Off-line teach assist apparatus and on-line control apparatus

In a programmable manipulator apparatus for performing work operations with respect to a workpiece movable along a predetermined workpiece path, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected position of said manipulator arm in said plurality of manipulator axes and a corresponding projected workpiece position, said projected manipulator arm position being calculated in a teaching phase in accordance with a predetermined projected workpiece velocity and a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of:

• means for reading out said command signals in a predetermined manner;
• means responsive to two successive command signals for generating a predetermined number of sequential position, velocity and acceleration control signals for each of said manipulator axes;
• and
• means responsive to said control signals for moving said manipulator arm to said projected position in accordance with movement of said workpiece.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having encoder means for said axes operative to develop position signals corresponding to the actual position of said arm and being arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of:

• means for positioning said arm during an initial teaching operation with a stationary workpiece to different positions corresponding to the desired operations of the manipulator relative to the stationary workpiece;
• means for calculating signals representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm;
• and
• means for storing said calculated arm position signals for use as command signals in controlling movement of said arm in a playback cycle with a moving workpiece.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of:

• means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation;
• means for converting said position signals correponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates;
• and
• means for translating said resulting Cartesian coordinates to account for the projected movement of said workpiece in terms of positional displacement units along said reference axis during the projected elapsed time for said arm to traverse the distance between successive taught positions on said workpiece at the maximum dynamic capabilities of said arm.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes, and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of:

• means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation;
• means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates;
• means for calculating the time interval required for said arm to traverse the distance between successive taught positions when the workpiece is moving at a predetermined velocity and said arm is moving at the maximum dynamic capabilities;
• and
• means controlled by said calculating means for translating said resulting Cartesian coordinates to account for movement of said workpiece along said reference axis during said calculated time interval.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of:

• means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation;
• means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates;
• means for calculating the time interval required for said arm to traverse the distance between successive taught locations when said arm is moving at the maximum dynamic capabilities throughout said time interval and said workpiece is moving along said reference axis at a predetermined velocity;
• and
• means controlled by said calculating means for translating said resulting Cartesian coordinates to account for movement of said workpiece along said reference axis during said calculated time interval.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of:

• means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation;
• means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates;
• means for calculating the path of movement and the minimum time which are required for said arm when moving at predetermined dynamic parameters in order to position said arm at the taught location relative to the workpiece when the workpiece is moving at a predetermined velocity;
• and
• means controlled by said calculating means for translating said resulting Cartesian coordinates to values corresponding to said taught location relative to a moving workpiece.

The method of programming a manipulator to perform a series of operations on a workpiece while the workpiece is moving along a predetermined path, the manipulator having an arm which is movable in a plurality of axes and encoder means for said axes operative to develop position signals corresponding to the actual position of said arm, the method comprising the steps of:

• moving said arm to different positions relative to a stationary workpiece during an initial teaching operation, said positions corresponding to desired operations of the manipulator relative to the stationary workpiece;
• precomputing signals representing the path of said manipulator arm to move between successive taught positions in the minimum projected elapsed time and corresponding to positions of said arm accounting for projected workpiece movement;
• and
• storing said calculated signals for use in controlling movement of said arm during playback with a moving workpiece.

The method of programming a manipulator to perform a series of operations on a workpiece while the workpiece is moving along a predetermined path, the manipulator having an arm which is movable in a plurality of axes and means for said axes operative to develop position signals corresponding to the actual position of said arm, the method comprising the steps of:

• moving said arm to different positions relative to a stationary workpiece during an initial teaching operation, said positions corresponding to desired operations of the manipulator relative to the stationary workpiece;
• precomputing signals representing the path of said arm projected for playback operations of said series of operations with a moving conveyor, said signals representing the path of said arm calculated in terms of the maximum dynamic parameters of arm movement and accounting for projected workpiece movement;
• and
• storing said precomputed signals for use in controlling movement of said arm during playback with a moving workpiece.

In programmable manipulator apparatus for performing work operations with respect to a workpiece movable along a predetermined workpiece path, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected dynamic manipulator parameters of said manipulator arm in said plurality of manipulator axes with respect to a corresponding projected workpiece position, said projected manipulator arm positions being calculated in a teaching phase in accordance with a predetermined projected workpiece velocity and a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of:

• means for reading out said command signals in a predetermined manner;
• means responsive to two successive command signals for generating a predetermined number of sequential positions, velocity and acceleration control signals for each of said manipulator axes;
• and
• means responsive to said control signals for moving said manipulator arm in accordance with movement of said workpiece.

