Abstract:
Various disclosed embodiments include methods, systems, and computer-readable media for identifying a motion path for an industrial robot. According to one embodiment, a method includes identifying a plurality of points at which at least one component of the industrial robot is positioned during performance of a task. The identified points include at least a starting point and an ending point of the component for performing the task. The method also includes generating one or more motion paths for the industrial robot to perform the task based on the identified points. The method further includes identifying and predicting energy consumption by the industrial robot for the one or more generated motion paths. The method also includes selecting the motion path for the industrial robot based on the identified energy consumption. Additionally, the method includes storing information about the energy consumption by the industrial robot for the selected motion path.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY 
     The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/776,386, filed Mar. 11, 2013, entitled “Reducing Energy Consumption of Industrial Robots by Using New Methods for Motion Path Programming.” The content of the above-identified patent document is incorporated herein by reference 
    
    
     TECHNICAL FIELD 
     The present disclosure is directed, in general, to computer-aided design, visualization, simulation, and manufacturing (“CAD”) systems, product data management (“PDM”) systems, product lifecycle management (“PLM”) systems, offline programming software for robot (“OLP”) systems, and similar systems that manage data for products and other items (individually and collectively, product lifecycle management systems (“PLM”) systems). 
     BACKGROUND OF THE DISCLOSURE 
     PLM systems can provide users with helpful and intuitive views of systems, objects, topologies, and other items. 
     An industrial robot is a numerically controlled, multipurpose manipulator programmable in three or more axes. Typical applications of industrial robots include welding, painting, assembly, pick and place (such as packaging, palletizing, and surface mount technology), product inspection, and testing. Industrial robots are capable of accomplishing these tasks with high endurance, speed, and precision. 
     There is a need for improved control of industrial robots. 
     SUMMARY OF THE DISCLOSURE 
     Various disclosed embodiments relate to systems and methods for reducing energy consumption by industrial robots using motion path programming. 
     Various embodiments include systems, methods, and mediums for identifying a motion path for an industrial robot. According to one embodiment, a method includes identifying a plurality of points at which at least one component of the industrial robot is positioned during performance of a task. The identified points include at least a starting point and an ending point of the component for performing the task. The method also includes identifying a plurality of motion paths for the industrial robot to perform the task based on the identified points. The method further includes the taxonomy, selection, and calculation of energetically optimized motion paths and in a second step identifying energy consumption by the industrial robot for one or more of the identified motion paths. The method also includes selecting the motion path for the industrial robot based on the identified energy consumption. Additionally, the method includes storing information about the energy consumption by the industrial robot for the selected motion path. 
     The foregoing has outlined rather broadly the features and technical advantages of the present disclosure so that those skilled in the art may better understand the detailed description that follows. Additional features and advantages of the disclosure will be described hereinafter that form the subject of the claims. Those skilled in the art will appreciate that they may readily use the conception and the specific embodiment disclosed as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the disclosure in its broadest form. 
     Before undertaking the DETAILED DESCRIPTION below, it may be advantageous to set forth definitions of certain words or phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, whether such a device is implemented in hardware, firmware, software or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases. While some terms may include a wide variety of embodiments, the appended claims may expressly limit these terms to specific embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, wherein like numbers designate like objects, and in which: 
         FIG. 1  illustrates a block diagram of a data processing system in which an embodiment can be implemented; 
         FIG. 2  illustrates a block diagram of a motion path programming system in which various embodiments of the present disclosure may be implemented; 
         FIG. 3  illustrates an example of an industrial robot in which various embodiments of the present disclosure may be implemented; 
         FIG. 4  illustrates an example of motion path planning in an environment where an industrial robot is located in accordance with an illustrative embodiment of the present disclosure; and 
         FIG. 5  illustrates a flowchart of a process for identifying a motion path for an industrial robot in accordance with disclosed embodiments. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 through 5 , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably-arranged device. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments. 
