JPS58171281A - Adaptable robot - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to automatic batch assembly techniques using manipulators controlled by computer programs. More specifically, the present invention not only reduces operator-dependent machine downtime for changeovers or correcting faulty conditions during job setup, but also maximizes robot utilization. It combines small batch assembly activities with progressive flow operation activities.

[Conventional technique]

The use of robots at work stations and assembly areas to automate manufacturing activities is well known.

Progressive assembly lines use single-purpose or limited-purpose robots. A forward assembly line is an operation in which parts are passed through work stations on a moving conveyor.

Robots are used at these work stations to perform all tasks such as welding, material handling, and moving and painting. These are single-activity robots that are set up, equipped, and programmed to perform a single sequence of task activities on assemblies and parts that are moved through a work station. be.

Although the use of such robots has resulted in input savings and higher system efficiency, even with the best planning there is a considerable amount of time when these various single purpose robots are idle. Downtime can be attributable to one or all of the following conditions, for example: Periods during which all activities are stopped, such as a reduction in the quantity of a product, various out-of-stock conditions where related tasks are stopped, or in extreme cases, changes in equipment for different products.

One key to economically rational use of sophisticated robot robots used in conjunction with assembly operations for progressive line operations is to maximize the amount of work the robot performs. This maximization involves minimizing total idle time by giving the robot other, lower priority tasks. However, giving such a low-priority job means (3) Whether this job will be delivered to the robot or not.
This includes providing a means to enable robots to travel to their jobs.

[Disclosure of the present invention]

The present invention allows the robot to occupy space at work stations along the powered roller conveyor of a manufacturing assembly line, thereby optimizing the overall production time of these highly sophisticated and expensive robots. The present invention relates to the adaptation of batch assembly systems with adaptive robots. In combination with such a system, one mobile work station port is replaced by a powered roller conveyor that passes through the robot's work envelope. This conveyor is provided with a detection device that determines whether work is present in the stage area in front of the robot or within the robot's working area itself. In response to detecting the presence of work, the manipulator performs the appropriately programmed work and repeats this sequence of operations until no more work is present on the conveyor. Then (4), the manipulator moves to the mobile work station tasks and performs these tasks until more work is presented on the conveyor or there are no more jobs at the mobile work station port. do.

[BEST MODE FOR CARRYING OUT THE INVENTION 3 The robots and computing devices described herein have been selected for illustration; other types of robots and related devices may depart from the spirit of the invention. It should be clear that it can be used without any modification.

For a complete understanding of the system for operating the robot, generally designated 8, please refer to FIG.

An automated manipulator 10 is attached to the end of arm 14. Arm 14 is perpendicular relative to arm 16 and can be moved along arm 16 by a trolley 18 having a motor. The arm 16 has parallel tracks 28 and 30, respectively.
The respective ends are connected to trolleys 24 and 26 movable along. Trolley 26 has a motor, and trolley 24 is an idler.

Trunk 28 is attached to base 64 by posts 36 and 38. Trunk 30 is connected to base 34 by posts 42 and 44.

Columns 42 and 44 are also longer than columns 66 and 68. The arm 14 and thus the arm 16 along which the manipulator 10 is moved is positioned with an angular offset from the horizontal. In the structure shown, an angular offset of approximately 60 degrees has been found to be suitable. Therefore, the arm 14 forms approximately 60 degrees with the horizontal.

The working envelope of robot 8 includes the space enclosed by tracks 28 and 30, rails 46 and 4B and dashed line 51. The area or frame surrounded by this broken line 51 is tilted 30 degrees as shown. The work envelope of the robot 8 may be divided into multiple independent work areas.

The dashed areas 52 and 54 represent locations for mobile work stations that are adapted elsewhere and are brought into the work envelope of the robot 8 and directed to the self-contained task when the work is to be performed. Two corresponding ports 56 and 55 are located inside pace 34. Each port 56
and 55 includes alignment posts 58 that align with alignment holes present on the six wheelbarrows used in the system. Each port 56 and 54 is provided with a rotatable pneumatic clamp type launch 59 for locking the mobile work station wheelbarrow in place. FIG. 1 also shows a fragment of a powered roller conveyor 60 passing through the robot 8. Stops 70 and 72 are located on the conveyor 60.
exists.

The manipulator 10 is positioned by a fluidically moved arm 14 and operated under computer control. A suitable manipulator is that disclosed in US Pat. No. 4,162,318. The exemplary control system also has a first control system.
Also shown are a keyboard display input device 62 for input, a processor/storage device 64, a printer 66 for node copy output, and a fluid power source 6B.

The details of the robot system and system control elements described above are not particularly relevant to the present invention. Its operation (7) and its interaction with the manipulator itself, as well as the required hose and cable connections, are described by IBMRobot.
System T General Infor
mationManual and Users'
Guide GA34-0180-1 and related updated Technical Newsletter
is explained in.

FIG. 2 is a perspective view of the front of the robot 8 configured to perform tasks in three separate work areas.

