Abstract:
In a method to test a brake of a robot that has a number of axes, an actuator associated with one of the axes, a brake associated with this axis that is set up to at least reduce a movement of this axis, and a torque sensor associated with this axis, which determines the torque acting on this axis. The brake is activated, the torque acting on the axis is determined by the torque sensor given an activated brake, and the functional capability of the brake is assessed in a processor based on an evaluation of the torque determined by the torque sensor.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention concerns a method to test a brake of a robot. 
     2. Description of the Prior Art 
     Robots are manipulation machines that are equipped for independent handling of objects with appropriate tools and can be programmed in multiple movement axes, in particular with regard to orientation, position and workflow. Robots essentially possess a robot arm with multiple axes and arms that are moved by actuators. The actuators are, for example, electrical actuators. 
     In order to stop the movement of the robot, these normally possess brakes. For early detection of a potential failure of the brake of an electromotor of a robot (caused by wear or fouling, for example), EP 1 215 475 B1 discloses to engage the brake of an electromotor for a short time in a rotation speed-regulated operation and to measure at least the motor current of the electromotor during this time period in order to determine the braking torque of the brake of the electromotor. However, for this method it is necessary that the electromotor applies a relatively large motor torque overcoming the braking torque. This method is thus not suitable if the installed braking torque is greater than the motor torque. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a more flexible method for testing a brake of a robot. 
     The object of the invention is achieved by a method for testing a brake of a robot, which includes
         operation of a robot of axes, wherein the robot has an actuator associated with one of the axes, a brake associated with this axis that is set up to at least reduce a movement of this axis, and a torque sensor associated with this axis, which torque sensor is set up to determine the torque acting on this axis,   activation of the brake,   determination of the torque acting on the axis by means of the torque sensor given an activated brake and   assessment of the functional capability of the brake based on an evaluation of the torque determined by means of the torque sensor.       

     Robots have multiple axes that can be moved by means of actuators (for example electrical actuators). Robots can moreover have one or more torque sensors that, in conventional robots, are used to regulate and interact with the environment, for example. The torque sensors are associated with the axes and determine the torque associated with the relevant axis. 
     According to the invention, such a torque sensor is used for a testing of a brake of the robot in that the torque determined by means of the torque sensor is used to assess the functional capability of a brake of the robot possessing a plurality of axes. The brake is provided to at least reduce a movement of one of the axes of the multiple of axes, and the torque sensor is set up to determine the torque acting on this axis. 
     The axis is also associated with the actuator (which, for example, can be an electrical actuator) that in turn possesses an electrical motor and possibly power electronics activating the electrical motor. In operation of the robot, the actuator charges an actuator torque on the axis so that this moves, for example in particular with a predetermined speed, or the axis holds at an in particular predetermined position or moves along a predetermined trajectory. 
     The torque determined by means of the torque sensor can, for example, be used for a static test (i.e. to determine a breakaway torque of the brake) or for a dynamic test in which the relevant axis of the robot moves. 
     According to the method according to the invention, the robot is, for example, operated in a predetermined operating state and the brake is activated. A torque that is determined by the torque sensor thereby acts on the axis. An analysis of this torque or of a torque profile associated with the torque thereupon allows a conclusion of the braking torque applied by the brake, and thus of the functional capability of the brake. 
     The determined torque can be analyzed, for example, by a comparison thereof with a desired torque associated with the predetermined operating state that acts given a functional brake. The desired braking torque can be determined, for example, by means of an earlier measurement or have been determined based on a model-based estimation. 
     According to one embodiment of the method according to the invention, the robot is operated in a controlled or regulated operating state as, for example, the predetermined operating state, wherein due to the predetermined operating state the axis in particular possesses a predetermined position, moves with a predetermined speed or moves along a predetermined trajectory. 
