Abstract:
Disclosed here is a method for controlling at least one industrial device using a remote infrastructure environment having at least one computing resource and a cloud communication network. The method includes establishing communication between the at least one industrial device and the remote infrastructure environment, transmitting data from the at least one computing resource using the cloud communication network to a plant communication network, the at least one industrial device configured to perform at least one predetermined function in response to at least a portion of the transmitted data and receiving data from the at least one industrial device by the at least one computing resource using the cloud communication network, the received data generated in response to performance of the at least one predetermined function.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/160,893, filed Mar. 17, 2009 and claims priority to U.S. Provisional Patent Application No. 61/294,265, filed Jan. 10, 2010, both of which are hereby incorporated by reference in their entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention generally pertains to systems and methods for industrial communication and more specifically, industrial communication through a remote infrastructure environment. 
       BACKGROUND 
       [0003]    An assembly line in a manufacturing facility typically includes multiple automated robots. The robots can include connectors on ends of their wrists for receiving respective end effectors, and each robot is in communication with a respective control system that controls the operation of the robot and the end effector. Each control system typically includes a programmable logic controller (PLC), which is programmed to control its robot and end effector to perform a specific operation or set of operations. For example, a control system coupled to a robot carrying a welding end effector may be programmed to control the robot to move the welding end effector into a specific position and to actuate the welding end effector once in the specific position. In this example, the control system can be programmed to control movement of the robot in three dimensions and rotation of the robot in up to three dimensions, as well as actuation of the end effector. 
         [0004]    However, the assembly line may be reconfigured in order to, for example, accommodate a different type of work piece. Reconfiguring the assembly line typically requires that the operations performed by many of the robots and end effectors be changed. As a result, many of the control systems must be re-programmed to control their respective robots and end effectors in a different manner. For example, if a welding end effector is removed from a robot and replaced with clamping end effector, the control system must be updated to properly control the robot and clamping end effector. As another example, the control system may need to be reprogrammed if operation performed by the end effector differs in any way, such as in duration or location, even if the end effector remains the same. 
         [0005]    Apart from reprogramming, control systems employing these on-site PLCs (i.e. PLCs physically located at the manufacturing facility) typically, for example, increase the costs of the manufacturing facility. Further, as discussed previously, reprogramming and/or performing maintenance on each PLC can be time-consuming and can reduce the efficiency of the assembly line. 
       SUMMARY 
       [0006]    Embodiments of a method for controlling at least one industrial device using a remote infrastructure environment having at least one computing resource and a cloud communication network are disclosed herein. In one such embodiment, the method includes establishing communication between the at least one industrial device and the remote infrastructure environment and transmitting data from the at least one computing resource to a plant communication network using the cloud communication network. The at least one industrial device is configured to perform at least one predetermined function in response to at least a portion of the transmitted data. The method also includes receiving data by the at least one computing resource from the at least one industrial device using the cloud communication network. The received data is generated in response to performance of the at least one predetermined function. 
         [0007]    Embodiments of a method for communicating with at least one industrial device using a remote infrastructure environment having at least one computing resource and a cloud communication network. The method includes establishing communication between the at least one industrial device and the remote infrastructure environment and receiving data by the at least one industrial device from the at least one computing resource using a plant communication network. Further, the method includes performing at least one predetermined function in response to at least a portion of the received data. The method also includes transmitting data to the at least one computing resource from the at least one industrial device using the cloud communication network. The transmitted data is generated in response to performance of the at least one predetermined function. 
