Abstract
A method and a device monitors a working process, in which a workpiece is worked continuously along each of at least one working path during at least one working time period using a working tool arranged on a collaborative robot. The device includes a sensor apparatus for monitoring the environment of the collaborative robot and a detection device for detecting an object in a manipulation region around each working path of the collaborative robot. A working machine has a monitoring device of this type. The detection device is connected to a device for emitting an instruction signal within an instruction phase in the event that an object is detected in the manipulation region of a working path of the collaborative robot, so that the working process can be continued along the at least one working path without interruption.
Claims
1. A method for monitoring a working process, in which a workpiece (2) is worked continuously along each of at least one predetermined working path (x.sub.Bi) on the workpiece (2) during at least one working time period (Δt.sub.Bi) by means of a working tool (3) arranged on a collaborative robot (1), wherein the environment of the collaborative robot (1) is monitored and an object (4) in a manipulation region of the collaborative robot (1) around one of the predetermined working paths (x.sub.Bi) on the workpiece (2) is detected, wherein in the event that an object (4) is detected in the manipulation region of the collaborative robot (1) around one of the predetermined working paths (x.sub.Bi) on the workpiece (2) within an instruction phase (Δt.sub.I) an instruction signal (I) is emitted and the working process is continued along one of the predetermined working paths (x.sub.Bi) on the workpiece (2) without interruption, for as high a manufacturing quality as possible.
2. The method according to claim 1, wherein an alarm (W), preferably in the form of an acoustic, visual and/or tactile alarm (W), is emitted as instruction signal (I).
3. The method according to claim 1, wherein a command signal (A) is emitted as instruction signal (I) to the collaborative robot (1) for the re-planning of the working process.
4. The method according to claim 3, wherein in accordance with the emitted command signal (A) in the event of the detection of an object (4) in the manipulation region around one of the predetermined working paths (x.sub.Bi) of the collaborative robot (1) the working process is changed by preferably the sequence of predetermined the working paths (x.sub.Bi) being altered.
5. The method according to claim 3, wherein in accordance with the emitted command signal (A) in the event of the detection of an object (4) in the manipulation region around one of the predetermined working paths (x.sub.Bi) of the collaborative robot (1), the working of the workpiece (2) is continued at reduced working speed (v.sub.B′) along at least one of the predetermined working paths (x.sub.Bi).
6. The method according to claim 1, wherein the emitted instruction signal (I) is adapted to the type and/or the position and/or location of the detected object (4).
7. The method according to claim 1, wherein immediately before an imminent collision of the collaborative robot (1) with the detected object (4), the working of the workpiece (2) is stopped in a controlled manner.
8. A device (10) for monitoring a working process, in which a workpiece (2) can be worked continuously along each of at least one predetermined working path (x.sub.Bi) on the workpiece (2) during at least one working time period (Δt.sub.Bi) by means of working tool (3) arranged on a collaborative robot (1), said device comprising a sensor apparatus (5) for monitoring the environment of the collaborative robot (1) and a detection device (6) for detecting an object (4) in a manipulation region of the collaborative robot (1) around one of the predetermined working paths (x.sub.Bi) on the workpiece (2), wherein the detection device (6) is connected to a device (7) for emitting an instruction signal (I) within an instruction phase (Δt.sub.I) in the event that an object (4) is detected in the manipulation region of the collaborative robot (1) around one of the predetermined working paths (x.sub.Bi) on the workpiece (2), so that the working process can be continued along one of the predetermined working paths (x.sub.Bi) on the workpiece (2) without interruption, for as high a manufacturing quality as possible.
9. The device (10) according to claim 8, wherein the device (7) is formed for emitting an instruction signal (I) by an alarm device (7′) for emitting an alarm (W).
10. The device (10) according to claim 8, wherein the device (7) for emitting an instruction signal (I) is formed by a device (7″) for emitting a command signal (A) to the collaborative robot (1) for re-planning the working process.
11. The device (10) according to claim 9, wherein the alarm device (7′) is formed by a loudspeaker (8), a visual display (9) and/or a vibration device (11).
12. The device (10) according to claim 8, wherein the detection device (6) is connected wirelessly to the device (7) for emitting an instruction signal (I).
13. The device (10) according to claim 8, wherein the detection device (6) is connected to an interface (12) for connection to the collaborative robot (1).