     According to one variant of the method according to the invention, the actuator associated with the axis is subsequently deactivated. The torque determined by the torque sensor is correlated with the braking torque applied by the brake, such that a conclusion of the functional capability of the brake is possible based on an analysis of the torque determined by means of the torque sensor. The analysis of the torque determined by means of the torque sensor ensues, for example, by a comparison with the aforementioned and previously determined comparison or desired torque profile. With this variant of the method according to the invention the selection of suitable speeds with which the axis is operated during the predetermined operating state allows either a conclusion or static and dynamic braking torque of the brake by means of the analysis of the torque determined by means of the torque sensor. Alternatively, an actuator torque to be applied by the actuator can also be set during the determination of the braking torque. The axis (in particular a gearing possibly associated with the axis) is thereby unloaded during the function test. 
     According to a further embodiment of the method according to the invention, this possesses the following method steps:
         mechanical prevention of a movement of the axis with means independent of the brake,   activation of the brake,   generation of an actuator torque by means of the actuator that is greater than a braking torque to be applied by the brake and   assessment of the functional capability of the brake via evaluation of the torque determined by means of the torque sensor and of the actuator torque.       

     According to this variant of the method according to the invention, the breakaway torque of the brake can be determined in that on the one hand the actuator generates an actuator torque that is greater than the braking torque applied by the brake. Moreover, a movement of the axis (caused in particular by the actuator torque) is mechanically prevented in that the axis is, for example, mechanically arrested or—for this variant of the method according to the invention—the axis is brought into a mechanical end stop of the robot that is provided for said axis so that the actuator cannot move the axis further. In that the actuator torque applied by the actuator is greater than the braking torque to be applied by the brake, an output torque acts on the axis, which is in turn determined by the torque sensor. A conclusion about the braking torque can in turn be drawn based on the evaluation of the actuator torque and the torque determined by means of the torque sensor, and thus the functional capability of the brake can be assessed. Depending on the mechanical prevention of the movement of the axis, the braking torque applied by the brake corresponds less to the actuator torque than the torque determined by means of the torque sensor. A torque acting on the axis due to the force of gravity must possibly still be taken into account. The actuator torque applied by the actuator can, for example, be determined via an electrical current of an electromotor possessing the actuator if the actuator is an electrical actuator. Based on this variant of the method according to the invention, the axis remains at rest during the function testing of the brake, which has the result of no or at least relatively little wear on the brake. 
     According to a further embodiment of the method according to the invention, the following method steps are implemented:
         activation of a brake during a standstill of the axis,   increase of the actuator torque to be applied by the actuator up to a predetermined actuator torque and   detection that the brake is functionally capable if the torque sensor detects a change of the torque before reaching the predetermined actuator torque.       

     According to this variant, the robot is at rest and the brake is closed (activated). The torque sensor in this operating state determines no torque on the axis, or a relatively slight torque (for example due to gravity). The actuator torque to be applied by the actuator is subsequently increased (for example step-by-step or continuously) until the actuator reaches the predetermined actuator torque. The predetermined actuator torque in particular corresponds to a desired braking torque that the brake should apply at a minimum if it is functionally capable. If, during the increase of the actuator torque, the torque sensor determines no change of the torque, the braking torque is thus greater than actuator torque and the brake is still functionally capable. In contrast to this, if the torque sensor determines a change of the torque before the actuator reaches the predetermined actuator torque, an impairment of the functional capability of the brake can be concluded. 
     It is additionally also possible to further increase the actuator torque to be applied by the actuator after the actuator has reached the predetermined actuator torque. An acceleration torque can then be determined based on the torque of the axis that is determined by means of the torque sensor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  schematically illustrates a robot with multiple axes, in which the present invention can be used. 
         FIG. 2  schematically illustrates one of the axes of the robot of  FIG. 1 . 
         FIGS. 3 and 4  are flowcharts respectively illustrating different embodiments for testing the functional capability of the brake in the robot in accordance with the present invention. 
         FIG. 5  schematically illustrates the axis of  FIG. 2  in a different operating state of the robot. 
