SORTING SYSTEM, MOBILE ROBOT, METHOD FOR OPERATING A SORTING SYSTEM, COMPUTER PROGRAM PRODUCT AND COMPUTER-READABLE MEDIUM

Abstract

In one aspect the invention relates to a sorting system (SortS) for sorting processed parts (P) from a workpiece (W), which has been processed by a laser processing machine (L), in particular a laser sheet processing machine, comprising:—A working table (WT) for supporting the workpiece (W) with the processed parts (P), which have been processed by the processing machine (L),—A fleet of interacting legged mobile robots (MR) for sorting the processed parts (P) in a collaborative manner to a target destination.

Claims

1-26. (canceled)

27. A legged mobile robot (MR) of a fleet of interacting autonomous legged mobile robots (MR), for sorting processed parts (P) of a workpiece (W), which has been processed by a workpiece processing machine (L), in particular a sheet workpiece processing machine in form of a laser cutting machine, with: A control unit (DCU, CCU), which is configured for providing control instructions for controlling the mobile robot (MR), wherein a set of robot-specific control instructions is generated autonomously and locally on each of the mobile robot (MR) of the fleet of robots for the respective mobile robot (MR) for gripping processed parts (P) from a working table (WT) and for transporting the gripped processed parts (P) to a target destination in a cooperating manner; A sensor system (S) with first sensors (S1) for coordinated navigation with other mobile robots (MR) of the fleet and with second sensors (S2) for gripping; A network interface (NMI) to a network (NW) for communication with other mobile robots; (MR) and A gripping and movement unit (G) for gripping at least one processed part (P) from the working table (WT) and for moving the mobile robot (MR) for sorting the gripped processed part (P) to a target destination.

28. The legged mobile robot (MR) according to claim 27, wherein the mobile robot (MR) is legged and wherein the gripping and movement unit (G) comprises at least four legs (L) and in particular six legs (L), wherein each leg (L) may be provided with a tool of a set of different tools.

29. The legged mobile robot (MR) according to claim 28, wherein at least a part of the legs (L) of the gripping and movement unit (G) are configured to move the mobile robot (MR) and to grip and carry cut parts (P) and to fixate the mobile robot (MR) in a stable position.

30. The legged mobile robot (MR) according to claim 27, wherein the gripping and movement unit (G) comprises clamping means (Cl) for engagement with a grate-like support element (E), in particular with a tooth thereof, of the working table (WT) for securely positioning the mobile robot (MR) in a stable position on the working table (WT) and/or to fixate it thereon.

31. The legged mobile robot (MR) according to claim 27, wherein the gripping and movement unit (G) comprises three separate units: a gripping unit (GU), a movement unit (MU) and clamping means (Cl).

32. The legged mobile robot (MR) according to claim 31, wherein the gripping and movement unit (G) and in particular the gripping unit (GU) comprises suction cups (SC), in particular vacuum suction cups.

33. The legged mobile robot (MR) according to claim 27, wherein the sensor system (S) of the mobile robot (MR) comprises an optical sensor vision system (OSV).

34. The legged mobile robot (MR) according to claim 27, wherein the control unit (DCU, CCU) is adapted to calculate a center of gravity of the mobile robot (MR) while gripping the processed parts (P) and for providing tilt avoidance control instructions to avoid tilting/tipping of the mobile robot (MR).

35. The legged mobile robot (MR) according to claim 27, wherein the mobile robot (MR) comprises a charging port (CP), preferably a wireless charging port.

36. Sorting system (SortS) for sorting processed parts (P) from a workpiece (W), which has been processed by a workpiece processing machine (L), in particular a sheet processing machine in form of a laser cutting machine, comprising: A working table (WT) for supporting the workpiece (W) with the processed parts (P), which have been processed by the workpiece processing machine (L), A fleet of interacting autonomous legged mobile robots (MR), according to claim 27, for sorting the processed parts (P) in a collaborative manner to a target destination.

37. Sorting system (SortS) according to claim 36, directed to the sorting system, wherein the sorting system (SortS) comprises a central control unit (CCU) for at least partially coordinating the control of the sorting process and wherein all or a selected set of the mobile robots (MR) are/is equipped with a control interface to the central control unit (CCU).