         [0008]    Embodiments of an industrial device for communicating with a remote infrastructure environment having at least one computing resource and a cloud communication network are also disclosed herein. In one such embodiment, the device includes a network interface for establishing communication with a plant communication network and a controller. The controller is configured to receive data from the at least one computing resource and perform at least one predetermined function in response to at least a portion of the received data. The controller is also configured to transmit data to the at least one computing resource through the plant communication network. The transmitted data is generated in response to performance of the at least one predetermined function. The plant communication network is also operatively coupled to the cloud communication network to transfer the transmitted data. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
           [0010]      FIG. 1  is a schematic view of an industrial communication system; 
           [0011]      FIG. 2  is a top plan view of an assembly line; 
           [0012]      FIG. 3  is a schematic view of a robot; and 
           [0013]      FIG. 4  is a schematic view of an end effector. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Examples of an industrial communication systems for communicating to industrial appliances are described herein with references to  FIGS. 1-4 . As shown in  FIG. 1 , an industrial communication system  100  can include a remote infrastructure environment  8  having one or more computing resources  10  and a cloud communication network (e.g. Internet) in communication with a plant server  12 . The plant server  12  can be in communication via a plant communication network  14  (e.g. a local area network (LAN) with various industrial devices or appliances. For example, industrial devices or appliances can be a first robot  16 , a first end effector  18 , a second robot  20 , a second end effector  22 , and/or additional robots, end effectors or other industrial devices not shown in  FIG. 1 . Alternatively, or in addition to the plant server  12  being in communication with plant communication network  14 , the industrial system  100  can be in direct communication with the cloud communication network  11  to send data to and/or receive data from the industrial appliances. Both the cloud communication network  11  and the plant server  12  can communicate data to visual and/or audible display  22 . 
         [0015]    As shown in  FIG. 2 , a manufacturing plant  44  can include one or more assembly lines  46 , each of which has one or more workstations  48  where work pieces (not shown) are processed. The industrial appliances, here the first robot  16 , its first end effector  20 , the second robot  18 , and its second end effector  22 , can be positioned sufficiently close to the assembly line  46  to process a work piece at the workstation  48 . The plant server  12  can also be located within the manufacturing plant  44 . 
         [0016]    Referring back to  FIG. 1 , the computing resource  10  can be hardware, software or any combination thereof. In one embodiment, the cloud resource is a remote server including a microprocessor and memory with software stored thereon. The computing resource  10  can also be, as non-limiting examples, a PLC, a laptop computer, a desktop computer, a workstation, a handheld device, microprocessor, a storage database or any combination thereof. Of course, other cloud resources are available and other embodiments may use any other suitable device, combination of devices. Similar to the function of the PLC as described previously, the computing resource  10  can be used to control the operation of the industrial appliances such as the first robot  16 , its first end effector  20 , the second robot  18 , and its second end effector  22 . 
         [0017]    Generally, conventional manufacturing plants use on-site PLCs to control the industrial appliances located therein. By some or all eliminating PLCs from the manufacturing plant  44  (i.e. PLCs that are physically located at the manufacturing plant), a manufacturing plant can, for example reduce costs by no longer having to provide and maintain the hardware (i.e. PLC) and software to programmed thereon to control the industrial appliances. Of course, in some embodiments, manufacturing plants  44  may still contain one or more PLCs controlling some industrial appliances whereas other appliances will be communicating with the remote infrastructure environment  8  without the use of a PLC. 
         [0018]    Further, the elimination of some or all PLCs in a manufacturing plant can increase the plant&#39;s operating efficiency by having the capability to remotely control and communicate from the cloud communication network  11  to the industrial appliances. Further, the operating efficiency of the can also be increased by having the capability, as will be discussed in more detail below, to simultaneously talk to the robots and their associated end effectors (e.g. first robot  16  and end effector  18 ). 
         [0019]    As discussed previously, the computing resource  10  can be in communication with the plant server  12  and/or the industrial appliances via, for example, the cloud communication network  11 . The computing resource  10  and cloud communication network  11  may be based on a public, private, hybrid computing model or any other suitable computing model. In a public computing model, the computing resource  10  can be run or managed by a third party entity and made available to a group of unrelated or related customers, companies organizations and/or other entities. For example, in one public computing model, the computing resource  10  can be run or managed by a manufacturer of industrial appliances that supplies these appliances to different manufacturing plants. As such, the computing resource  10  (e.g. servers, storage systems, and network resources) can be shared by the customers and can used to communicate with industrial appliances in different and/or unrelated plants. However, for example, even in a public computing model, a particular plant may have its own private cloud resources, which may not be available for use by other plants. 
         [0020]    In a private computing model, the computing resource  10  can be built for the exclusive use of one customer, organization or other entity. For example, in one private computing model, the computing resource  10  can be run or managed by a company owning multiple manufacturing plants. The private computing model can be hosted by the particular company itself or a third party entity. Private computing models permit a customer, organization or other entity to have a high level of control over the cloud resources  10 . 