         FIG. 6  is a flowchart schematically illustrating a further embodiment for testing the functional capability of the brake in the robot in accordance with the present invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  shows a robot  1  with kinematics for movements in, for example, six degrees of freedom. The robot  1  has (in a generally known manner) articulations  2  through  4 , arms  5 ,  6 , six movement axes A 1  through A 6  and a flange  7  at which an effector (for example a tool; not shown in detail) can be attached. 
     Each of the movement axes A 1  through A 6  is moved by an actuator (not shown in detail). The actuators respectively comprise an electrical motor  9 - 11 ,  21 , for example, as it is generally known to those skilled in the art.  FIG. 2  shows the arm  5  that can be pivoted on the axis A 3  by means of the motor  21 . 
     In the case of the present exemplary embodiment, the electrical actuator associated with the axis A 3  possesses a gearing  23 . A movement of the arm  5  relative to the axis A 3  can also be braked with a brake  22 . A torque acting on the axis A 3  is measured with a torque sensor  24 . A torque sensor and a brake can likewise respectively be associated with the remaining axes A 1 , A 2 , A 4 -A 6 . 
     The robot  1  also has a control computer  12  that is connected (in a manner not shown) with the actuators of the robot  1  and controls these by means of a computer program running on the control computer  12  so that the flange  7  of the robot  1  implements a predetermined movement. The term “control” also encompasses the term “regulate”. 
     Furthermore, in the case of the present exemplary embodiment the torque sensor  24  and the brake  22  are also connected with the control computer  12  so that the control computer  12  can control or regulate the movement of the robot  1  based on the signals measured with the torque sensor  24  and can activate the brake if necessary. 
     In order to test the functional capability of the brake  22 , in the case of the present exemplary embodiment the following function test of the brake  22  that is illustrated by means of a flow chart presented in  FIG. 3  is implemented. 
     First, the robot is operated in a predetermined controlled or regulated operating state in which the axis A 3  exhibits a predetermined movement state (Step S 1  of the flow chart of  FIG. 3 ). This is achieved in that the control computer  12  activates the electrical motor  21  such that this generates a motor torque so that this transitions the axis A 3  into the predetermined movement state. Alternatively, the robot  1  can also be operated in a controlled or regulated operating state such that the axis A 3  moves with a predetermined speed, i.e. such that the arm  5  moves around the axis A 3  with a predetermined angular velocity. This is achieved in that the control computer  12  activates the electrical motor  21  such that this generates a motor torque so that the arm  5  pivots the around the axis A 3  with the predetermined angular velocity. 
     If the robot  1  is situated in this operating state, the control computer  12  automatically activates the brake  22  (Step S 2  of the flow chart) and deactivates the motor  21  so that this no longer generates a motor torque (Step S 3  of the flow chart). 
     In this operating state, the torque sensor  24  generates a signal that corresponds to a torque acting on the axis A 3 . This signal is supplied to the control computer  12 . A computer in turn runs on the control computer  12 , which computer program evaluates the torque acting on the axis A 3  based on the signal originating from the torque sensor  24  in order to draw a conclusion about the state of the brake  22  (Step S 4  of the flow chart). 
     In the case of the present exemplary embodiment, a reference torque profile is stored in the control computer  12  for this evaluation, which reference torque profile is to be expected for the function test of the brake  22  that was just described if the brake  22  is still sufficiently functional. The control computer is capable of testing the brake  22  by means of its computer program based on a comparison of the torque profile determined by means of the torque sensor  24  within the scope of the function test with the reference torque profile. Alternatively, during the braking procedure the reference torque profile is calculated based on a model, whereby a defined, predetermined operating state is not necessary. 
     The reference torque profile was generated during a comparison measurement with a functional brake  22 , for example, or was determined based on a model-based estimation. 