     Disclosed embodiments recognize that off-line programming of robots (OLP) has traditionally been focused on the creation of collision free motion paths with a focus on speed and minimal time consumption in task performance. The amount of energy consumed by the industrial robot was not considered. 
     Disclosed embodiments, described herein, provide improvements to the planning and programming of the motion path of an industrial robot that use less energy in performance of the task. In various embodiments, the present disclosure generates simulations to select optimal paths for task performance that reduce energy consumption while meeting timing requirements associated with the task performance. 
       FIG. 1  illustrates a block diagram of a data processing system  100  in which an embodiment can be implemented, for example, as a PLM system or an OLP system particularly configured by software or otherwise to perform the processes as described herein, and, in particular, as each one of a plurality of interconnected and communicating systems as described herein. The data processing system  100  illustrated includes a processor  102  connected to a level two cache/bridge  104 , which is connected in turn to a local system bus  106 . Local system bus  106  may be, for example, a peripheral component interconnect (PCI) architecture bus. Also connected to local system bus  106  in the illustrated example are a main memory  108  and a graphics adapter  110 . The graphics adapter  110  may be connected to display  111 . 
     Other peripherals, such as local area network (LAN)/wide area network (WAN)/Wireless (e.g. WiFi) adapter  112 , may also be connected to local system bus  106 . Expansion bus interface  114  connects local system bus  106  to input/output (I/O) bus  116 . I/O bus  116  is connected to keyboard/mouse adapter  118 , disk controller  120 , and I/O adapter  122 . Disk controller  120  can be connected to a storage  126 , which can be any suitable machine usable or machine readable storage medium, including but not limited to nonvolatile, hard-coded type mediums, such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), magnetic tape storage, and user-recordable type mediums, such as floppy disks, hard disk drives, and compact disk read only memories (CD-ROMs) or digital versatile disks (DVDs) and other known optical, electrical, or magnetic storage devices. 
     Also connected to I/O bus  116  in the example illustrated is audio adapter  124 , to which speakers (not illustrated) may be connected for playing sounds. Keyboard/mouse adapter  118  provides a connection for a pointing device (not illustrated), such as a mouse, trackball, trackpointer, etc. 
     Those of ordinary skill in the art will appreciate that the hardware illustrated in  FIG. 1  may vary for particular implementations. For example, other peripheral devices, such as an optical disk drive and the like, also may be used in addition to or in place of the hardware illustrated. The illustrated example is provided for the purpose of explanation only and is not meant to imply architectural limitations with respect to the present disclosure. 
     A data processing system in accordance with an embodiment of the present disclosure includes an operating system employing a graphical user interface. The operating system permits multiple display windows to be presented in the graphical user interface simultaneously, with each display window providing an interface to a different application or to a different instance of the same application. A cursor in the graphical user interface may be manipulated by a user through the pointing device. The position of the cursor may be changed and/or an event, such as clicking a mouse button, may be generated to actuate a desired response. 
     One of various commercial operating systems, such as a version of Microsoft Windows™, a product of Microsoft Corporation located in Redmond, Wash., may be employed if suitably modified. The operating system is modified or created in accordance with the present disclosure as described. 
     LAN/WAN/Wireless adapter  112  can be connected to a network  130  (not a part of data processing system  100 ), which can be any public or private data processing system network or combination of networks, as known to those of skill in the art, including the Internet. Data processing system  100  can communicate over network  130  with server system  140 , which is also not part of data processing system  100 , but can be implemented, for example, as a separate data processing system  100 . 
       FIG. 2  illustrates a block diagram of a motion path programming system  200  in which various embodiments of the present disclosure may be implemented. In this illustrative embodiment, the motion path programming system  200  includes a programming data processing system  205  that programs motion paths for an industrial robot  210 . For example, the programming data processing system  205  is an example of one embodiment of the data processing system  100  in  FIG. 1 . 