         [0021]    The computing resource  10  may be located at any suitable location regardless of whether a public, private and hybrid computing model is employed. For example, the cloud resource, the computing resource  10  can be hosted at a location remote from a manufacturing plant or at the plant itself. As discussed previously, the cloud resource can be located at a facility operated by a manufacturer of industrial appliances or at a facility of a company owning multiple manufacturing plants. Of course, the computing resource  10  may be hosted at any other suitable location. 
         [0022]    Although, as described previously, cloud communication network  11  may be the Internet, cloud communication network  11  may also be any other suitable communication protocol or infrastructure. For example, in other embodiments, cloud communication network  11  can be a virtual private network, a private network (e.g. Multiprotocol Label Switching), a point-to-point network or any other suitable network or any combination thereof. 
         [0023]    Additionally, the computing resource  10  can be in communication with multiple plant servers  12 , such as plant servers  12  located at different manufacturing plants or with the industrial appliances located at the different manufacturing plants. Similarly, more than one computing resource  10  can be in communication with a single plant server  12  or the industrial appliances. The memory of the computing resource  10  can be loaded with various types of information, such as operational instructions and software updates for one or more industrial appliance. Thus, the computing resource  10  can transmit information, such as industrial appliance software and/or maintenance updates and industrial appliance operating instructions, to the plant server  12 . The computing resource  10  can also transmit this information directly to the industrial appliances. Additionally, the computing resource  10  can receive information from each plant server  12  or directly from the industrial appliances. Information received by the computing resource  10  from the plant server  12  or the industrial appliances can be used, as examples, to monitor the efficiency and condition of the industrial appliances. 
         [0024]    The plant server  12  can be a server including a microprocessor and memory with software stored thereon. In addition to receiving information from the computing resource  10 , the plant server  12  can receive information locally, such as by manually entering the information into the plant server  12 , by uploading information to the plant server  12  using an information storage device such as a CD-ROM drive or a portable hard-drive, or by transferring information to the plant server  12  from a computer via the plant communication network  14 . The plant server  12  can communicate information to/from the industrial appliances (e.g., the first robot  16 , the first end effector  18 , the second robot  20 , and the second end effector  22 ) via the plant communication network  14  as is discussed below in greater detail. 
         [0025]    As discussed previously, the plant communication network  14  can be a LAN and can include, as examples, one or more wireless routers for communication based on IEEE standard 802.11 (also known as Wi-Fi) and/or components such as hubs, routers, switches, bridges, and wires for communication based on IEEE standard 802.3 (also known as Ethernet). The plant communication network  14  can enable communication from the plant server  12  to the industrial appliances, such as the first robot  16 , first end effector  18 , second robot  20 , and second end effector  22  as shown in  FIG. 1 . Also, instead of the LAN, another type of communication system can be used for communication between the plant server  12  and the industrial appliances, such as a CAN (Campus Area Network) if, for example, the manufacturing plant  44  is of sufficient size to warrant the use of the CAN. 
         [0026]    Display  22  can provide information regarding information/data collected from or sent to the industrial appliances, status reports of the industrial appliances, maintenance management information any other information as desired or required. Display  22  can be located within the manufacturing plant  44  or at a location remote therefrom. Although only one display  22  is shown, the industrial communication system  100  many include more than one display or no displays as desired or required. The display  22  can be configured by a user to display all of the information related to industrial appliances in the manufacturing plant  44  (or other plants) or can be configured to display only a subset of that information. Of course, other suitable displays are available. 
         [0027]    Known control systems for controlling robots and end effectors can have many drawbacks. For example, reprogramming each control system when changing end effectors or other changing the operation performed by the robot can be inefficient. 
         [0028]    Embodiments described herein can have many advantages over known control systems for robots. For example, efficiency can be improved because an end effector can be programmed prior to installation on a robot. As another example, software updates, such as updates providing new instructions, can easily be communicated to robots and/or end effectors to enable an assembly line along which the robots and end effectors are positioned to be more efficiently reconfigured. 
