54.

In addition, the communication I / F 21 transmits the current value signal and the voltage value signal output from the A / D converter 57 to the power consumption calculation unit 14 via the communication I / F 17.
The power detection unit 23 includes a current detection unit 56, voltage detection circuits 58a, 58b, and 58c, and an A / D converter 57.

(Operation of the embodiment)
Now, the operation of the robot control apparatus 10 configured as described above will be described with reference to FIGS.

  When a power switch (not shown) included in a power control box (not shown) is turned on by an operator (hereinafter, this operation is simply referred to as power-on, and an off operation that is the reverse operation is referred to as power-off). The system control unit 12 turns on the electromagnetic contactor MC based on the on operation. Further, the power consumption calculation unit 14 activates a power consumption calculation program stored in the storage unit 15.

  FIG. 3 is a flowchart of the power consumption calculation program. In S10 shown in FIG. 3, the power consumption calculation unit 14 calculates the power consumption based on the time until the servo-on signal is input, the current value signal and the voltage value signal transmitted from the power detection unit 23, and the calculation. Accumulate results. When the operator operates a servo-on switch (not shown) of the teach pendant TP and a servo-on signal as a servo command is input from the teach pendant TP to the robot controller 10, the determination in S20 is "YES" and the process proceeds to S30. By this servo-on signal, each servo motor of the manipulator 30 is servo-locked at a preset position.

  In S30, the power consumption calculation unit 14 stores the accumulated power consumption calculated and accumulated in S10 in the storage unit 15 as the accumulated power consumption during the servo-off time t1 (see FIG. 6) from power-on to servo-on. , The process proceeds to S40.

  In S40, the power consumption calculation unit 14 calculates power consumption based on the current value signal and the voltage value signal transmitted from the power detection unit 23 until the work program of the manipulator 30 is activated, and accumulates the calculation results. . When the operator inputs a start signal for the work program of the manipulator 30 to the robot control device 10, the power consumption calculation unit 14 sets the determination in S50 to “YES” and proceeds to S60.

Therefore, from S50, the reproduction of the work program is started, that is, welding is started (production is started) by the manipulator 30 with respect to a workpiece (not shown).
FIG. 4B shows an example of the work program P *** displayed on the monitor display unit 41. In this work program P ***, for each step, a command (command) of a work (process) to be performed by the manipulator 30 and various parameters (for example, a moving speed, etc.) required when the work (process) is performed. The motion control unit 13 outputs a control command to the manipulator 30 based on a command (command) and feedback for each step.

  For example, in FIG. 4B, “100% JOINT” in step “001” and step “002” is a speed of 100% indicating the ratio to the maximum speed that the manipulator 30 can output, and the steps “001” and It indicates that the respective positions are moved by joint interpolation (JOINT) toward the target position (teaching position) taught in “002”. Also, “500 mm / s LIN” in step “003” indicates that the target position (teaching position) taught in step “003” is moved by linear interpolation (LIN) at a speed of 500 mm / s. Show.

  In S60, the power consumption calculation unit 14 stores the accumulated power consumption calculated and accumulated in S40 in the storage unit 15 as the accumulated power consumption at time t2 from when the servo is turned on until the work program starts to be reproduced. The process proceeds to S70.

  In S <b> 70, the power consumption calculation unit 14 consumes based on the current value signal and the voltage value signal transmitted from the power detection unit 23 until the step in which the motion control unit 13 currently performs processing in the work program ends. The power is calculated and the calculation result is accumulated until the next step is transferred.

  In S80, the power consumption calculation unit 14 determines whether or not the operation program has shifted to the next step. If the operation program has shifted to the next step, it determines “YES” and shifts to S90.

  In S90, the power consumption calculation unit 14 stores the cumulative power consumption calculated and accumulated in S70 as the cumulative power consumption in the processing period tSn (n = 1, 2,...) Of the step of the work program. Then, the process proceeds to S100.

  In S100, the power consumption calculation unit 14 determines whether or not the work program has ended. If the work program has not ended in S100, it is determined that the process has shifted to the next step, and the process returns to S70 to calculate power consumption and accumulate the accumulated power consumption in the next step.

For this reason, the power consumption calculation unit 14 calculates the power consumption and acquires the accumulated power consumption at each step of the work program.
If it is determined in S100 that the work program has been completed, the process proceeds to S110, where the power consumption calculation unit is from the end of the reproduction of the work program (that is, the end of production) until the servo-off signal is input. 14 calculates power consumption based on the current value signal and voltage value signal transmitted from the power detection unit 23, and accumulates the calculation results.

