Off-line teaching method for industrial robot

Abstract: An off-line teaching method wherein transmission of execution data is facilitated to prevent occurrence of a transmission error and to facilitate a teaching operation and reduce the time for such teaching operation to permit construction of a fully automated production line. The method comprises the steps of teaching subdivided execution data for the working objects by way of the separate teaching system, storing the subdivided execution data thus taught, editing the subdivided execution data for each of the working objects, storing the thus edited subdivided execution data, and transmitting the execution data for each of the working objects together with an identification code of the working object to the industrial robot. The subdivided execution data are divided into information of operation of the industrial robot and working conditions for the industrial robot under the operation information. The method is applied also to a system which includes a plurality of industrial robots.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to an off-line teaching method for an industrial robot according to the preamble portion of claim 1, wherein, when working is to be performed by an industrial robot such as a welding robot, a teaching operation for the robot is not performed, but execution data which have been produced in advance by means of a separate teaching system are transported to the industrial robot to effect teaching of the robot. 2. Description of the Prior Art Conventionally, a teaching operation of a working program for an industrial robot such as a welding robot is performed by stopping a robot on a production line and moving the robot in accordance with an actual execution operation. With such teaching means, since a position of a working point of the robot is stored as coordinates on a robot coordinate system, wherein a reference position fixed with respect to the robot is set as the origin, when it is intended to perform a same working program for a same work piece (object for the working) but on a different robot, if the relationship between installation positions of the work piece and the robot is different, then a teaching operation must be performed for the individual robot. Consequently, much labor is required for a teaching operation. Further, if working steps are increased or the number of kinds of objects for the working is increased, then data may not be stored in a program memory of the robot because the amount of data is too great. Consequently, such an operation is necessitated to replace the program (execution data) from an external storage device by manual operation. Accordingly, it is difficult to construct an automated line such as an FMS (Flexible Manufacturing System) which automatically performs a series of working steps. Thus, in recent years, teaching means including an off-line teaching system which makes use of a computer has been and is being employed progressively in order to improve the operation rate and facilitate a teaching operation of a robot. For example, as shown in Fig. 8 representing the state of the art according to the preamble portion of claim 1, a personal computer 3 which serves as a separate teaching system is connected to a control panel 2 for controlling a welding robot 1 so that the control panel 2 may control the welding robot 1 in accordance with execution data (a program) which have been produced in advance using the personal computer 3. In such an off-line teaching system, using the personal computer 3, block data and so forth are produced in which (1) a teaching program or programs indicative of working contents of the robot 1, (2) working conditions which may be used at various working steps in the teaching program or programs (welding conditions of a data bank and so forth) and, (3) an effective order of a plurality of teaching programs, are gathered for individual work pieces. Then, when the robot 1 is to perform its working, the execution data (1) to (3) are transmitted from the personal computer 3 to the control panel 2. However, with the conventional off-line teaching method for an industrial robot described above, since the transmission of such execution data (1) to (3) from the personal computer 3 to the control panel 2 is executed one by one in accordance with a designation of the individual data by an operator, where there are a large number of data to be transmitted, the operation for such transmission is very complicated and a designation error of a data name may take place likely. In addition, in an automated line such as a FMS which is to cope with various work pieces, the amount of execution data is very great. Accordingly, it is difficult to construct an automated line where the conventional technique is employed. Further, in recent years, an automated line such as a FMS has been and is being developed which includes a plurality of robots so as to cope with various work pieces. One of the off-line teaching methods for executing teaching of such a system which includes a plurality of robots using a separate teaching system is conventionally disclosed in Japanese Patent Laid-Open No. 62-108314. According to the conventional method, a series of execution data for each of the robots with regard to various work pieces are described and produced on a work coordinate system with reference to the work piece using the separate teaching system. Then, in order to convert such execution data into coordinate data of a robot coordinate system with reference to