         [0029]    As shown in  FIG. 3 , the first robot  16  can include a robot control system  17 , which can be coupled directly to the robot  16  (e.g., to a base, an arm, or a wrist of the robot  16 ) or can be disposed adjacent to the robot  16 . The robot control system  17  can include a wireless card  24  for communication with the plant server  12  via the plant communication network  14 . The robot control system (RCS)  17  can alternatively include another type of network interface card (NIC), such as an Ethernet card, depending on the configuration of the plant communication network  14 . The wireless card  24  can be in communication with a CPU  26  for transmitting information received from the plant server  12  to the CPU  26 . The CPU  26  can be a microprocessor, and the CPU  26  can be in communication with a memory  28 . The memory  28  can be RAM, ROM, a hard-drive, or another type of memory. The CPU  26  can communicate information received from the wireless card  24  to the memory  28  for storage thereon. Additionally, the CPU  26  can retrieve information stored on the memory  28 , and the CPU  26  can execute software stored on the memory  28 . For example, the CPU  26  can execute a robot control program stored on the memory  28  and including instructions for controlling the robot  16  to move the end effector  18  into a predetermined position or along a predetermined path. Further, the RCS  17  can use its wireless card  24  to communicate with other devices, such as other industrial appliances, via the plant communication network  14 . 
         [0030]    Still referring to  FIG. 3 , the robot  16  can additionally include at least one servo, such as a first servo  30  and a second servo  32 , for generating forces that move the robot  16 . For example, activation of the first servo  30  can cause rotation of the robot  16  about its base, while activation of the second servo  32  can cause rotation of a wrist of the robot  16  relative to an arm of the robot  16 . The CPU  26  of the RCS  17  can be in communication the servos  30  and  32 . As a result, the RCS  17  can control the servos  30  and  32 , thereby controlling movement of the robot  16 . Additional servos can be included for additional movement of the robot  16  (e.g., the robot  16  can have six degrees of freedom and can have six servos, one corresponding to each degree of freedom), and the RCS  17  can be in communication with the additional servos to control operation of the additional servos. Further, the RCS  17  can be in communication with additional components not shown in  FIG. 3 , such as one or more sensors for detecting the position of the first robot  16 . The second robot  20  can also include one of the RCSs  17  and at least one servo, such as servos  30  and  32 . 
         [0031]    As shown in  FIG. 4 , the first end effector  18  can include an end effector control system or end effector control unit (EECU)  19 . The first end effector  18  and the EECU  19  can be packaged together such that they form an integral unit. As example, the EECU  19  can be installed in a housing on an exterior of the end effector  18 , or the EECU  19  can be housed within an exterior casing of the end effector  19 . The EECU  19  can include a wireless card  34  for communication with the plant server  12  or the cloud communication network  11  via the plant communication network  14 . The EECU  19  can alternatively include another type of network interface card (NIC), such as an Ethernet card, depending on the configuration of the plant communication network  14 . The wireless card  34  can be in communication with a CPU  36  for transmitting information received from the plant server  12  to the CPU  36 . The CPU  36  can be a microprocessor, and the CPU  36  can be in communication with a memory  38 . The memory  38  can be RAM, ROM, a hard-drive, or another type of memory. The CPU  36  can communicate information received from the wireless card  34  to the memory  38  for storage thereon. Additionally, the CPU  36  can retrieve information stored on the memory  38 , and the CPU  36  can run software stored on the memory  38 . For example, the CPU  36  can execute an end effector control program stored on the memory  38  and including instructions for controlling the end effector  18 . Further, the EECU  19  can communicate with other industrial appliances, such as the RCS  17 , via the plant communication network  14 . 