     For an alternative function testing of the brake  22 , the control computer  12  does not deactivate the motor  21  after activation of the brake  22  but rather operates said motor  21  with a predetermined motor torque in order, for example, to reduce the resulting braking torque. It is thereby possible to reduce the mechanical load, for example of the gearing  23 . For this function test the computer program running on the control computer  12  can also be executed such that this determines the function of the brake  22  not only based on the evaluation of the torque profile determined by the torque sensor  24  but also based on the motor torque applied by the motor  21 . The motor torque can, for example, be determined based on measured electrical currents of the motor  21 . 
       FIG. 4  illustrates an alternative embodiment of the function test of the brake  22  that is implemented according to the following in the case of the present exemplary embodiment: 
     The control computer  12  initially controls the motors  9 - 11 ,  21  such that the axis A 3  or, respectively, the arm  5  is brought into a mechanical end stop  25  of the robot  1  that is provided for the axis A 3  (Step S 1 ′ of the flow chart of  FIG. 4 ). It is thereby mechanically prevented that the axis  3  can move beyond the end stop  25 , even if the motor  21  applies a corresponding motor torque. 
     If the axis A 3  or, respectively, the level  5  is located at its end stop  25 , the control computer  12  activates the brake  22  (Step S 2 ′ of the flow chart of  FIG. 4 ) and induces the motor  21  to generate a motor torque that is greater than the braking torque that is to be expected from the brake  22  if the brake  22  is functional (Step S 3 ′ of the flow chart of  FIG. 4 ). The end stop  25  prevents a movement of the axis A 3  or, respectively, of the arm  5  beyond the end stop  25 . 
     The computer program running on the control computer  12  subsequently calculates the braking torque generated by the brake  22  based on the [sic] by means of the torque sensor  24  and the motor torque applied by the motor  21 . The control computer  12  can draw a conclusion about the functional capability of the brake  22  (Step S 4 ′ of the flow chart of  FIG. 4 ) based on information stored in the control computer  12  about the braking torque associated with a functional brake  22  and a comparison with the current braking torque of the brake  22  that is determined within the scope of the function test. 
     In the exemplary embodiment shown in  FIG. 2 , the movement of the axis A 3  through the end stop  25  is prevented.  FIG. 5  shows an embodiment in which the movement of the axis A 3  or of the arm  5  is realized via a catch  26  by means of which the arm  5  is attached to a wall  27  in order to prevent a movement of the axis A 3 . 
       FIG. 6  illustrates an additional embodiment of a function test of the brake  22  that, in the case of the present exemplary embodiment, is implemented according to the following: 
     The robot  1  is initially operated in a predetermined operating state in which it is at rest, meaning in particular that the axis A 3  or, respectively, the lever  5  are not moved (Step S 1 ″ of the flow chart of  FIG. 6 ). Moreover, the brake  22  is closed (Step S 2 ″ of the flow chart of  FIG. 6 ). 
     The control computer  12  subsequently activates the motor  21  such that this, for example, increases its motor torque acting on the axis A 3  continuously or step-by-step until this motor torque reaches a predetermined desired motor torque (Step S 3 ″ of the flow chart of  FIG. 6 ). The predetermined desired motor torque is selected such that the axis A 3  specifically does not move upon reaching this motor torque if the brake  22  is functional. 
     If the brake  22  is functional, then the torque determined by the torque sensor  24  does not change or changes only relatively slightly while the motor torque increases. Contrarily, if the brake  22  is no longer functional since, for example, it can no longer apply the necessary braking torque, the torque sensor  24  then determines a relative change of the torque acting on the axis A 3 . It is thus possible for the control computer  12  to draw conclusions about the functional capability of the brake  22  based on an evaluation of the torque determined by means of the torque sensor  24  (Step S 4 ″ of the flow chart of  FIG. 6 ). 
     In the case of the present exemplary embodiment, it is further provided to additionally increase the motor torque applied by the motor after this has reached the desired motor torque so that the control computer  12  can calculate an acceleration moment acting on the axis A 3  by means of the torque determined by the torque sensor  24  (Step S 5 ″ of the flow chart of  FIG. 6 ). 
     Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.