Patent Description:
Automated manufacturing such as that occurring on assembly lines can involve a series of workstations implementing robot systems to perform various manufacturing tasks. Such tasks can include machining, assembly and testing on products that are moved sequentially from one workstation to the next. In addition to automated processes, manual manufacturing processes can be performed by humans during a product's progress through such an assembly line. Humans working on the assembly line can be segregated from areas in which automated tasks are performed, for example by erecting physical barriers that prevent access to areas in which an occupant could be injured by a robot during its operation.

<CIT> discloses a method for controlling a robot, which is designed to be operated in a working mode, in which a part of the robot is moved at a speed at which there is a risk of injury to a person. The working mode is deactivated if a safety device detects that the person has entered an action region of a displaceable part. A sensor unit determines a position and a posture of the person while the person is outside the action region of the part. A prediction unit determines an action region of the person. A collision monitoring unit monitors whether the two action regions overlap. The robot can optionally be switched from the working mode into a safety mode.

<CIT> discloses methods and systems for determining and presenting virtual safety cages for robotic devices. The robotic device may comprise a robotic manipulator mounted on a movable apparatus. The robotic device comprises a robotic manipulator constituted by a robotic arm mounted on a movable apparatus constituted by a moveable holonomic cart.

<CIT> discloses a method for monitoring an environment of an automated machine, such as an autonomously driven robot. The robot comprises a chassis and an articulated arm mounted on the chassis. The robot further comprises sensors enabling detection of presence of obstacles within the working environment of the robot. If an object, such as a person, is detected within an innermost zone, the robot is immediately stopped.

<CIT> discloses a flexible workshop installation using one or more assemblies formed by a robot arm and its carrier and a transfer device. The carrier is provided with means allowing it to be attached at will, either to the part to be processed, or to a moving rolling beam or similar of the workshop.

<CIT> discloses a mobile robot having a seating part, a moving apparatus to move the seating part, and a robot part with a base part to be attached to the seating part, a body capable of rotating around a vertical axis normal to an attaching surface which the seating part to be attached to the base part, and an arm connected to the body having a plurality of joints.

One object of the present disclosure is to provide a method for supervising a working area that enables an increased automation and/or efficiency of operations carried out in the working area.

A further object of the present disclosure is to provide a method for supervising a working area that enables an efficient and safe collaboration between a person and a collaborative robot.

A still further object of the present disclosure is to provide a method for supervising a working area that enables an improvement of ergonomics and/or safety for persons carrying out work in the working area.

A still further object of the present disclosure is to provide a method for supervising a working area that enables an improvement of quality and/or flexibility of work carried out in the working area.

A still further object of the present disclosure is to provide a simple method for supervising a working area.

A still further object of the present disclosure is to provide a robot system solving one or more of the foregoing objects.

A still further object of the present disclosure is to provide a robot system that can easily and rapidly be installed or modified.

A still further object of the present disclosure is to provide a control system solving one or more of the foregoing objects.

According to one aspect, there is provided a method for supervising a working area in which a collaborative robot and a carrying robot are arranged to operate, according to claim <NUM>. The method allows for an efficient, flexible and secure combination of collaborative robots and carrying robots, such as carrying robots constituted by traditional industrial robots. The method comprises operating the collaborative robot irrespective of whether a person within the dangerous region is detected or not.

The step of detecting whether or not a person is within a dangerous region may comprise detecting whether or not a person is within the working area. Alternatively, the step of detecting whether or not a person is within a dangerous region may comprise detecting whether or not a person is within proximity to the carrying robot, e.g. within a working range of the carrying robot. Thus, the dangerous region is constituted by a space around the carrying robot in which there is a potential risk of collision between the carrying robot and the person. A dangerous region may alternatively be referred to as an exclusionary volume.

Throughout the present disclosure, the safe mode of the carrying robot may comprise moving the carrying robot at reduced speed. Alternatively, the safe mode of the carrying robot may comprise stopping the carrying robot. When the safe mode of the carrying robot is deactivated, the carrying robot may operate in a working mode, e.g. allowed to operate at full speed. When the carrying robot moves at full speed, one or more parts of the carrying robot may move at a speed at which there is a risk of injury to a person. The carrying robot may for example fill magazines, pick up parts and/or move one or more collaborative robots when the safe mode is deactivated. These tasks may also be carried out by the carrying robot, but at a lower speed, when the carrying robot adopts a safe mode comprising moving the carrying robot at reduced speed.