     The industrial robot  210  includes, at a high level, mechanical components  215 , at least one motor  220 , and at least one controller  225 . The mechanical components  215  are the movable portions of the industrial robot  210  that are used to perform a task. The mechanical components  215  may include, for example and without limitation, movable, extendable, and/or rotatable components, such as a base, arms, and peripheral devices, such as an end effector or end-of-arm-tooling (EOT). The robot  210  includes at least one and preferably more than one motor  220 . The motor  220  provides mechanical energy to one or more of the components  215  to perform functions in the overall performance of a task. The motor  220  may be, for example and without limitation, electrical, pneumatic, or combustion. The controller  225  controls the operation of the industrial robot  210 . For example, the controller  225  may be programmed to control the motor  220  to move one or more of the components  215  along a programmed motion path in performing a task. 
     The programming data processing system  205  programs the robot  210  to perform a task in accordance with a specified motion path. For example, the programming data processing system  205  may program the controller  225  to control the motor  220  to move the mechanical components  215  at a specified speed and direction in accordance with a specified timing pattern to enable the robot  210  to perform the task. In this manner, each of the components  215  moves at various points along a specified motion path. For example, the programming data processing system  205  may program the robot  210  to perform a task by starting at a starting point, controlling grippers to lift an object, moving the object to a specified point, releasing and placing the object at the specified point, and stopping at an ending point. Each of these points the robot  210  moves to are points along the motion path. The programming data processing system  205  includes a programming application  230  that allows a programmer to program the robot  210 . The Tecnomatix Process Simulate programming application is an example of one type of programming application that is commercially available from Siemens Product Lifecycle Management Software Inc. 
     In various embodiments of the present disclosure, the programming data processing system  205  programs the motion path of the robot  210  with consideration for energy efficiency and optimization. For example, programming data processing system  205  may factor the movement capabilities of the robot  210 , the time constraints of the task, and the geometric constraints of the working environment to identify a motion path where the robot  210  uses as little energy as possible to perform the task while meeting any timing constraints for the task and avoiding collision with any obstacles that may exist in the environment. The programming application  230  may include information about and/or provide a graphical representation of the robot  210  that includes the robot&#39;s  210  capabilities and constraints, such as, for example and without limitation, extension of extendable components, rotation of rotatable components, motor output power, and the distance, directions, and speed with which the various components  215  can be moved including movement of and/or re-positioning of the robot  210  itself, for example, via a movable pedestal of the robot  210 . For example, this information may be identified from product specifications or programmed into the programming application  230 . The programming application  230  may include information about and/or provide a graphical representation of the environment that the robot  210  is to perform the task, which may include locations and sizes of obstacles the robot  210  needs to avoid and/or objects the robot  210  is to interact with while performing the task. The programming application  230  may also include information about the task the robot  210  is to perform, such as, for example, a starting point, an ending point, and one or more functions to be performed along the way. 
     Using this information, the programming data processing system  205  determines a motion path for the robot to perform the task. For example, the programming data processing system  205  may divide the movements of robot  210  to perform the task into segments that are categorized into movement categories. For example, the categories may include directional acceleration, cornering movement, lifting, lowering, etc. For each of the categories, the programming data processing system  205  may apply various optimization algorithms based on the physics and kinetics of the robot  210  to determine an optimal path or paths from an energy perspective. 
     For example, if the task were for the robot  210  to lift an object over a fence, one motion path may be to lift the object straight up from the ground to the required height, move the object horizontally to the desired location, and lower the object to the ground. The programming data processing system  205  may identify one energetically optimized movement path as a parabolic path with acceleration at the start of the path, use of the kinetic energy of the moving object and the arm of the robot  210  to clear the fence, and then deceleration and lowering of the object to the desired location. In this example, the programming data processing system  205  may calculate an amount of energy used to perform the task based on the weight of the object and robot&#39;s  210  arm, the lifting height and movement distance. The programming data processing system  205  may calculate or estimate the energy consumption of each path to determine that the parabolic motion path is the more energy efficient path. The determination of the motion path may also be independent of the particular robot as the path selection is based on the application of physics and kinetics. 