         [0032]    Still referring to  FIG. 4 , the first end effector  18  can additionally include a tool  40 . The tool  40  can be a device for operating on a work piece, such as a welding gun, a clamp, an adhesive applicator, a paint sprayer, or a stud welder. The EECU  19  can be in communication with the tool  40  to control the operation of the tool  40 . The first end effector  18  can also include other components, such as one or more of a timer  41  for determining the duration of time that the tool  40  operates (alternatively, the CPU  36  can perform a timing function), one or more servos  42  for moving or actuating the tool  40 , and one or more sensors  43  for detecting the operation of the tool  40 . Depending on the type of tool  40 , the sensor  43  can detect whether the tool  40  is in an “on” state or an “off” state, the progress of the tool  40  in performing an operation, the efficiency of the tool  40 , and/or another status of the tool  40 . Each of the timer  41 , servo  42  and sensor  43  can be in communication with the CPU  36 , and the CPU  36  can actuate the servo  42  to control the tool  40  in response to the end effector control program with input from the timer  41  and sensor  43 . Depending on the type of tool  40 , another tool actuating device can be included instead of or in addition to the servo  42 . For example, a pneumatic device, a motor, a valve, and/or an electrical circuit for activating the tool  40  can be included instead of or in addition to the servo  42 . The second end effector  22  can also include one of the EECUs  19  and other components such as the tool  40 , timer  41 , servo  42  and/or sensor  43 . 
         [0033]    Due to the inclusion of the EECU  19 , as well as any of the timer  41 , servo  42  and sensor  43  that are included, the first end effector  18  can be a self-contained unit that can control its own function. The end effector  18  can thus rely on the first robot  16  solely for positioning the end effector  18 . The end effector  18  need not necessarily receive a control signal originating from a controller that also controls the robot  16 . That is, separate and independently functioning control systems, the RCS  17  and the EECU  19  in the examples shown in  FIGS. 2 and 3 , can control the first robot  16  and the first end effector  18  carried by the first robot  16 , respectively. Though the operation of the EECU  19  can be independent of the RCS  17  and the end effector  18  can rely on the robot  16  solely for positioning, it is also possible for the EECU  19  and RCS  17  to communicate with each other via the plant communication network  14  or other communication system as mentioned above. For example, the RCS  17  can communicate the position of the robot  16  and/or end effector  18  to the EECU  19 , which can take the position of the robot  16  and/or end effector  18  into consideration when controlling the tool  40 . Further, the RCS  17  and EECU  19  of the first robot  16  and first end effector  18  can communicate with industrial appliances other than each other, such as the RCS  17  and EECU  19  of the second robot  20  and second end effector  22 . As a result, the RCS  17  and EECU  19  of the second robot  20  and second end effector  22 , respectively, can control their respective industrial appliances based on input received from the RCS  17  and/or EECU  19  of the first robot  16  and first end effector  18 , respectively. 
         [0034]    Additionally, the plant server  12  can update software and operating instructions, among other information, on the memory  28  of the RCS  17  and the memory  38  of the EECU  19  by communicating with the RCS  17  and EECU  19  via the plant communication network  14 . The plant server  12  can communicate independently with the each RCS  17  and EECU  19 . Thus, different industrial appliances can be updated or receive new operating instructions independently from other industrial appliances, though different updates and new information can be transferred simultaneously to multiple industrial appliances. Communication between the plant server  12  and the robots  16  and  20  and end effectors  18  and  22  can be beneficial for multiple reasons. For example, new operating instructions can be provided if the assembly line  46  is reconfigured, such as by changing the operations performed by the robots  16  and  20  or their end effectors  18  and  22 , respectively, to process a different type of work piece. As another example, instructions can be updated if a bug is discovered in a previous version of the instructions, or if one of the robots, robot  16  for example, malfunctions and an adjacent robot, robot  20  for example, can be reconfigured to perform the same operation via a robot control program update and/or end effector change. 
         [0035]    Updating instructions on the robots  16  and  20  and/or end effectors  18  and  22  via the plant communication network  14  can also increase the efficiency of the manufacturing plant  44 . For example, the end effector  18  can be programmed to perform a certain function prior to installation on the robot  16 , such as if the end effector  18  is replacing a previous end effector. The end effector  18  can be reprogrammed while being transported to the robot  16  on an automated guided vehicle, or while in a storage facility. Thus, once the end effector  18  is installed, the robot  16  and end effector  18  can begin performing operations. Additionally, having the server  12  with the ability to control all robots  16  and  20  and end effectors  18  and  22  can increase the efficiency of the assembly line  44  because all control systems can be accessed from a single location (i.e., the server  12 ). 
         [0036]    The above-described examples have been described in order to allow easy understanding of the invention and do not limit the invention. On the contrary, the invention is intended to cover various modifications and equivalent arrangements, whose scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structure as is permitted under the law.