The first working area is occupied by a conveyor 60 passing therethrough. The same mechanical elements referred to in FIG. 1 are given the same reference numerals in FIG. Stop 70 is associated with the front area on the conveyor. Associated with the stop 70 is a sensor 71 connected to the control system of the robot 8 . On the conveyor 60 is a kit 8 containing various associated assembly parts 84, 86 and 88.
0 is moving.

The alignment fixture 90 is attached to the surface 50 of the robot 80 pace 34.
exists above. Base plate 8B is shown adjacent to upright plate 89(8), which is provided as part of alignment fixture 90. Alignment fixture 90 also includes an air cylinder 91 which, when energized, causes upright plate 89 to engage base plate 88 for subsequent assembly operations. Upright plate 89 includes alignment pins (not shown) that mate with correspondingly sized apertures in base plate 88 . Tool 9 present in the retaining aperture of the fixture 90
2 is provided to be gripped by the manipulator 10 in order to attach the part 98 to the base plate 88.

Parts 98 are fed from a feed tube 100 that is supported on the robot 80 frame by columns 102 .

The other stop station 72 (FIG. 1) is not visible in FIG. This station 7
2 is because the kit 80 is a station at which movement on the conveyor 60 is stopped within the work envelope of the robot 8.

In the two wheelbarrow areas 52 and 54 (FIG. 1) there are wheelbarrows 1 oriented to the tasks of two mobile work stations.
06 and 130 exist. Each is equipped to perform a specific task.

The wheelbarrow 106 is provided with a tool 122 which, when gripped by the manipulator 10, can pick up parts from an area 124 of the wheelbarrow 106 and place them onto the subassemblies present at 126. When the appropriate number of parts from area 124 have been positioned on the subassembly, the subassembly can be dropped through shoe 128 into a container that can be conveniently emptied by an operator. A decision post 127 is provided on the wheelbarrow 106 to enable the manipulator 10 to determine its position relative to the wheelbarrow within the work envelope.

Of interest is the main working surface 129 of the wheelbarrow 106, which is tilted upwards by 30 degrees so that the various parts fed from the area 124 are fed primarily by the influence of gravity. This eliminates the need for complex mechanical arrangements.

Similarly, the shoe 12B is angled downwardly toward a collection pin, not shown.

Similarly, wheelbarrow 130 is equipped to perform different tasks. Specifically, components in gravity-fed slide 132 are picked up by a tool (not shown) and deposited in work area 150 onto a plate fed from source 140.

Judgment post 152 is provided to serve the same function as judgment post 127 on wheelbarrow 106.

Although mobile work station wheelbarrows 106 and 16D are equipped to support very different assembly tasks, they have common features. That is, the master wheelbarrow has similar dimensions and has no working area 56 or 55 (FIG. 1).
It's designed to fit in perfectly. Each is provided with a decision column to determine the position of the manipulator. Each has a source of parts or subassemblies to be worked on by one or more tools, and a place to take the finished article.

FIG. 6 is a more clearly illustrated view of the kit 80 of FIG. This kit is shown as an example only;
It will be obvious to those skilled in the art that there can be many variations and configurations of kits depending on the variety of transport and work done on the kits. However, of particular interest in exemplary embodiments of the present invention, and important in a manufacturing environment, is that the kit has appropriate dimensions for the conveyor and that the parts carried in the kit can be removed from the kit or Apertures 82 and 86 are provided to allow manipulator 10 to operate on parts conveyed into the kit without having to remove the kit from conveyor 60. That is, as shown in FIG.
8 is conveyed into the kit 80 adjacent the aperture 83 in the wall of the kit so that when the kit 80 is stopped along the conveyor 60 at station 72, the base plate 88
is adjacent to the upright plate 89 of the alignment fixture 90. As mentioned above, the upright plate 89 is used to enable the manipulator 10 to properly attach the parts 98, shown as garbage legs, to the base plate 88.

FIG. 4 is a top view of a manufacturing line that fully utilizes the concepts of the present invention. As shown, powered roller conveyor 6
0 is shown passing through two robots) 8711 [20B. In the winter (11), the robot has a work envelope that is divided into three independent work areas as shown in FIGS. 1 and 2.

Therefore, work is done on the contents of kit 80 when kit 80 is within the work envelope of robot 208. In this way, the contents of kit 80 are ready to receive work within the work envelope of robot 8. The tasks provided at mobile work stations 206.230.106 and 130 may directly support the main activity of this manufacturing line or may support other activities. The main thing is that robots are given tasks that can be done according to priorities)2
0B and 8 are to be maximized with minimal downtime. For example, as shown, the kits on conveyor 60 may be assigned the highest priority and the robot may stop working or otherwise They are now able to move on to work in independent work areas. The robot can obviously be controlled in such a way that it can provide visual or audible signals (12) to the operator where attention is required as usual. It is this automatic transfer to lower priority activities that characterizes the adaptability of the batch assembly techniques that may be used in the present invention.