38. Sorting system (SortS) according to claim 36, wherein the sorting system (SortS) is controlled by a system of distributed control units (DCU), which are provided locally on the autonomously operating mobile robots (MR).

39. Sorting system (SortS) according to claim 36, wherein at least two mobile robots (MR) exchange collaboration messages for building a cooperating team of mobile robots by applying a consensus algorithm for cooperating behavior, wherein the collaboration messages comprise a collaboration request message set, an availability response message set, an initialization message set and a synchronization message set.

40. Sorting system (SortS) according to claim 36, wherein the sorting system (SortS) comprises at least one ramp (R) for facilitating the movement of the mobile robots (MR) to and from the working table (WT).

41. Sorting system (SortS) according to claim 36, wherein the sorting system (SortS) comprises a plan interface (I) for receiving a cutting plan or a sorting plan and wherein the plan interface (I) is preferably implemented on all or a selected set of the mobile robots (MR).

42. Sorting system (SortS) according to claim 36, wherein the sorting system (SortS) comprises a navigation system (NS) and wherein at least a part of the navigation system (NS) is preferably implemented on all or a selected set of the mobile robots (MR).

43. A method for operating a sorting system (SortS) according to claim 36, wherein a set of robot-specific control instructions is generated autonomously and locally on each of the mobile robots (MR) of the fleet of robots for the respective mobile robot (MR) for gripping processed parts (P) from the working table (WT) and for transporting the gripped processed parts (P) to a target destination in a cooperating manner.

44. Method according to claim 43, wherein each of the mobile robots (MR) is exchanging messages with each other for informing the other mobile robots (MR) of the own control instructions and/or for being informed about the foreign control instructions of the other mobile robots (MR).

45. Method according to claim 43, wherein the method comprises to receive a cutting plan and/or a sorting plan from the processing machine (L), in particular a cutting machine and generating the set of control instructions in reply to the received cutting plan or sorting plan.

46. Method according to claim 43, wherein each mobile robot (MR) of the fleet of mobile robots exchanges messages in order to enable cooperative acting within the sorting process.

47. Method according to claim 46, wherein a mobile robot (MR) generates a job order message to be distributed to all mobile robots of the fleet in case the robot is not able to execute or complete its task according to the received control instructions.

48. Method according to claim 43, wherein each mobile robot (MR) of the fleet of mobile robots uses a coordinate navigation algorithm (NS) and in particular a stigmergy algorithm for calculating its movement path dynamically in a changing environment including changes due to movements of other robots or already sorted parts, wherein a navigation process is continuously optimized and wherein optimization consists of an iterative improvement of the currently best solution.

49. Method according to claim 43, wherein for controlling navigation of the fleet of mobile robots (MR) neural networks are used and/or evolutionary computation techniques are applied.

50. A computer program product comprising program elements which cause a processor in a mobile robot (MR) to carry out the steps of the method for sorting processed parts (P) as defined in claim 43, when the program elements are loaded into a memory of the processor.

51. A computer-readable medium on which program elements are stored that can be read and executed by a processor, in order to perform steps of the method for sorting processed parts (P) as defined in claim 43, when the program elements are executed by the processor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0100] FIG. 1 is an overview of the structure and architecture of the sorting system according to a preferred embodiment of the present invention;

[0101] FIG. 2 is a schematic representation of a mobile robot according to a preferred embodiment of the present invention;

[0102] FIG. 3 is schematic representation of a clamping unit of the mobile robot, engaging with a grate-like structure of the working table;

[0103] FIG. 4 is another schematic representation of the sorting system with two robots performing a collaborative transportation task of a cut part;

[0104] FIG. 5 is a more detailed view of one robot gripping a cut part out of the workpiece on the working table;

[0105] FIG. 6 is a block diagram of components of the sorting system according to a preferred embodiment of the present invention;

[0106] FIG. 7 is a flow chart of a sorting procedure;

[0107] FIG. 8a shows the gripping unit with a 3-jaw clamping means;

[0108] FIG. 8b shows the gripping unit with a rotating clamping means;

[0109] FIG. 8c shows the gripping unit with a 2-jaw clamping means;

[0110] FIG. 8d shows the gripping unit with part gripping clamping means;

[0111] FIG. 9 is a block diagram of components of the mobile robot according to a preferred embodiment of the present invention;

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0112] Generally, the proposed solution relates to a distributed system of mobile robot's MR for cooperatively transporting cut parts P from a working table WT to a target destination, e.g. different sorting boxes or conveying belts.