14. The device (10) according to claim 8, wherein the detection device (6) is connected to a database (13), which database (13) comprises various instruction signals (I) as a function of the type and/or the position and/or the location of the detected objects (4).
15. A working machine (18), in particular a welding device (19), comprising a collaborative robot (1), for the continuous working of a workpiece (2) during at least one working time period (Δt.sub.B) along at least one working predetermined path (x.sub.B), wherein the monitoring device (10) according to claim 8 is provided.
Description
[0028] The present invention is explained more closely with the aid of the enclosed drawings. There are shown therein:
[0029] FIG. 1 a schematic diagram of a working machine for carrying out a working process;
[0030] FIG. 2 a block diagram of a monitoring device according to the invention for monitoring a working process;
[0031] FIG. 3 an embodiment of a monitoring device for monitoring a working process;
[0032] FIG. 4 a further embodiment of a monitoring device integrated in a welding robot;
[0033] FIG. 5 a working process consisting of several working paths, during which no object was detected in the manipulation region;
[0034] FIG. 6 the working process according to FIG. 5, wherein an object was detected in the manipulation region of a working path and a corresponding alarm is emitted as instruction signal;
[0035] FIG. 7 a variant of the working process according to FIG. 6, wherein an object was detected in the manipulation region of a working path and corresponding to a command signal as instruction signal a re-planning of the working takes place;
[0036] FIG. 8 a further variant of the working process according to
[0037] FIG. 6, wherein an object was detected in the manipulation region of a working path and corresponding to a command signal as instruction signal the working process is re-planned; and
[0038] FIG. 9 a further variant of the working process according to FIG. 6, wherein an object was detected in the manipulation region of a working path and corresponding to a command signal as instruction signal the working of a working path is continued at reduced speed.
[0039] FIG. 1 shows a schematic diagram of a working machine 18 for carrying out a working process in which a workpiece 2 is worked by means of a working tool 3, arranged on a collaborative robot 1, during at least one working time period Δt.sub.Bi along at least one working path x.sub.Bi. In the simplest case, a working path x.sub.B is worked during a working time period Δt.sub.B, for example a weld seam is produced along a working path x.sub.B. In addition to such simple working processes, conventional working processes comprise the working of several working paths x.sub.Bi at several working time periods Δt.sub.Bi, wherein, between the working of the individual working paths x.sub.Bi, pauses are inserted in which the collaborative robot 1 is re-positioned, tools are changed or working parameters are altered. The present invention relates to working processes in which an interruption of the working of a working path x.sub.Bi leads to changes of the manufacturing quality and, in certain circumstances, the tool 2 even has to be rejected thereby. Welding methods, soldering methods, painting methods, surface treatment methods, for example by means of plasma jets, and many more, are named as examples of such working processes. As already mentioned above, additionally or alternatively to the collaborative robot 1, the workpiece 2 can also be moved with a corresponding apparatus (not illustrated).
[0040] FIG. 2 shows a block diagram of a monitoring device 10 according to the invention for monitoring a working process. The monitoring device 10 contains a sensor apparatus 5 for monitoring of the environment of the collaborative robot 1 or respectively at least of the manipulation region around the working path x.sub.B of the collaborative robot 1. A detection device 6 is connected to the sensor apparatus 5, which detection device detects objects 4 in a manipulation region around each working path x.sub.B of the collaborative robot 1. Objects 4 can concern for example items on the working path x.sub.B, in the vicinity of the working path x.sub.B or persons in the manipulation region. Connected to the detection device 6 is a device 7 which, in the event of the detection of an object 4 in the manipulation region of a working path x.sub.B, emits an instruction signal I. The emitted instruction signal I of the device 7 can be an alarm W, whereby an operating personnel can be made aware of the detection of an object 4 and can be prompted to remove the object 4 within an instruction phase Δt.sub.I. Additionally or alternatively thereto, a command signal A can also be emitted to the collaborative robot 1 as instruction signal I for the re-planning of the working process. The command signal A can arrive in various ways (wireless or wired) to the collaborative robot 1, where for example a decision can be made with the aid of stored alternative working processes, whether a change or respectively re-planning of the working process is possible. In so far as the object 4 can not be successfully removed from the manipulation region or that the working process can not be successfully changed or re-planned within this instruction phase Δt.sub.I, the usual standard protective measures of the collaborative robot 1 are initiated and usually a stopping of the movement of the robot occurs and thus a termination of the working process. Through the instruction signal I, which is emitted by the device 7 when an object 4 is detected in the manipulation region of the working path x.sub.B, the possibility exists, however, to take measures in order to be able to continuously proceed with the working process or at least individual working paths x.sub.Bi. Thereby, the quality of the working process and thus of the worked workpiece 2 can be increased and a rejection can be prevented.