In a programmable manipulator having a manipulator arm movable in a plurality of axes and arranged adjacent a predetermined work path to perform a series of work operations on a workpiece moving along said work path, the combination of:

• means having stored therein a first series of program work operation command signals representing positions of said manipulator arm in said plurality of axes and a second series of track alarm command signals representing positions of said manipulator arm, each of said track alarm command signals representing a predetermined static point on the workpiece at corresponding workpiece positions;
• means for detecting a predetermined improper operating mode of said manipulator arm with respect to said workpiece;
• means for controlling the sequential read out of said first series of program work operations in accordance with movement of said workpiece;
• means responsive to said first and second series of command signals for moving said manipulator arm to the positions represented by said command signals;
• and
• means responsive to said detecting means for controlling the read out of said second series of track alarm command signals.

In a programmable manipulator having a manipulator arm controllable in a plurality of axes and arranged adjacent a workpiece moving along a predetermined work path to perform a predetermined series of work operations on a workpiece moving along said work path, said manipulator arm including a work head for selective contact with said workpiece, the combination of:

• means for positioning said arm at different positions relative to a stationary workpiece during an initial teaching operation;
• means for calculating signals representing a predetermined change in orientation of said manipulator arm relative to the workpiece for work operations in contact with and tracking the workpiece movement, said predetermined change in orientation being calculated to change the orientation of said manipulator arm by said predetermined orientation change between the initial contact of said manipulator arm and the workpiece and the projected termination of the workpiece contact;
• and
• means for storing said calculated signals for use as command signals in controlling movement of said arm in a playback cycle to perform said predetermined series of work operations on the workpiece.

In a programmable manipulator having a manipulator arm movable in a plurality of axes and arranged adjacent a predetermined work path to perform a series of work operations on a workpiece moving along said work path, the combination of:

• means having stored therein a first series of program work operation command signals representing positions of said manipulator arm in said plurality of axes and one or more series of escape path signals representing positions of said manipulator arm, each of said series of escape path command signals representing a series of manipulator arm positions to withdraw said manipulator arm away from said workpiece to a predetermined position;
• means actuable by an operator for generating an escape mode signal;
• means for controlling the sequential read out of said first series of program work operations in accordance with movement of said workpiece;
• means responsive to said first series of command signals and said escape path command signals for moving said manipulator arm to the positions represented by said command signals;
• and
• means responsive to said escape mode generating means for controlling the read out of a predetermined one of said series of escape path command signals in accordance with the number of the work operation command signals at which said escape mode generating means is actuated.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle while the workpiece is moving along a predetermined path, the combination of:

• means for positioning said manipulator arm during an initial teaching operation to different locations relative to a stationary workpiece;
• predict means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions and accounting for projected playback workpiece movement without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said predict means comprising means for determining the projected minimum execution time required in each of said axes for the manipulator arm to accomplish said projected path of movement between each of said initial teaching positions accounting for projected workpiece movement and without exceeding said predetermined dynamic parameters, and means for comparing said minimum projected execution times in each of said axes to determine the axis requiring the largest projected execution time for each movement between teaching positions, said predict means utilizing said largest execution time to determine said projected path of movement between each of said initial teaching positions;
• and
• means for storing said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle while the workpiece is moving along a predetermined path, the combination of:

• means for positioning said manipulator arm during an initial teaching operation to different locations relative to a stationary workpiece defining a predetermined playback work cycle;
• predict means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions and accounting for projected playback workpiece movement without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said predict means comprising means for determining the limit axis for each movement of said manipulator arm between said successive teaching positions, said limit axis being defined as that axis requiring the greatest execution time during the projected path of movement of said manipulator arm between each of said successive initial teaching positions accounting for projected workpiece movement and without exceeding said predetermined dynamic parameters, said predict means utilizing each of said limit axis determinations to calculate said projected path of movement between each of said teaching positions to perform said projected playback work cycle in minimum projected execution time with respect to a workpiece moving at a projected velocity;
• and
• means for storing said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent to a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of:

• means for positioning said arm at different locations relative to the workpiece during an initial teaching operation;
• means for precomputing signals representing movement of said arm between said different locations relative to said workpiece corresponding to movement at the maximum dynamic capabilities of said manipulator arm;
• and
• means for storing said precomputed signals for use as command signals in controlling movement of said arm in a playback cycle.

The method of programming a manipulator to perform a series of operations on a workpiece, the manipulator having an arm which is movable in a plurality of axes and encoder means for said axes operative to develop position signals corresponding to the actual position of said arm, the method comprising the steps of:

• moving said arm to different positions relative to the workpiece during an initial teaching operation, said positions corresponding to desired operations of the manipulator relative to the workpiece;
• precomputing signals representing the path of said manipulator arm to move between successive taught positions in the minimum projected elapsed time;
• and
• storing said calculated signals for use in controlling movement of said arm during playback.

The method of programming a manipulator to perform a series of operations on a workpiece, the manipulator having an arm which is movable in a plurality of axes and means for said axes operative to develop position signals corresponding to the actual position of said arm, the method comprising the steps of:

• moving said arm to different positions relative to the workpiece during an initial teaching operation, said positions corresponding to desired operations of the manipulator relative to the workpiece;
• precomputing signals representing the path of said arm projected for playback operations of said series of operations, said signals representing the path of said arm calculated in terms of the maximum dynamic parameters of arm movement;
• and
• storing said precomputed signals for use in controlling movement of said arm during playback.