  When the work program ends, that is, at the final step of the work program, the manipulator 30 returns to the preset origin position and the servo motor is in the servo lock state (ie, the robot is stopped).

  When the servo-off signal is input to the robot control device 10 by the operator, the power consumption calculation unit 14 determines “YES” in S120 and proceeds to S130.

  In S130, the power consumption calculation unit 14 stores the accumulated power consumption calculated and accumulated in S110 in the storage unit 15 as the accumulated power consumption during time t3 (see FIG. 6) from the end of the reproduction of the work program to the servo-off. After that, the process proceeds to S140.

In S140, the power consumption calculation unit 14 calculates power consumption based on the current value signal and the voltage value signal transmitted from the power detection unit 23 until the power is turned off, and accumulates the calculation results.
When a power switch (not shown) included in a power control box (not shown) is turned off by the operator, the system control unit 12 turns off the electromagnetic contactor MC based on the off operation.

  When the power switch is turned off, the determination as to whether the power is off is “YES” in S150, and the process proceeds to S160. In S160, the power consumption calculation unit 14 calculates the accumulated power consumption calculated in S140 and accumulated. After the amount is stored in the storage unit 15 as the accumulated power consumption during the servo-off time t4 (see FIG. 6) from the servo-off to the power-off, this flowchart is ended.

Thereafter, the operator operates the input means of the teach pendant TP to read the monitoring result of the work program from the storage unit 15 and display it on the monitor display unit 41.
An example in which the accumulated power consumption acquired in each step of the work program is displayed on the monitor display unit 41 of the teach pendant TP is shown in FIG.

  In FIG. 5, the horizontal axis indicates the step (STEP) of the work program, and the vertical axis indicates the power consumption (KVA). In the figure, on the horizontal axis, “001” is the first step of the work program, and “012” is the final step.

  As shown in the figure, the accumulated power consumption is converted into a bar graph for each step of the work program, so that it is possible to easily know which step has a large or small accumulated power consumption. For example, in FIG. 5, in step “002” of the work program P ******, the manipulator 30 is operated by joint interpolation to cut air, but the accumulated power consumption in this step is higher than in other steps. You can see that it ’s big. From this, it is understood that the power consumption can be suppressed by reviewing the moving distance of this step. In addition, since the accumulated power consumption can be shown for each step of the work program, it is possible to provide suitable judgment materials such as which step can reduce the power consumption within a range that does not affect the tact time, It is possible to correct the work program with reduced power consumption.

  Although not shown in the figure, the accumulated power consumption during the servo-off time t1, the servo-off time t4, and the times t2 and t3 is displayed and calculated on the monitor display unit 41 of the teach pendant TP in the same manner as in the above step. It is possible to easily know whether the accumulated power consumption is large or small. For this reason, it is possible to provide a suitable material for determining at what time the amount of power consumption can be suppressed, and in order to suppress the power consumption, for example, it is possible to improve work such as shortening one of the time zones. It becomes.

The robot control apparatus 10 according to the present embodiment has the following features.
(1) The robot control apparatus 10 of the present embodiment includes a power detection unit 23 (power detection unit) that detects power supplied to the servo motor M that drives the manipulator 30, and a power detection unit for each step of the work program. A storage unit 15 (storage unit) for storing the accumulated power consumption detected by the power detection unit 23 and a monitor display unit 41 for notifying the accumulated power consumption for each step of the work program stored in the storage unit 15 ( Notification means).

  As a result, according to the present embodiment, since the accumulated power consumption of the industrial robot is stored and notified for each step of the work program, the worker can know the accumulated power consumption for each step of the work program. it can. For this reason, it can be easily understood that the accumulated power consumption amount is large in any step of the work program, so that the worker can correct the work program while balancing the tact time and the power consumption.

  For example, in a work program step, if the manipulator has a sudden acceleration or a sudden deceleration, and that step has a larger cumulative power consumption than the other steps, that step is not significantly affected by the tact time. If the degree of sudden acceleration or sudden deceleration is changed, the accumulated power consumption can be suppressed to save power.

  (2) In the robot control apparatus 10 according to the present embodiment, the power detection unit 23 (power detection unit) is configured such that the servo-off time t1 (first servo-off) from when the power supply to the servomotor M is started until the servo-on is performed. Time) and the power consumption in the servo-off time t4 (second servo-off time) from when the servo-off is canceled when the servo-on is released until the power supply to the servo motor M is cut off, and the storage unit 15 (storage means) Stores the accumulated power consumption during the first servo-off time and the second servo-off time.