[0041] FIG. 3 shows an embodiment of a monitoring device 10 for monitoring a working process. The monitoring device 10 contains a sensor apparatus 5 which can be formed for example by a camera 14. The sensor apparatus 5 is connected to the detection device 6 for example at an image processing device for the processing of the images which are captured with the camera 14. The device 7 for emitting an instruction signal I is formed here by an alarm device 7′ for emitting an alarm W. For example, a loudspeaker 8, a visual display 9 or a vibration device 11 can be provided as alarm device 7′, which can be used optionally or cumulatively. In addition to directly connected alarm devices 7′, various alarm devices 7′ can also be connected wirelessly to the detection device 6 (not illustrated). The detection device 6 of the monitoring device 10 can have an interface 12 for connection to the collaborative robot 1, via which a command signal A of a device 7″ can be emitted to the collaborative robot 1 (not illustrated) for re-planning the working process. Further interfaces (not illustrated) for connection to other components involved in the working process are also conceivable.
[0042] A database 13 which contains various alarms W or command signals A as a function of the type and/or the position and/or the location of detected objects 4, can be connected to the detection device 6. Thereby, as a function of the type, position or location of the detected object 4, a different instruction signal I of the device 7 can be emitted. The database 13 can also be connected to the detection device 6 via a network 15, in particular the internet.
[0043] FIG. 4 shows a further embodiment of a monitoring device 10 which is integrated in a welding robot. In this example embodiment, a welding torch is arranged as working tool 3 on the collaborative robot 1, or respectively the welding device 19 is integrated in the collaborative robot 1. In the illustrated example embodiment, the monitoring device 10 is situated remote from the welding device 19, but can also be integrated therein. An alarm device 7′ in the form of a loudspeaker 8 is provided as part of the monitoring device 10 or else externally, which alarm device emits an alarm W on detection of an object 4 in the manipulation region of the working path x.sub.B. The alarm W can also be emitted to a welder S for example in the form of a visual alarm W to the head-up display of a welding helmet 16. The welder S is thereby prompted to remove the object 4 from the manipulation region of the working path x.sub.B, so that the working process can be continued. The connection of a device 17 for removing a detected object 4 with the monitoring device 10, which removing device 17 automatically removes the detected object 4 out of the manipulation region of the collaborative robot 1 is also conceivable. A device 7″ for emitting a command signal A to the collaborative robot 1 as further instruction signal I can be provided as a further part of the monitoring device 10. The command signal A can be transmitted to the collaborative robot 1 via an interface 12 of the monitoring device 10, in order to be able to change or re-plan the working process on detecting an object 4. On a change of the working process it is important that in the event of the change of the access of the collaborative robot 1 with respect to the working path x.sub.B, the TCP (Tool Centre Point) remains the same, so that a working of the working path x.sub.B can be guaranteed with the same quality.
[0044] FIG. 5 shows working process consisting of several working paths x.sub.B1 to x.sub.B6, during which no object 4 was detected in the manipulation region. Six working paths x.sub.B1 to x.sub.B6, which are worked one after the other, are situated on the workpiece 2. Accordingly, the working B takes place beginning with time t.sub.0 with the working of the first working path x.sub.B1. which takes place during the working duration Δt.sub.Bi with a working speed v.sub.B up to the time t.sub.1. After a pause, the working of the working path x.sub.B2 is begun at the time t.sub.2, which is terminated at the time t.sub.3. After termination of the working of the working path x.sub.B6 at the time t.sub.11, the working process is completed. Since no object 4 is situated in the manipulation region of a working path x.sub.B1 to x.sub.B6, also no instruction signal I is emitted in the form of an alarm W or of a command signal A during the working duration.