each robot or into coordinate data of a reference coordinate system with reference to a working space in which the robots are installed, coordinate transformation matrices are calculated and stored in a memory. With the conventional off-line teaching method for a system which includes a plurality of robots, coordinate transformation matrices between three kinds of coordinate systems must be calculated and stored. Such operation is very complicated, and much labor and time is required for a teaching operation. Further, the document EP-A-0 067 446 discloses a robot control data processing apparatus comprising a robot control data dividing processor for dividing robot control data adapted for monitoring and controlling robots into a plurality of divisional operation elements and storing the robot control data in unit of the operation element, and a robot control data editing processor for selectively combining and editing one or more of the plurality of the divisional operation elements. The robot control data consists of operation sequence data which instruct the sequence of operations of the robot, and position data which instruct positions at which the operations are performed, wherein the operation sequence data are input from a source program whilst the position data are input by on-line teaching. Furthermore, the document EP-A-0 346 839 discloses a system for teaching, controlling and monitoring industrial robots which includes a storage section comprising a first storage means for storing data describing working positions and a second storage means for storing data describing motion patterns of the robots, as well as a teaching section for automatically preparing teach data of each robot by selecting one of the different working positions and one of the motion patterns for the robot in accordance with the type of work. SUMMARY OF THE INVENTION Accordingly, the object of the present invention is to further develop the known off-line teaching methods to the effect that the transmission of execution data to the industrial robot is facilitated to prevent the occurrence of transmission errors. This object is solved by the features indicated in the characterizing portion of claim 1. An advantageously developed embodiment of the invention is subject-matter of claim 2. According to the invention, the off-line teaching method is characterized by the steps of editing the taught and stored execution data for each of the work pieces so that the individual, edited execution data comprises block data each including names of several processing programs which are registered in accordance with an order in which they are to be executed, processing programs each including several steps having a name of processing condition data to be executed at the respective step, and processing condition data each including various set processing conditions, storing the thus edited execution data, setting the name of the industrial robot to which the edited execution data are to be transmitted, the name of the respective work piece and the name of the respective block data, and transmitting the edited execution data for each of the work pieces together with an identification code of the work piece to the industrial robot, wherein, firstly, the designated block data are transmitted, secondly, all of the processing programs registered in the designated block data are transmitted, and, thirdly, all of the processing condition data registered in the transmitted processing programs are transmitted. As a result, the transmission of the execution data is remarkably facilitated by the claimed hierarchical structure of the execution data, whilst the occurrence of a transmission error is reliably prevented due to the fact that the execution data is transmitted in accordance with the above hierarchical structure. Preferably, a reference coordinate system is set in a working space in which the industrial robot is installed while a position of a working point of the industrial robot is described in the execution data in accordance with the reference coordinate system, and a coordinate transformation matrix for coordinate transformation from the reference coordinate system to a robot coordinate system with reference to the individual industrial robot is taught in advance, and then, when the execution data are to be transmitted to the industrial robot, the position of the working point of the industrial robot described in the execution data in accordance with the reference coordinate system is converted into a position of a working point of the robot coordinate system using the coordinate transformation matrix. With the off-line teaching method. only two kinds of coordinate systems are required including the reference coordinate system and the robot coordinate system for the individual industrial robot. Besides, even if the positional arrangement between one of the industrial robots and a work piece is varied, this can be coped with by re-setting the corresponding coordinate transformation matrix. The above and other features and advantages of the present invention will become apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a block diagram illustrating the structure of execution data stored in a memory in accordance with an off-line teaching method for an industrial robot according to an embodiment of the present invention; Fig. 2 is a flow diagram illustrating the structure of execution data upon transmission of the data: Fig. 3 is a flow chart illustrating a transmitting operation of execution data: Fig. 4 is a flow