In programmable manipulator apparatus for performing work operations with respect to a workpiece, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected dynamic manipulator parameters of said manipulator arm in said plurality of manipulator axes to accomplish said work operation, said projected manipulator arm positions being calculated in a teaching phase in accordance with a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of:

• means for reading out said command signals in a predetermined manner;
• means responsive to two successive command signals for generating a predetermined number of sequential position, velocity and acceleration control signals for each of said manipulator axes;
• and
• means responsive to said control signals for moving said manipulator arm in accordance with movement of said workpiece.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of:

• means for positioning said manipulator arm during an initial teaching operation to different locations relative to a workpiece;
• means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions relative to the workpiece without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said calculating means comprising means for determining the projected minimum execution time required in each of said axes for the manipulator arm to accomplish said projected path of movement between each of said initial teaching positions relative to the workpiece without exceeding said predetermined dynamic parameters, and means for comparing said minimum projected execution times in each of said axes for each of said movements between teaching positions to determine the axis requiring the largest projected execution time, said calculating means utilizing said largest execution time to determine said projected path of movement between each of said initial teaching positions;
• and
• means responsive to said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of:

• means for positioning said manipulator arm during an initial teaching operation to different locations relative to the workpiece defining a predetermined playback work cycle;
• means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said calculating means comprising means for determining the limit axis for each movement of said manipulator arm between said successive teaching positions, said limit axis being defined as that axis requiring the greatest execution time during the projected path of movement of said manipulator arm between each of said successive initial teaching positions without exceeding said predetermined dynamic parameters, said calculating means utilizing each of said limit axis determinations to calculate said projected path of movement between each of said teaching positions to perform said projected playback work cycle in minimum projected execution time;
• and
• means responsive to said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

The method of controlling a manipulator to perform a series of operations on a workpiece, the manipulator having an arm which is movable in a plurality of axes and encoder means for said axes operative to develop position signals corresponding to the actual position of said arm, the method comprising the steps of:

• moving said arm to different positions relative to the workpiece during an initial teaching operation, said positions corresponding to desired operation of the manipulator relative to the workpiece;
• determining the path of movement with respect to time of said manipulator arm corresponding to movement of said arm between successive taught positions in the minimum execution time for each movement of said arm between successive taught positions and without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, each of said minimum execution times being obtained by determining the minimum execution time required in each of said axes for the manipulator arm to accomplish movement between each of said successive taught positions without exceeding said predetermined dynamic parameters, and utilizing the largest axis execution time for said axes to determine the minimum execution time for each of said movements of said manipulator arm between said successive taught positions;
• and
• controlling movement of said manipulator arm to perform said derived operations of the manipulator arm relative to the workpiece in said minimum execution times in response to said determined path of movement.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of:

• means for positioning said arm at different locations relative to the workpiece during an initial teaching operation representing taught arm positions with respect to the workpiece;
• means for storing position signals during said initial teaching operation representing said taught arm positions;
• workpiece deviation sensing means for generating deviation signals representing the deviation of the workpiece in a playback cycle with respect to a predetermined workpiece orientation in said initial teaching operation;
• precomputing means responsive to said generated deviation signals and said stored position signals for generating precomputed command signals during said playback cycle representing positions of said arm accounting for projected workpiece movement and accounting for the deviations of the workpiece from the predetermined workpiece orientation during the teaching operations, said generated command signals representing movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm;
• and
• means responsive to said generated command signals for controlling movement of said manipulator arm during said playback cycle.

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having encoder means for said axes operative to develop position signals corresponding to the actual position of said arm and being arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of:

• means for positioning said arm during an initial teaching operation with a stationary workpiece to different positions corresponding to the desired operations of the manipulator relative to the stationary workpiece;
• means for calculating signals during said initial teaching operation representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm;
• means for storing said position signals representing said taught arm positions;
• and
• means responsive to said stored signals for controlling movement of said arm in correlation with a moving workpiece during a playback cycle, said movement controlling means comprising means for generating signals during said playback cycle representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm.

The method of programming a manipulator to perform a series of operations on a workpiece while the workpiece is moving along a predetermined path, the manipulator having an arm which is movable in a plurality of axes and encoder means for said axes operative to develop position signals corresponding to the actual position of said arm, the method comprising the steps of:

• moving said arm to different positions relative to a stationary workpiece during an initial teaching operation, said positions corresponding to desired operations of the manipulator relative to the stationary workpiece;
• precomputing signals during said initial teaching operation representing the path of said manipulator arm to move between successive taught positions in the minimum projected elapsed time and corresponding to positions of said arm accounting for projected workpiece movement;
• and
• storing position signals representing said taught arm positions.