  As a result, according to the present embodiment, the operator can grasp the accumulated power consumption during the servo-off time t1 from the power-on to the servo-on and the servo-off time t4 from the servo-off to the power-off when the servo-on is released. When the accumulated power consumption during this time is large, it is possible to save power by suppressing the accumulated power consumption by shortening these times.

  (3) In the robot control device 10 of the present embodiment, the power detection unit 23 (power detection unit) and the storage unit 15 (storage unit) are provided in the robot control device that controls the manipulator 30, and the monitor display unit 41 (notification) The means) is configured as a display means provided in a (portable operation device) capable of communicating with the robot control device 10, and displays (notifies) the accumulated power consumption for each step of the work program.

  As a result, according to the present embodiment, the cumulative power consumption of each step of the work program is displayed on the monitor display unit 41 of the teach pendant TP, thereby easily realizing the effects (1) and (2). can do.

In addition, this invention is not limited to the said embodiment, You may comprise as follows.
In the above embodiment, the cumulative power consumption of the servo off time t1, the servo off time t4, and the times t2 and t3 is calculated. However, all or one of the processes for calculating the cumulative power consumption of these times is calculated. The part may be omitted.

  In the embodiment, the monitor display unit 41 is used as the notification unit. However, instead of the monitor display unit 41 or in addition to the configuration of the monitor display unit 41, a printer connected to the robot control apparatus 10 is notified. Alternatively, by using a printer as a notification means, the operator can be informed of the relationship between the step of the work program graphed or described in a table format, or the time zone and the accumulated power consumption. It becomes possible.

  In the embodiment, a single manipulator 30 and a robot control device have been described. However, when a plurality of manipulators 30 are connected to a common robot control device, a power detection unit 23 is provided for each manipulator 30. The current and voltage data detected by each power detection unit 23 is totaled by the main control unit 11, and the accumulated power consumption for each manipulator 30 is stored in the storage unit 15 within the same step of the work program. You may make it monitor. It goes without saying that actuators other than the manipulator 30 (positioner, slider, servo torch, servo gun, etc.) may be monitored.

  ・ In addition, if each of the manipulators installed in the factory is monitored as in the above-mentioned embodiment using the communication network in the factory, continuous monitoring of the power saving amount indispensable for greenhouse gas emission transactions Can be done without difficulty.

MC ... Magnetic contactor, TP ... Teach pendant (portable operation device),
10 ... Robot controller, 11 ... Main controller, 12 ... System controller,
13 ... motion control unit, 14 ... power consumption calculation unit, 15 ... storage unit (storage means),
16 ... Communication I / F, 17 ... Communication I / F, 20 ... Motor controller,
21 ... Communication I / F, 23 ... Power detection unit (power detection means),
25 ... power supply unit, 30 ... manipulator, 41 ... monitor display unit (notification means),
42 ... Input means, 43 ... Communication I / F, 50 ... Motor drive circuit,
51 ... three-phase AC power supply, 52 ... rectifier circuit,
53 ... smoothing capacitor, 54 ... semiconductor switching circuit,
55 ... Shunt resistor, 56 ... Current detector, 57 ... A / D converter,
58a, 58b, 58c... Voltage detection circuit.

Claims (3)

An industrial robot power consumption monitoring device that operates according to a work program,
Power detection means for detecting power consumption consumed by a servo motor that drives the actuator;
Storage means for accumulating the power consumption detected by the power detection means for each step of the work program and storing it as a cumulative power consumption amount;
A power consumption monitoring apparatus for an industrial robot, comprising: notification means for notifying the cumulative power consumption for each step of the work program stored in the storage means. The power detection means further supplies power to the servomotor after a first servo-off time from when power supply to the servomotor is started to when the servo is turned on, and after servo-off is released when the servo-on is released. Detect power consumption in the second servo off time until is shut off,
2. The power consumption monitoring apparatus for an industrial robot according to claim 1, wherein the storage unit stores the accumulated power consumption amount during the first servo-off time and the second servo-off time. The power detection unit and the storage unit are provided in a robot control device that controls the actuator, and the notification unit is a display unit provided in a portable operation device capable of communicating with the robot control device,
3. The power consumption monitoring apparatus for an industrial robot according to claim 1, wherein the display means notifies the cumulative power consumption for each step of the work program.

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