chart illustrating a coordinate transformation procedure according to the off-line teaching method: Fig. 5 is a diagrammatic perspective view showing a reference coordinate system and a robot coordinate system according the off-line teaching method: Fig. 6 is a flow diagram showing a system to which the off-line teaching method is applied: Fig. 7 is a flow diagram showing a welding FMS to which the off-line teaching method is applied: and Fig. 8 is an illustration showing a conventional off-line teaching system. DESCRIPTION OF THE PREFERRED EMBODIMENTS An off-line teaching method for an industrial robot according to the present invention is applied to a welding robot as an example of an industrial robot in an embodiment of the invention described below. Referring first to Fig. 1. execution data for various kinds of work pieces are entered by way of a personal computer 3 (refer to Figs. 6 to 8) serving as a separate teaching system and are stored into a storage device such that they are gathered for individual kinds of work pieces with individual work names applied thereto. The execution data for each of kinds of work pieces include working programs (operation information for a robot) 1 to m and welding condition data (working conditions under each piece of the operation information) 1 to n. Here, referring to Fig. 2, each of the working programs 1 to m includes several steps 1 to i each having a name of welding condition data to be executed at the step while each of the welding condition data 1 to n includes various set welding conditions such as a welding current. a welding voltage and a welding speed. Further, the individual execution data are stored in an edited condition as block data 1 to ℓ for each work piece as seen in Figs. 1 and 2. Each of the block data 1 to ℓ includes names of several working programs which are to be executed by a robot 1 or robots 1a, 1b and 1c (refer to Figs. 5 to 8) and are registered in an edited condition in accordance with an order in which they are to be executed. Accordingly, when execution data for individual work pieces are to be transmitted to the robot 1 or robots 1a to 1c, or more particularly to control panels 2, 2a, 2b and 2c of the robot 1 or robots 1a to 1c, a name of a robot to which data are to be transmitted, a name of a work piece and a name of block data are set. In response to such setting, the personal computer 3 serving as an off-line teaching system performs transmission of execution data in accordance with a flow of operations shown in Fig. 3. In particular, designated block data are first selected and transmitted to a designated robot 1 or 1a, 1b or 1c (step A1). Then, all of the working programs registered in the designated block data are transmitted (step A2), and finally, all of the welding condition data registered in the transmitted working programs are transmitted (step A3). Meanwhile, in the off-line teaching method of the embodiment, a reference coordinate system O o -xyz (refer to Figs. 5 and 6), wherein a reference position O o in a working space in which each of a plurality of welding robots 1a to 1c (three in the embodiment shown) is installed, is set as the origin as shown in Fig. 6, using the personal computer 3 serving as a separate teaching system (refer to step B1 of Fig. 4). Then, a position T I of a working point of a welding torch 1A of the robot 1 or each of the robots 1a to 1c with respect to a work piece W is described as a position coordinate [P I ] (i is a number of a teaching point) on the reference coordinate system 0 o -xyz and is taught as execution data to be stored by the personal computer 3 (refer to step B2 of Fig. 4). A coordinate transformation matrix [S] J (j is a number of a robot, and j = 1 to 3 in the present embodiment) for the coordinate transformation from the reference coordinate system O o -xyz to a robot coordinate system O R -xyz, wherein a reference position O R of the robot 1 or each of the robots 1a to 1c is set as the origin (refer to Figs. 5 and 6), is actually measured for the robot 1 or each of the robots la to lc and is taught in advance by the personal computer 3 so as to be stored in the memory (refer to step B3 of Fig. 4). Since such teaching of data is performed in advance, when execution data are to be transmitted to the individual robot 1 or robots 1a to 1c, a working point position [P I ] of the robot 1 or each of the robots 1a to 1c on the reference coordinate system O o -xyz is converted into a working point position [R I ] J (= [S] J [P I ]) on a robot coordinate system O R -xyz for the robot 1 or each of the robots 1a to 1c (refer to step B4 of Fig. 4). Accordingly, where the three welding robots 1a to 1c having different installation data S on the reference coordinate system O o -xyz are connected to the off-line teaching system of the present embodiment as shown in Fig. 6, if coordinate transformation matrices [S] J (j = 1 to 3) for the coordinate transformation between the robot coordinate systems O R -xyz of the individual robots la to lc and the reference coordinate system O o -xyz are set at step B3, then execution data on a robot coordinate system of each of the robots 1a to 1c can be calculated readily in accordance with the execution data [P I ] common to the three robots 1a to 1c. In this manner, according to the method of the present embodiment, since necessary data are edited and stored as block data for individual works, only if predetermined block data are selected for each work piece, necessary data are all transmitted in such a hierarchical