Next, the operation of the present invention will be explained. In a manufacturing environment, the first step is to design a manufacturing line. Work stations 106 and 130 oriented to mobile tasks as well as work to be done on workpieces being transported on conveyor 60 within the work envelope of the robot.
Individual work stations must be designed, such as:

Once the work station design and equipment have been optimized, the robot is programmed to perform the movements required to perform all of the tasks associated with each work station. While the design of the hardware and testing of the work station is an iterative process in nature, so is the design of the software necessary to operate the manipulator to accomplish the desired task. As an additional requirement, error detection routines must also be developed.

That is, a problem unique to the present invention is the requirement for the manipulator to take some positive action upon detection of an irrecoverable erroneous condition. This proactive action is to proceed to the task with the next priority.

The details of this design stage are not directly relevant to the present invention.

Specific terms related to the specific manipulators illustrated.
l'j: A Machine Language (AML), which is the program support provided with this for the IBM Robotic System.
It is.

Once the hardware and software required for a particular manufacturing process has been designed and the actual manufacturing process is ready,
A mobile work station is positioned adjacent the robot's work envelope. Of course, the robots occupy relatively fixed positions, and part of the design of the production line is to orient the powered conveyor so that it passes approximately adjacent to or through the work envelope of all robots, as shown. things are included.

The final, dynamic step is priority assignment.

Although the work carried on the conveyor is always the top priority work, the priority of the additional work areas can change rapidly from day to day.

When the above preparations are completed, any given manufacturing process begins as indicated by starting point 600 in FIG. The first determination made within the robot controller and shown at decision block 602 is whether a kit is present.

It should be understood that the kit is used as an example only in this description and that the determination is made based on feedback from sensor 71 associated with stop 70 in FIGS. 1 and 2. If there are too many kits adjacent to the robot's workspace, the robot automatically advances to the next (lower) priority task workspace as indicated by block 304.

If the kit is present, the action performed at block 606 is to advance it into precise alignment in this work area. It is recalled that the stop 72 and associated sensors can be used for this purpose. Block 308 is the beginning of an iterative sequence of steps that includes a determination at 310 that each step in the sequence has been successfully completed. Once a step has been completed satisfactorily, the system then determines at decision block 312 whether all tasks have been completed. If there are further steps to be performed, control continues to the instructions represented by block 308. If the operation of the step comprising is not successful, a faulty seal is introduced as indicated by block 314. The error routine used in the present invention includes determining the success of recovery as indicated at decision block 616.

If recovery is not possible, the manipulator is commanded to proceed to the next task.

If the recovery is successful, the robot returns to its initial task sequence, in this case the task associated with the work carried on the conveyor 6o.

Once the task is successfully completed, the robot will move to block 31.
2, it is controlled to determine whether all the work in this work area has been completed. If not, control is returned to processing block 308 to complete the task step associated with this work area. When this task is completed, control of the robot returns to determining the presence of other kits at decision block 302. If there are no more kits, the robot moves on to the next priority task.

The tasks in each work area are the same mistakes! I want to be reminded of the money I receive.

The above describes the process by which idle robot time is minimized by giving the robot other work to accomplish when there is no highest priority work item or the task is in an irrecoverable error state. .

Although the invention has been described with respect to specific hardware and software environments, its basic concepts may be applied to other specific environments. For example, the robot may be of a basic type, such as a humanoid or turret type, mounted on the floor, ceiling, or wall, and/or of a less dynamic type.

Rough 1. BIVf Robot System I A robot may be used that describes the work envelope in polar coordinates rather than in Cartesian coordinates.

The IBM robot system I has a work envelope length of approximately 1
Although shown as having 15 wheelbarrows, it will be appreciated that other work area dimensions may be selected and the wheelbarrow dimensions determined accordingly. Similarly, turret-type robots can be installed such that independent work stations are located at radial positions. Finally, although the conveyor has been described as passing through the envelope, it will be clear to those skilled in the art that the conveyor could pass adjacent or tangent to the work envelope. The only condition is that the manipulator must reach far enough to accomplish all the desired tasks. This is only a matter of choice and design.

[Brief explanation of the drawing]

FIG. 1 is a diagram of a robot system showing the hardware components in accordance with the present invention. FIG. 2C is a perspective view of the robot of FIG. 1 including three work areas. FIG. 6 is a perspective view of the kit. FIG. 4 is a diagram illustrating a manufacturing line layout for an exemplary application using the present invention. FIG. 5 is a flowchart useful in understanding the operation of the present invention. 8...Robot, 10...Manipulator, 1
4.16...Arm, 24.26...Trolley, 3
4... Base, 51... Working envelope, 52.5
4... Mobile work station, 60... Conveyor, 62... Display input device, 64... Processor/storage device, 66... Printer, 68...
Fluid power source, 80...Kit, 106.160...
··Wheelbarrow.

Claims (1)

[Scope of Claims] A manipulator capable of highly precise movements in a plurality of directions; a work envelope divided into a plurality of independent work areas; a mobile work station for tasks; and all of the above mobile work stations. a device connected to the work area; at least one conveyor device positioned to pass adjacent to the work envelope in the separate work area; An adaptive robot controlled by a computer program comprising an inspection device positioned along the conveyor system to determine when the working area in the robot is reached.