[0045] FIG. 6 shows the working process according to FIG. 5, wherein an object 4 was detected in the manipulation region of a working path, here the working path x.sub.B3. The working B is begun with working of the working path x.sub.B1 and is continued with the working of the working path x.sub.B2. Promptly before the working of the working path x.sub.B3, an object 4 is detected by the detection device 6 in a working path, here in the working path x.sub.B3 and an alarm W is promptly emitted as instruction signal I. The alarm W is begun at a time t.sub.WA and is emitted until the object 4 has been removed. In the illustrated example embodiment, the end of the alarm W takes place at the time t.sub.WE, whereupon the working process is continued with the working of the working path x.sub.B3 and can be ended according to plan, as in the case of the working according to FIG. 5.
[0046] FIG. 7 shows a variant of the working process according to FIG. 6, wherein an object 4 was detected in the manipulation region of the working path x.sub.B3 and in accordance with a command signal A as instruction signal I a re-planning of the working process takes place. In this example embodiment, a re-planning of the working takes place by the sequence of the working paths x.sub.Bi being changed. In the illustrated example embodiment, after the working of the working path x.sub.B2 at the time t.sub.4 the working of the working path x.sub.B4 is continued, thereafter the working of the working path x.sub.B5 and the working of the working path x.sub.B6 is carried out. During the working of the working path x.sub.B6, the detected object 4 is removed at time t.sub.IE from the manipulation region, whereby the emission of the instruction signal I or respectively command signal A is stopped. Thereafter, the working with the working path x.sub.B3 is completed in changed sequence. As long as the object 4 is detected in the manipulation region, the emission of the instruction signal I or respectively command signal A takes place (between the times t.sub.IA and t.sub.IE).
[0047] FIG. 8 shows a further variant of a working process, wherein an object 4 was detected in the manipulation region of the working path x.sub.B3 and in accordance with a command signal A to the collaborative robot 1 a re-planning of the working process takes place. In contrast to the example embodiment according to FIG. 7, a re-planning of the working process does not take place here through changing of the sequence of the working paths x.sub.Bi, but rather through lengthening the pause between the working of the working path x.sub.B2 and working of the working path x.sub.B3, until the object 4 has been successfully removed from the working path x.sub.B3 or respectively its manipulation region. In the illustrated example embodiment, an object 4 is detected in the manipulation region between the times t.sub.IA and t.sub.IE. At the time t.sub.IE the removal of the object 4 from the working path x.sub.B3 takes place and the emission of an instruction signal I or respectively command signal A thus ends. Thereafter, at the time t.sub.4 the working of the working path x.sub.B3 can be continued and the working can be completed according to plan up to the working of the working path x.sub.B6. In this variant, the working duration as a whole is indeed increased, however no interruption of the working of the individual working paths x.sub.Bi takes place during the working time periods Δt.sub.Bi, whereby the quality of the working is not negatively influenced.
[0048] In FIG. 9 a further variant of the working process according to FIG. 6 is illustrated, wherein an object 4 was detected in the manipulation region of the working path x.sub.B3 and in accordance with a command signal A as instruction signal I the working of a working path is continued with reduced speed. Here, after the detection of an object 4, the working which is currently being carried out, here the working of the working path x.sub.B2, is completed, and thereafter the working of the working path x.sub.B3, in the region of which the object 4 was detected, is carried out with reduced speed v.sub.B′ compared to the normal working speed v.sub.B, whereby the working time period Δt.sub.B3 of the working of the working path x.sub.B3 is lengthened and thus more time is created in order to remove the object 4 from the working path x.sub.B3 or to change the movement of the collaborative robot 1. When at the time t.sub.IE the object 4 is no longer detected, the working of the workpiece 2 with working of the working path x.sub.B3 with normal working speed v.sub.B can be ended and with the working of the further working paths x.sub.B4 and x.sub.B5 can be continued and finally completed with the working of the working path x.sub.B6. Also in this variant of the working method, the total duration of the working is increased compared to the variant according to FIG. 5 and it is nevertheless guaranteed that the workings of the individual working paths x.sub.Bi can be carried out without interruption continuously during the working time periods Δt.sub.Bi.
[0049] The present invention guarantees a carrying out of a working process with uninterrupted working of the working path or respectively working paths, without the quality of the worked workpiece 2 being impaired.