     In various embodiments, the identification of the energy efficient motion path may be automatic. For example, the programming data processing system  205  may receive and/or identify information about the task, an existing motion path, the robot  210 , and/or the environment where the robot  210  is located. Based on these inputs, the programming data processing system  205  performs optimization and outputs an energy efficient motion path, which is programmed into the robot  210 . In another example, the programming data processing system  205  may automatically optimize an existing motion path for a robot. For example, the robot  210  may be initially programmed to perform a task using a specified motion path. The programming data processing system  205  may identify the different segments of the existing path and energetically optimize these sections with optimization algorithms that fit to the situation. The programming data processing system  205  may also optimize the connection points of the sections of the path the kinetic energy is handed over to the next section. After the optimization of the sections of the motion path, the programming data processing system  205  reconnects the sections to form an energetically optimized motion path for the task. The programming data processing system  205  may analytically calculate energy savings between the two paths for display to a programmer or operator. The amount of energy savings may be influenced by a dynamic and/or time factor. For example, a slow movement may use more energy than a dynamically optimized faster movement. 
     In other embodiments, the identification of the energy efficient motion path may be interactive. For example, the programming data processing system  205  may generate a simulation of one or more motion paths that may be used and receive inputs or selections from an operator or programmer as to which path segments and/or complete motion path to use. The programming data processing system  205  may dynamically calculate and display energy consumption values and/or task timing information to guide and/or assist the operator or programmer in creating and/or modifying the resultant motion path. 
     In various embodiments, the programming data processing system  205  calculates or estimates the amount of energy consumed by the industrial robot  210  using functions or algorithms for energy usage. For example, as discussed above, the programming data processing system  205  may know properties of the industrial robot  210  (e.g., extension length of extendable components, rotation axis (or axes) of rotatable components, motor output power, and/or the mass of the components  215 ), and properties of the task (e.g., the motion path and/or the mass of objects to be moved as part of the task) and use values for these known properties using mechanical equations or algorithms to determine energy usage. As non-limiting examples, the mechanical equations or algorithms that may be used in calculating energy include functions for kinetic energy (i.e., K=½ mass*velocity 2 ) or work energy (W=force*distance). 
     In some embodiments, the programming data processing system  205  may identify the energy consumption from actual simulation, testing, and/or use of the robot  210 . For example, the robot  210  and/or the programming data processing system  205  may measure the actual amount of energy received from the energy source  235  during testing or robot operation. As non-limiting examples, the measurement of the energy usage may be performed by an energy meter that is connected to or incorporated in the industrial robot  210 . The measured energy consumption for optimized and non-optimized paths may be used for verification of energy savings and/or further optimization of the motion path. 
     In some embodiments, the robot  210 , itself, may perform the identification of the motion path to be used to complete the task. For example, various components of the programming data processing system  205  may be implemented within the industrial robot  210 . The robot  210  can store and/or identify the properties of the robot  210  and the information about performing the task to determine the appropriate motion path. The robot  210  may determine and/or modify the motion path use in advance of performing the task or while performing the task. For example, the robot  210  may perform “offline” or “online” programming of the motion path to determine and/or modify the motion path used. In some embodiments, the robot  210  may use dynamic information about the properties of the robot  210  and/or the information about performing the task to determine and/or modify the motion path during or before performance of the task. For example, the robot  210  may identify dynamic information, such as, chances in goals for performance of the task (e.g., changes energy efficiency vs. time efficiency goals), movement of obstacles or similar nearby self-optimizing robots present in the environment, changes in objects (e.g., weight, shape, or orientation) lifted by the robot, or properties of the robot, (e.g., tools attached, battery, power remaining, malfunctioning components, etc.). In some embodiments, the robot  210  may identify such information from sensors (e.g., cameras, motion sensors, weight sensors, radar, etc.) that are positioned on or nearby the robot  210 . 
