Systems and method for descrete processes of joining in a system of industrial robots.
Field of invention The present invention relates to an industrial robot system adapted for processes of joining in specific positions. It should be understood that joining in specific positions means discrete processes where joining is performed in spots, such as spot welding, stud welding, press welding, clinching, riveting or laser welding.
Description of the background art It is known to have spot welding function packages where a spot welding timer is integrated into the weld power unit to reduce cost for the supplier and reduce packaging and interfacing for the integrator. The weld timers are typically programmed via an external timer programming unit (TPU), like a laptop, a proprietary device or a built in simple display. All weld timer relevant programs and parameters are stored in memories belonging to the weld timer, requiring sophisticated back-up routines, battery backup and memory units such as memory sticks.
Summary of the present invention
Problems From the standpoint of the background art as described above, it is a technical problem to provide system for industrial joining processes, such as spot welding, laser welding, clinching, stud welding or riveting, that requires less processing power, less memory, and less number of interfaces. It also is a technical problem to provide a joining system that is not dependent on proprietary software, but that can be programmed and controlled according to the users' demands. In the following, a joining system refers to one or several joining equipment.
Solution and advantages
With the purpose of solving one or more of the above identified problems, and from the standpoint of an industrial robot or group of robots adapted to co act with a system for a process of joining in specific positions, the present invention teaches that a robot comprises a memory unit and a master controller, where the memory unit is adapted to store working schedules. For a group of robots driven from the same controller,.the memory unit (MU) can be a standalone device connected to each robot via the controller or not and adapted to communicate simultaneously with each manipulator. The present invention specifically teaches that the master controller is adapted to control one robot or a group of several robots and the joining system, and that a robot is adapted to send a selected working schedule to a working timer belonging to the joining system according to what is required by a process to be performed. An industrial robot system comprising an industrial robot or group of robots and a joining system adapted for a process of joining in specific positions, said robot or group of robots comprising a memory unit and a master controller, said memory unit is adapted to store working schedules from at least one robot controller, that said robot controller is adapted to exchange information with other robot controllers through communication channels to which it is linked and that said master controller is adapted to control said robot or group of robots and said joining system, and said robot or group of robots is adapted to send a selected working schedule to a working timer belonging to said joining system according to what is required by a process to be performed. In order to simplify the communication between a robot or a group of robots and the joining system, and in order to provide a simple interface between a robot and a joining system, a robot is adapted to perform any communication with the joining system through existing network communication channels available in a robot or group of robots. It is comprised in the invention to use wireless or wired communication. It is further assumed that such communication channels may exist between controllers of one or several robots. In order to meet the requirements of high quality standards the present invention teaches that a master controller is adapted to perform weld quality logging according to information received from a unit adapted to perform quality
control and regulation belonging to a joining system via the existing communication channels. A master controller may also be adapted to perform quality control based on received information. These existing communication channels can be serial links, such as CAN or IBS or others. A robot controller belonging to a robot or a group of manipulators comprises the master controller, the MMI and the memory unit. The fact that a master controller of a robot or a group of manipulators is adapted to control a joining system as described above makes it possible to adapt a back-up function belonging to a robot or a group of manipulators to automatic back-up of the working schedules and quality parameters and results belonging to the quality logging. This fact also provides the possibility of performing the programming of the working schedules through the man machine interface MMI belonging to a robot or a group of manipulators. This MMI is adapted to provide a possibility for manual control of a robot or a group of manipulators and a joining system. The present invention also teaches that it is possible to control a robot by means of a programmable logic control (PLC), which PLC comprises a master controller, an MMI and a memory unit. The present invention also teaches that any used PLC may be made out of a standard personal computer (PC) or any other controller adapted to perform such tasks. It should be understood that an inventive robot or a group of robots is adapted to co act with two or more joining processes. If the joining system is one or several spot weld guns, then the working schedules are weld schedules. An inventive system for a process of joining in specific positions adapted to co act with a robot or a group of robots will now be described. The joining system comprises joining tools which are adapted to communicate with one or several robots, to receive a working schedule from one or several robots, and to perform a working process according to received working schedules. The joining system comprises a unit adapted to perform a quality control and regulation of the working parameters according to received working
schedules. This unit is adapted to communicate information concerning working quality logging to a master controller belonging to a robot or group of robots via communication channels belonging to that robot or group of robots. A joining process may for instance be spot welding. In this case the joining tool is one or several spot weld guns. In such an embodiment the working schedules and working parameters are weld schedules and weld parameters, and the joining system comprises a weld timer adapted to generate a control voltage according to a given working schedule and a power unit adapted to convert the control voltage to a weld current. It should be understood that the joining tool also might be one or several riveting tool, one or several clinching tool, one or several stud welding tool, or one or several laser welding tool, with thereto belonging working schedules and working parameters. The present invention also relates to a method for quality control in relation to an inventive robot or group of robots co acting with an inventive joining system. The present invention teaches that a unit belonging to the joining system may be brought to perform a quality control and regulation of working parameters according to a received working schedule. The unit is brought to communicate information concerning working quality logging to a master controller belonging to one or several robots. A master controller is brought to perform weld quality logging according to received information. A master controller may also be brought to perform weld quality logging according to received information. It is for instance possible to leave the decision of whether a joint is OK or not to the quality control unit or to the master controller after receiving respective information from the unit in the joining system. In the case of a production line consisting of several robot controllers, the information collected on one controller can be passed to another via communication channels. A back-up function belonging to one or several robots is brought to perform automatic back-up of the quality parameters and results belonging to the quality logging. The unit and the master controller are brought to communicate via communication channels belonging to a robot or a group of robots.