structure as shown in Fig. 2 to the the robot 1 or robots 1a to 1c. Accordingly, transmission of execution data is facilitated remarkably, and consequently, occurrence of a transmission error is prevented with certainty and edition, and management of data can be performed readily. Further, in the method of the embodiment, only two kinds of coordinate systems including the reference coordinate system O o -xyz and the individual robot coordinate systems O R -xyz are required, and consequently, a teaching operation to the three robots 1a to 1c can be performed readily in a short period of time. Further, even if the positional arrangement between one of the individual robots 1a to 1c and the work piece W thereof is varied, it is easy to cope with such variation by re-setting the corresponding coordinate transformation matrix [S] J , and execution data on the coordinate systems of the individual robots 1a to 1c can be obtained readily from the common execution data [P I ]. Accordingly, construction of a fully automated production line such as a FMS which involves transmission of a large amount of data is permitted. Subsequently, a particular welding FMS to which the method of the embodiment described above is applied will be described with reference to Fig. 7. The welding FMS shown includes three welding robots 1a to 1c connected to be controlled by way of control panels 2a to 2c, respectively, a personal computer (off-line teaching system) 3 which transmits execution data to the control panels 2a to 2c in such a manner as described above, three sliders 4a to 4c for adjusting the positions of the robots 1a to 1c, respectively, three positioners 5a to 5c for adjusting the positions of work pieces of the robots 1a to 1c, respectively, a work piece transporting device 6 for transporting a work piece (not shown) from a work piece carrying in table 7a to one of the positioners 5a to 5c at working positions of the robots 1a to 1c, a work piece carrying out table 7b for receiving a work piece after working from the work piece transporting device 6 and carrying away the work piece, a transporting device control panel 8 for controlling the work piece transporting device 6, a work piece setter 9 for detecting and setting a work piece carried in, and a computer 10 for the production control for controlling the entire system including the personal computer 3 and the transporting device control panel 8. In the welding FMS having such construction as described above, an operator will place a work piece onto the work piece carrying in table 7a and enter a name of the work piece and a name of block data into the computer 10 for the production control by way of the terminal device, that is, the personal computer 3. Thus, the computer 10 for the production control detects an inoperative one of the three welding robots la to lc and instructs the work piece transporting device 6 of transportation of the work piece to the working position (positioner 5a, 5b or 5c) of the inoperative robot while it transmits, to the personal computer 3 serving as an off-line teaching system, the name of the work piece, the name of the block data and a number of the robot to which the data are to be transmitted. Consequently, the work piece transporting device 6 carries in the work piece to the positioner of the designated robot while the personal computer 3 selects execution data corresponding to the thus received work piece name and block data name from within its memory device and transmits the selected execution data to the control panel 2a, 2b or 2c of the designated robot. In this instance, the personal computer 3 converts working point positions [P I ] in the execution data described on the reference coordinate system O o -xyz into position coordinates [R I ] J = [S] J [P I ] of the robot coordinate system of the designated robot using the coordinate transformation matrix [S] J for the designated robot and transmits them to the control panel 2a, 2b or 2c of the designated robot. The designated robot 1a, 1b or 1c thus performs, after the carrying in of the work piece is completed, a welding operation to the work piece in accordance with the execution datatransmitted thereto. Then, after a welding completion signal is received from the designated robot, the computer 10 for the production control transmits a work piece carrying out instruction to the work piece transporting device 6, and consequently, the work piece is carried out to the work piece carrying out table 7b by the work piece transporting device 6 after completion of welding. In this manner, with the welding FMS to which the method of the present invention is applied, fully automatic welding can be performed only if an operator supplies a work piece and enters a work piece name and a data block name. It is to be noted that, while the industrial robot in the embodiment described above is described being a welding robot, the method of the present invention is not limited to this and can be applied similarly to various other types of robots. Further, while the case wherein three robots are involved is described in the embodiment, the present invention is not limited to this. Particularly, the transmission procedure of execution data described hereinabove with reference to Figs. 1 to 3 can be applied not only to the case in which a plurality of industrial robots are involved but also in a similar manner to the other case in which only one industrial robot is involved. Also in the latter case, similar effects to those of the embodiment described above can be achieved.