[0113] The overall structure is shown in FIG. 1. A processing machine may be a laser cutting machine L, which provides cut parts P in a workpiece W. The laser machine is controlled by an electronic (or digitized) cutting plan. After completion of the cutting process, the workpiece W with the cut parts P formed therein is transferred on a working table WT out of the laser machine L. Now, the cut parts P need to be sorted or transported to a target destination.

[0114] As can be seen in FIG. 1, the laser cutting machine L is equipped with a movable cutting table or working table, located outside of the machine in a discharge area with a workpiece W on it. The workpiece W is cut and forms a residual grid and several cut parts P. Legged mobile robots MR perform the unloading of parts P. The legged mobile robots MR are of insect-like shape and have at least three (3) walking legs L, preferably four (4) or more preferably sic (6) walking legs L. At least one of the legs L comprises gripping means G or a gripper extremity. Alternatively, also 2 or 3 gripping means may be provided. Ramps R allow the mobile robots MR to access and exit the working table WT where they walk preferably along the residual grid, on the pins or edge E of the working table WT or on larger cut parts P, which are not in danger of falling through a grate structure of the working table WT. The mobile robots MR collect cut parts P and stock them in a collecting area, e.g. on pallets, in boxes or the like. Wireless charging areas CP (e.g. inductive, optical or electromagnetic) facilitate electrical re-charging of the mobile robots MR. Alternatively, a cable bound charging could be installed.

[0115] FIG. 2 shows a mobile robot MR in more detail. The robot MR has several and at least three walking legs L, equipped with clamps means Cl and clamp motorization M for support grate walking.

[0116] The support grate walking with the respective means is shown in more detail in FIG. 3. The working table WT has several (with respect to the longitudinal axis of the working table WT) transversally extending support elements E, forming a grate. The support elements E have an upper side which is jagged or toothed as can be seen in FIG. 3, for minimizing the contact area with the cut parts P. The mobile robot MR comprises clamping means Cl for engagement with the teeth of the support element E of the working table WT. Thus, the working table WT has a support grate lane with pins or teeth for the engagement with a mobile robot's leg L and in particular with clamping means Cl. Alternatively, to the clamping means Cl, shown in FIG. 3, also cup-like (normal or vacuum suction cups SC) ends of the legs L could be used. Further alternatively, electromagnetic acting leg ends could be used. Possible embodiments for the gripping unit G with different options for clamping means Cl are explained in more detail below with respect to FIG. 8.

[0117] FIG. 4 shows several mobile robots MR with two of them cooperating in a common transportation task of one single cut part P, being too heavy or large for a single robot MR. For this common cooperation task, an allocation and/or a consensus algorithm is used to be executed on the robot's MR to control the two mobile robots MR autonomously in a self-organizing manner. Of course, the co-operative team may consist of two or more mobile robots MR, depending on the respective task. In order to organize the collaboration, a consensus algorithm or a collaboration algorithm is applied and executed. In the fleet of mobile robots one of them may be assigned a master mobile robot, and one or more others slave mobile robots. The master mobile robot is instructed to initiate collaboration on a spot of collaboration.

[0118] FIG. 5 shows the working table WT with the grate-like support element E. The support element E having a workpiece Won it having cut parts P to be transported to the target destination. Mobile robot MR is picking a cut part P to unload.

[0119] FIG. 6 shows a possible embodiment of a sorting system SortS with a central(ized) control CCU. The sorting system SortS comprises a fleet of mobile robots MR, which are in data exchange with each other and with a navigation system NS. The navigation system NS may be an indoor navigation system, e.g. operating with beacons. A central control unit CCU is adapted to control the fleet of mobile robots MR in order to provide a cooperating team of robots for a common task. For that purpose, the central control unit CCU receives information about the following items, by means of different messages: [0120] cut part message; [0121] part production step message; [0122] automation factory topology message; [0123] machine topology message; [0124] local robot's state message, comprising an ID of the robot MR, a type of the robot MR (e.g. weight, dimension, power . . . ), current task of the robot MR, position of the robot MR, charging battery status etc.