The present invention also relates to various computer program products, which, when executed by a computer, will cause the computer to act as a master controller according to an inventive robot, or as a robot controller or PLC belonging to an inventive robot or a group of robots, or a working timer and unit for quality control and regulation according to an inventive joining system. The present invention also relates to a computer readable medium, upon which computer program code from any inventive computer program product is stored. The advantages of an industrial robot or a group of such robots, a system for joining processes, a method for quality control management or any computer program product according to the present invention are that the present invention will provide a cost reduction of the weld timer / power unit configuration due to less demands on the weld timer(s) concerning memory, processing power and the number of interfaces. An inventive programming MMI can be robot or PLC dependent according to users demands and not dependent of proprietary software. All working schedules and quality parameters to set up the working timer can be backed-up automatically with the back-up of the robot controller or PLC. Working quality logging can be done via existing network communication channels already available in a robot controller or PLC or other media. Customizing the working routines, stepper routines or PLC interaction can be done in robot language like RAPID or PLC logic by the integrator without consulting the work timer supplier making customizing done more rapidly. The invention provides a cost reduction since only one TPU is used and since the existing network of a robot or group of robots is used for communication. The invention also provides an easy way of storing quality data or sharing this data within a group of robots or a group of controllers.
Brief description of the drawings A robot, a joining system, a method and various computer program products according to the present invention will now be described in detail with reference to the accompanying drawings, in which: Figure 1 is a schematic and simplified illustration of a robot and a joining system according to known technique,
Figure 2 is a schematic and simplified illustration of a robot and a joining system according to a first embodiment of the present invention, Figure 3 is a schematic and simplified illustration of a robot and a joining system according to a second embodiment of the present invention, Figure 4 is a schematic and simplified illustration of a robot and a joining system according to a third embodiment of the present invention, Figure 5 is a schematic and simplified illustration of an inventive computer readable medium, Figure 6 is a schematic and simplified illustration of a group of robots and a joining system, and Figure 7 is a schematic and simplified illustration of a group of controllers and groups of robots with joining systems.
Description of embodiments as presently preferred Figure 1 shows an industrial robot 1 ' according to known technique. The robot 1' is adapted to co act with a system 2' for joining processes in specific positions. As it can be seen in figure 1 , known technique shows that the joining system 2' comprises a man machine interface (MMI) 21 ', a memory unit 22', a working timer 23", a power unit 24' and a joining tool 25'. In the illustrated example, the working timer 23' is a weld timer and the joining tool 25' is a spot weld gun. The MMI 21 ' is in the figure schematically illustrated as a built in simple device. It might also be an external TPU, like a laptop computer or a detached proprietary device. The present invention relates to an industrial robot 1 , schematically illustrated in figure 2. An inventive robot 1 is adapted to co act with a system for joining processes 2 in a specific position. The robot 1 comprises a memory unit 12 and a master controller 13, where the memory unit 12 is adapted to store working schedules.