Claims: An off-line teaching method for at least one industrial robot (1; 1a, 1b, 1c), according to which execution data with which a predetermined processing of various work pieces (W) is to be performed by said industrial robot (1; 1a, 1b, 1c) are produced in advance by way of a separate teaching system (3), and, when the processing is to be executed by said industrial robot (1; 1a, 1b, 1c), the thus produced execution data are transmitted to said industrial robot (1; 1a, 1b, 1c) to teach the latter, said method comprising the steps of teaching said execution data for the work pieces (W) by way of said separate teaching system (3), said execution data including processing programs (1 to m) and processing condition data (1 to n) for each step (1 to i) of said respective processing program (1 to m), and storing said execution data thus taught, said method being characterized by the steps of editing said execution data for each of said work pieces (W) so that said individual, edited execution data comprises block data (1 to 1) each including names of several processing programs (1 to m) which are registered in accordance with an order in which they are to be executed, processing programs (1 to m) each including several steps (1 to i) having a name of processing condition data (1 to n) to be executed at the respective step (1 to i), and processing condition data (1 to n) each including various set processing conditions, storing the thus edited execution data, setting the name of the industrial robot (1; 1a, 1b, 1c) to which said edited execution data are to be transmitted, the name of the respective work piece (W) and the name of the respective block data (1 to 1), and transmitting said edited execution data for each of said work pieces (W) together with an identification code of said work piece (W) to said industrial robot (1; 1a, 1b, 1c), wherein, firstly, the designated block data (1 to 1) are transmitted (step A1), secondly, all of said processing programs (1 to m) registered in said designated block data (1 to 1) are transmitted (step A2), and, thirdly, all of said processing condition data (1 to n) registered in said transmitted processing programs (1 to m) are transmitted (step A3). An off-line teaching method according to claim 1, wherein a reference coordinate system (O o-xyz ) is set in a working space in which said industrial robot (1; 1a, 1b, 1c) is installed while a position ([P i ]) of a working point of said industrial robot (1; 1a, 1b, 1c) is described in said execution data in accordance with said reference coordinate system (O o-xyz ), wherein a coordinate transformation matrix ([S] j ) for coordinate transformation from said reference coordinate system (O o-xyz ) to a robot coordinate system (O R-xyz ) with reference to said individual industrial robot (1; 1a, 1b, 1c) is taught in advance, and wherein, when said execution data are to be transmitted to said industrial robot (1; 1a, 1b, 1c), said position ([P i ]) of said working point of said industrial robot (1; 1a, 1b, 1c) described in said execution data in accordance with said reference coordinate system (O o-xyz ) is converted into a position ([R i ] j ) of a working point of said robot coordinate system (O R-xyz ) using said coordinate transformation matrix ([S] j ).

Inventors: MURAKAMI TSUDOI, SEKINO TERUYOSHI, MURAKAMI, TSUDOI, SEKINO, TERUYOSHI
Applicants: KOBE STEEL LTD, KABUSHIKI KAISHA KOBE SEIKO SHO ALSO KNOWN AS KOBE STEEL LTD.
Application year: 1990
Main classification: G05B19
IPC codes: G05B19, B25J9, B23K9