[0125] The central control unit CCU may be in data exchange with a shop floor control system SFCS (if present) and/or with a machine control MC, which could e.g. be the control of the cutting machine. In case that there is no SFCS communication, it will be with the control unit of the cutting machine. Further the central control unit CCU may exchange messages with a control system of the working table WT in order to synchronize movement of the working table WT with respect to movement of the fleet of robots MR. For providing control instructions for control of the fleet of mobile robots MR, the central control unit CCU may have a plan interface I for receiving a cutting plan and/or a sorting plan.

[0126] The central control unit CCU is adapted to execute the collaboration algorithm or at least a server's part thereof (wherein a client's part of the collaboration algorithm may reside and may be executed on a processing unit of each of the mobile robots MR. The central control unit CCU may further be adapted to execute the sorting plan algorithm, the coordinate navigation algorithm, the walking motion algorithm, and/or the allocation algorithm.

[0127] FIG. 7 is a flow chart of a control method for a fleet of mobile robots MR. The shop floor control system SFCS or alternatively the control unit of the laser machine L initiates production of cut parts P by initiating cutting process in the laser machine L. The central control unit CCU gathers information about productions jobs (e.g. cutting and/or machining plans and production steps. In a next step, the central control unit CCU distributes individual task tickets TT to the mobile robots MR. In the following step, the respective mobile robot MR acknowledges the task ticket's acceptance to the central control unit CCU. In the next step, the fleet of mobile robots MR is monitored until a mobile robot MR is reporting a task ticket completion message to the central control unit CCU. The central control unit CCU checks task completion status. In case the status represents, that the job is completed successfully, the central control unit CCU reports the job completion to the shop floor control system SFCS or alternatively to the control unit of the laser machine L. Otherwise (no job completion) the monitoring loop is executed for the fleet of robots so that it is branched back to the monitoring step.

[0128] The task ticket distribution is repeated until all task tickets are processed.

[0129] FIG. 8 shows different embodiments for the gripping and movement unit G of the mobile robot MR. FIG. 8a shows the gripping and movement unit G with an actuator A and a 3-jaw clamp, forming the clamping means Cl. The gripping and movement unit G additionally comprises a gripping unit GU. The gripping unit GU has the functionality of gripping processed parts—in addition to the clamping functionality for clamping the mobile robot MR itself on the grate-like support structure, shown in FIG. 3. In this or in other example embodiments, the legs L may be equipped with rubber pads P for avoiding slipping of the gripping and movement unit G. FIG. 8b shows an example embodiment wherein the gripping and movement unit G comprises a movement unit MU. The movement unit MU provides the functionality of moving the mobile robot MR. The gripping and movement unit G may be equipped with a rotating clamping means Cl. The gripping and movement unit G may comprise an optical sensor vision system OSV of the sensor system S, in order to optically observe and control the gripping process by mans of control instructions provided by the control unit DCU, CCU. FIG. 8c shows the gripping unit G with a 2-jaw clamping means Cl and a respective actuator being controlled by the control unit DCU, CCU (this also holds for the other actuators in the other figures of FIG. 8). FIG. 8d shows the gripping means G with the gripping unit GU, which comprises a retractable part for engagement with a leg L, provided with suction cups SC and wherein the leg L with the suction cups SC may be moved up and down a longitudinal axis of the leg L.

[0130] FIG. 9 shows another, preferred embodiment with a distributed control unit DCU compared to the embodiment with the central control unit CCU, described with respect to FIG. 6. However, it is noted, that combination are possible, too. Thus, a central control unit CCU may be provided in addition to the distributed control unit DCU on each or selected mobile robots MR.

[0131] In a preferred embodiment, the mobile robot MR is operated and controlled fully autonomously by control instructions which are generated locally on the mobile robot MR. Each or selected mobile robots MR comprise a decentralized or distributed control unit DCU which interacts locally with a sensor system S. The sensor system S may comprise fist sensors S1 for coordinated navigation and second sensors S2 for gripping. The second sensors may be part of the optical sensor vision system OSV.