     The illustration of the motion path programming system  200  in  FIG. 2  is not intended to imply any physical or architectural limitations in the various embodiments that may be implemented in accordance with the principals of the present disclosure. For example, the industrial robot  210  may include any number of different components  215 , motor  220 , and controllers  225 . One motor  220  may be connected to and move one or more of the components along a motion path. Multiple motors  220  may work in combination to move along the motion path. Each motor  220  and/or component  215  may be controlled by a separate controller  225 , a hierarchy of controllers  225 , and/or one controller that controls overall operation of the robot  210 . 
       FIG. 3  illustrates one example of an industrial robot  300  in which various embodiments of the present disclosure may be implemented. In this illustrative example, the robot  300  is one example of an embodiment of the industrial robot  210  in  FIG. 2 . For example, the robot  300  may be programmed by the programming data processing system  205  to perform a task in an energy efficient manner. As illustrated, the robot  300  includes a rotatable base  305  that is rotatable about an axis as indicated by the arrows  310 . The robot  300  also includes lower arm  315  and upper arm  320  that are rotatable about axes  325  and  330 , respectively, as indicated by arrows  335  and  340 , respectively. 
     As illustrated, the robot  300  includes an end-of-arm section  345  that is movable up and down as indicated by arrows  350 . The end-of-arm section  345  includes a surface  360  providing connection to a peripheral device, such as an end effector or EOT. The surface  360  is rotatable about an axis  365  as indicated by arrows  370 . Examples of end effectors include welding devices, spray guns, grinding devices, a vacuum, and grippers (e.g., devices that can grasp an object using, for example, electromechanically or pneumatically supplied force). The robot  300  also includes tubing  375  that can provide, for example and without limitation, power, suction, compressed air, and/or fluids to the end-of-arm tool.  FIG. 3  is intended as one example of an industrial robot in which embodiments of the present disclosure may be implemented. Embodiments of the present disclosure may be implemented in any type of industrial robot. 
       FIG. 4  illustrates an example of motion path planning in an environment  400  where an industrial robot  405  is located in accordance with an illustrative embodiment of the present disclosure. In this illustrative example, the robot  405  is one example of an embodiment of the industrial robot  210  in  FIG. 2 . For example, the robot  405  may be programmed by the programming data processing system  205  to perform a task in an energy efficient manner. 
     In this illustrative embodiment, the robot  405  performs a task of moving an object  410  from a starting point  415  over an obstacle  420  to an ending point  425 .  FIG. 4  illustrates two possible motion paths that the robot  405  may take to perform this task. As illustrated by motion path  430 , the robot  405  picks up the object  410  with a gripper, lifts the object  410  vertically to a height above the obstacle  420 , moves the object  410  horizontally to the destination location, and lowers the object  410  down to the ending point  425 . To optimize this path for energy efficiency, the programming data processing system  205  may divide this motion path into segments that are then categorized (e.g., lifting, cornering, lateral movement, cornering, and lowering) with a focus on the overall goal of the motion path. After iterations of algorithms, the programming data processing system  205  identifies the motion path  435  as a motion path that meets the geometric and timing constraints while reducing the energy consumption of the robot  405  to perform the task. For example, the programming data processing system  205  may identify the proper amount of acceleration and lifting angle based on the object weight and the output power of the robot  405  to lift the object  410  a threshold clearance over the obstacle  420  and clear the obstacle  420  en route to the ending point  425 . Too much acceleration may waste energy, and too little acceleration may cause a collision. 
       FIG. 4  is intended as one example of a motion path that may be improved in accordance with the present disclosure. Embodiments of the present disclosure may analyze and optimize any other type of motion path of any level of complexity. 