The master controller 13 is adapted to control the robot 1 and the joining system 2, and the robot 1 is adapted to send a selected working schedule to a working timer 21 belonging to the joining system 2 according to what is required by a process to be performed. The robot 1 is adapted to perform any communication with the joining system 2 through existing network communication channels 14 available in the robot 1. The master controller 13 is adapted to perform weld quality logging according to information received from a unit 24 adapted to perform quality control and regulation belonging to the joining system 2 via the existing communication channels 14. The master controller 13 may also be adapted to perform quality control based on received information. These existing communication channels 14 are serial links, such as CAN or IBS or others. A back-up function 15 belonging to the robot 1 is adapted to automatic back-up of the working schedules and quality parameters and results belonging to the quality logging. The robot 1 comprises a man machine interface 11 (MMI) adapted to provide a possibility to manual control of the robot 1 and joining system 2. The programming of the working schedules may be performed through this MMI. Figure 2 shows that a robot controller 16 belonging to the robot 1 comprises the master controller 13, the MMI 11 and the memory unit 12. Figure 3 shows that the robot 1 is controlled by a programmable logic control 16' (PLC), which PLC 16' comprises the master controller 13', the MM1 11 ' and the memory unit 12'. The PLC 16' can be made out of a standard personal computer (PC) or any other controller adapted to perform such tasks. Figure 4 shows that the robot 1 " is adapted to co act with two or more joining processes 2"a, 2"b. Figure 6 is a group of robots driven by one robot controller that comprises the MMI 11 and the memory unit 12. The latter however could consist of a standalone device.
Figure 7 is a group of robot controllers each driving a group of robots according to Figure 6. Each robot controller consists of a MMI 11 and a memory unit 12. Each memory unit has also the ability to transfer information to other memory units through communication channels 14 to which it is linked. As can be seen in the figures, the joining system 2 can be a spot weld gun, where the working schedules are weld schedules. An inventive system 2 for a process of joining in specific positions adapted to co act with a robot 1 will now be described with renewed reference to figure 2. The joining system 2 comprises a joining tool 23. The joining system 2 is adapted to communicate with the robot 1 , and the joining system 2 is adapted to receive a working schedule from the robot 1 , and the joining system 2 is adapted to perform a working process according to received working schedule. The joining system 2 comprises a unit 24 adapted to perform a quality control and regulation of the working parameters according to received working schedule. This unit 24 is adapted to communicate information concerning working quality logging to a master controller 13 belonging to the robot 1 via communication channels 14 belonging to the robot 1. The figure shows a joining system 2 for spot welding. It is schematically shown that the joining tool 23 is a spot weld gun. In this embodiment the working schedules and working parameters are weld schedules and weld parameters, and the joining system 2 comprises a weld timer 21 adapted to generate a control voltage according to a given working schedule and a power unit 22 adapted to convert the control voltage to a weld current. It should be understood that the joining tool 23 also might be a riveting tool, where the working schedules and working parameters are schedules and riveting parameters. The joining tool may also be a clinching tool, where the working schedules and working parameters are clinching schedules and clinching parameters. The joining tool may also be a stud welding tool, where the working schedules and working parameters are stud welding schedules and stud welding parameters. The joining tool may also be a laser welding tool, where the working schedules and working parameters are laser welding schedules and laser welding parameters.
Again with reference to figure 2 an inventive method will be described where a unit 24, belonging to the joining system 2, is brought to perform a quality control and regulation of working parameters according to a received working schedule. The unit 24 is brought to communicate information concerning working quality logging to a master controller 13 belonging to the robot 1. The master controller 13 is brought to perform weld quality logging according to received information. The master controller may also be brought to perform weld quality logging according to received information. A back-up function 15 belonging to the robot 1 is brought to perform automatic back-up of the quality parameters and results belonging to the quality logging. The unit 24 and the master controller 13 are brought to communicate via communication channels 14 belonging to the robot 1. The present invention also relates to a number of different computer program products. These are schematically shown in figure 2. A first computer program product 31 comprises first computer program code 31 a, which, when executed by a computer, causes the computer to function as a master controller 13 belonging to an inventive robot 1. A second computer program product 32, schematically shown in figures 2, 3, 4, 5 and 7 comprises second computer program code 32a, which, when executed by a computer, causes the computer to function as a robot controller 16 or a PLC 16', 16" belonging to an inventive robot 1 , 1 " or group of robots. A third computer program product 33 comprises third computer program code 33a, which, when executed by a computer, causes the computer to function as a working timer 21 and a unit 24 for quality control and regulation belonging to an inventive joining system 2. The present invention also relates to a computer readable medium 4, schematically shown in figure 5, where the computer readable medium 4 is exemplified by a compact disc. Computer program code 31a, 32a, 33a according to the first, second or third computer program product 31 , 32, 33 is stored on the computer readable medium 4. It will be understood that the invention is not restricted to the aforede- scribed and illustrated exemplifying embodiments thereof and that modifications
can be made within the scope of the inventive concept as illustrated in the accompanying Claims.