[0132] The distributed control unit DCU interacts with the gripping and movement unit G for controlling a gripping and/or clamping task thereof. The distributed control unit DCU may optionally further interact with a control unit of the working table WT in order to synchronize movement (not shown in FIG. 9). The sensor system S and/or the distributed control unit DCU interact with the navigation system, which also may be at least partially provided locally on the mobile robot MR for calculating a transportation trajectory for the mobile robot in relation to the other mobile robots of the fleet. The distributed control unit DCU may have a plan interface I for receiving a cutting plan and/or a sorting plan. Usually the distributed control unit DCU will additionally be provided with a network interface NWI to a communication network, in particular for communication with the other robots MR of the fleet for synchronization. The distributed control unit DCU is adapted to execute a consensus algorithm for providing cooperative behavior on a common task.

[0133] Preferably, the distributed control unit DCU is adapted to execute the consensus algorithm, the sorting plan algorithm, the walking motion algorithm (or the stigmergy algorithm) and/or the coordinate navigation algorithm and the allocation algorithm. In other embodiments, at least some of the algorithms may be transferred to a central control unit CCU, which usually has more processing resources.

[0134] In a preferred embodiment, at least two mobile robots MR are used.

[0135] The mobile robot MR has an optical sensor system, which is used to estimate their position in the space. Further, the optical sensor system is used to detect cut parts P. The sensor system S of the mobile robot MR is preferably used to automatically detect navigation geometries (e.g. cutting grate pins, cut part elements, conveyor belts etc.).

[0136] The sensor system S of the mobile robot MR may preferably also be used to detect navigation geometries conditions (e.g. cutting grate pins being worn out, dirty etc). With this, the processing may be optimized in order to differentiate between failures (part P to be rejected) and good parts (without failures). Defective or faulty parts P need not to be sorted and are automatically excluded from being sorted.

[0137] Generally, the interfaces can be embodied as a hardware interface or as a software interface (e.g. PCI-Bus, USB or Firewire). In general, the control unit CCU, DCU can comprise hardware elements and/or software elements, for example a microprocessor, a field programmable gate array (an acronym is “FPGA”) or an application specific integrated circuit (an acronym is “ASIC”). The memory in the control unit CCU, DCU can be embodied as non-permanent main memory (e.g. random-access memory—RAM) or as permanent mass storage (e.g. hard disk, USB stick, SD card, solid state disk).

[0138] The network NW or communication channels can be realized as a LAN (acronym for “local area network”), in particular a Wi-Fi network, or any other local connection, e.g. via Bluetooth, ZigBee or USB (acronym for “universal serial bus”). The network can also be realized as a WAN (acronym for “wide area network”), in particular the network can be identical with the internet and may be based on an IP protocol. The network can alternatively also be realized as a VPN (acronym for “virtual private network”) or Lora WAN (Long Ranged Wide Area Network).

[0139] The control unit DCU, CCU may be provided as software and may be stored in a memory, which may be database or can be contained in a memory of a server, or it can be stored on a separate storage unit.

[0140] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality.

[0141] A single unit or device may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

[0142] The system for secure and remote update of a control device in accordance with the method as described above can be implemented as program code means of a computer program and/or as dedicated hardware.

[0143] A computer program may be stored/distributed on a suitable medium, such as an optical storage medium or a solid-state medium, supplied together with or as part of other hardware, but may also be distributed in other forms, such as via the Internet or other wired or wireless telecommunication systems.

[0144] Processes or steps, which have been described with respect to FIG. 7 are computer-implemented and may be embodied as software and/or hardware. At least some steps of the present invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices linked through a communications network NW. In a distributed computing environment, program modules may be located in local and/or remote memory storage devices.

[0145] The control unit CCU, DCU may execute machine-executable instructions to effect one or more aspects of the present invention. At least a portion of the machine executable instructions may be stored (temporarily or more permanently) on the storage devices and/or may be received from an external source via an input interface.

[0146] Any reference signs in the claims should not be construed as limiting the scope.

[0147] Wherever not already described explicitly, individual embodiments, or their individual aspects and features, described in relation to the drawings can be combined or exchanged with one another without limiting or widening the scope of the described invention, whenever such a combination or exchange is meaningful and in the sense of this invention. Advantageous which are described with respect to a particular embodiment of present invention or with respect to a particular figure are, wherever applicable, also advantages of other embodiments of the present invention.