       FIG. 5  illustrates a flowchart of a process for identifying a motion path for an industrial robot in accordance with disclosed embodiments. This process can be performed, for example, by one or more PLM data processing systems and/or one or more OLP data processing systems configured to perform acts described below, referred to in the singular as “the system.” The process can be implemented by executable instructions stored in a non-transitory computer-readable medium that cause one or more PLM data processing systems to perform such a process. The process illustrated in  FIG. 5  is an example of a process that may be performed by the programming data processing system  205  in  FIG. 2 . 
     The process begins by the system identifying a plurality of points for the industrial robot during performance of a task (step  505 ). For example, as part of this step, the system may identify at least a starting point and an ending point of the component for performing the task. The system may also identify a point that the robot will need to clear in performing the task. 
     The system generates one or more motion paths for the industrial robot to perform the task (step  510 ). For example, as part of this step, the system may identify segments between the various points for the performance of the task and categorize the segments based on movement. The system may then apply optimization algorithms based on the type of movement to generate a resultant path. In another example, the system may generate a simulation of performance of the task by the industrial robot based on the starting point, the ending point, the parameters of the industrial robot, and/or information about the task performed by the industrial robot. The system may then generate the one or more motion paths to allow the industrial robot to meet the timing requirement for performance of the task and avoid collisions with obstacles in the environment. 
     The system identifies energy consumption by the industrial robot (step  515 ). For example, as part of this step, the system may estimate, predict, or calculate the energy consumption or energy savings compared with a previous motion path. The system may display the energy consumption or savings to an operator or programmer. The system may also store information about the energy consumption by the industrial robot for the motion path(s) generated. 
     The system selects a motion path for the industrial robot (step  520 ). For example, as part of this step, the system may automatically select the motion path as an energy efficient path. The system may iteratively optimize or improve the path to arrive an optimal or improved motion path. In another example, the system may receive a selection of the motion path from a user. In another example, the system may select the motion path based on timing consideration, for example, a motion path that minimizes or reduces an amount of time to complete one or more tasks performed by the robot. In yet another example, the system may select the motion path based on a combination of timing and energy consumption factors. For example, the system may select a motion path that meets timing constraints and reduces energy or may select a motion path that meets energy consumption goals with a minimal or reduced amount of time to complete the task. 
     Disclosed embodiments provide the ability to apply physics and kinematics to reduce energy consumption of industrial robots. Disclosed embodiments plan and program the motion path of an industrial robot that use less energy in performance of a task. Disclosed embodiments generate simulations to select optimal paths for task performance that reduce energy consumption while meeting timing constraints and geometrical constraints associated with the task performance. 
     Of course, those of skill in the art will recognize that, unless specifically indicated or required by the sequence of operations, certain steps in the processes described above may be omitted, performed concurrently or sequentially, or performed in a different order. 
     Those skilled in the art will recognize that, for simplicity and clarity, the full structure and operation of all data processing systems suitable for use with the present disclosure is not being illustrated or described herein. Instead, only so much of a data processing system as is unique to the present disclosure or necessary for an understanding of the present disclosure is illustrated and described. The remainder of the construction and operation of data processing system  100  may conform to any of the various current implementations and practices known in the art. 
     It is important to note that while the disclosure includes a description in the context of a fully functional system, those skilled in the art will appreciate that at least portions of the mechanism of the present disclosure are capable of being distributed in the form of instructions contained within a machine-usable, computer-usable, or computer-readable medium in any of a variety of forms, and that the present disclosure applies equally regardless of the particular type of instruction or signal-bearing medium or storage medium utilized to actually carry out the distribution. Examples of machine usable/readable or computer usable/readable mediums include: nonvolatile, hard-coded type mediums, such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), and user-recordable type mediums, such as floppy disks, hard disk drives and compact disk read only memories (CD-ROMs) or digital versatile disks (DVDs). 
     Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form. 
     None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke paragraph six of 35 USC §112 unless the exact words “means for” are followed by a participle.