The working area may for example be constituted by an assembly area for vehicles, e.g. a final assembly area. However, a working area according to the present disclosure may be constituted by any type of area for assembly of parts in a series production or other working areas.

The method may further comprise lifting the collaborative robot into and/or out from a vehicle by means of the carrying robot. In this manner, collaborative work by a person and the collaborative robot can be carried out inside a semi-finished vehicle.

A carrying robot according to the present disclosure may be constituted by an industrial robot. The carrying robot comprises at least one automatically controlled, reprogrammable, multipurpose manipulator programmable in three or more axes. The carrying robot may be either fixed in place or mobile within the working area, or within a section of the working area. The carrying robot is termed carrying robot since it is configured to carry the collaborative robot. However, the collaborative robot does not have to be carried by the carrying robot at all times.

According to a further aspect, there is provided a robot system according to claim <NUM>.

Each of the collaborative robot, the carrying robot and the detection arrangement used in the robot system may be constituted by commercially available versions. Thus, a robot system according to the present disclosure may to a large extent use standardized elements or "building blocks".

A detection arrangement according to the present disclosure may comprise, for example, at least one scanner, camera, proximity sensor, visible light sensor, light barrier, optical sensor, laser sensor and/or infrared sensor in order to detect whether or not a person is within a dangerous region. The detection arrangement may alternatively be referred to as a safety arrangement.

The robot system may comprise one or several carrying robots and one or several collaborative robots. Each collaborative robot may be constituted by a single-arm robot, a dual-arm robot or a multi-arm robot. One example of a dual-arm robot is the YuMi ® by ABB. A collaborative robot according to the present disclosure is designed for direct interaction with a human.

The detection arrangement may be configured to detect whether or not a person is within a dangerous region by detecting whether or not a person is within the working area. Alternatively, the detection arrangement may be configured to detect whether or not a person is a dangerous region by detecting whether or not a person is within proximity to the carrying robot. The robot system may comprise a plurality of collaborative robots arranged to operate within the working area and the carrying robot may be arranged to move each collaborative robot within the working area. For example, the carrying robot may be configured to lift and move a first collaborative robot to a first position in the working area, to lift and move a second collaborative robot to a second position in the working area and to lift and hold a third collaborative robot during a work process.

According to a further aspect, there is provided a control system for supervising a working area in which a collaborative robot and a carrying robot are arranged to operateaccording to claim <NUM>.

The control system may be configured to jointly operate several or all carrying robots and/or collaborative robots within the working area, for example by means of the function MultiMove by ABB. MultiMove is a function that may be embedded into the control system that allows control of the axes of several manipulators such that they work like a single robot.

In the following, a method for supervising a working area in which a collaborative robot and a carrying robot are arranged to operate, a robot system comprising a collaborative robot and a carrying robot, and a control system for supervising a working area in which a collaborative robot and a carrying robot are arranged to operate, will be described. The same reference numerals will be used to denote the same or similar structural features.

<FIG> schematically represents a perspective view of a carrying robot <NUM> carrying a collaborative robot <NUM>. In this example, the carrying robot <NUM> is constituted by a commercially available traditional industrial robot having six axes, and the collaborative robot <NUM> is constituted by a commercially available collaborative dual-arm robot, such as the YuMi ® by ABB. However, the carrying robot <NUM> may be constituted by alternative types of industrial robots and the collaborative robot <NUM> may be constituted by alternative types of collaborative robots.

One feature of collaborative robots is safety, as these robots do not need to be fenced. This enables integration in existing applications where humans normally operate. Another feature associated with these robots is ease of integration. Collaborative robots should not require the integration time or complexity of traditional industrial robots.

The collaborative robot <NUM> typically has a limited load carrying capacity and only carries out low energy work. Therefore, the collaborative robot <NUM> is harmless to a human. The collaborative robot <NUM> may perform monotonous and repetitive work. A person can for example assist the collaborative robot <NUM> with making preparatory, complementary and/or more complex tasks.

The collaborative robot <NUM> is arranged on a base plate <NUM>. The carrying robot <NUM> comprises a tool, here exemplified as a gripper <NUM>. The carrying robot <NUM> holds the collaborative robot <NUM> by gripping the base plate <NUM> by means of the gripper <NUM>. The carrying robot <NUM> is configured to move the collaborative robot <NUM> in space. The collaborative robot <NUM> may carry out collaborative work together with a human while being held by the carrying robot <NUM>. In this case, the carrying robot <NUM> adopts the safe mode. The carrying robot <NUM> may put the collaborative robot <NUM> at any desired position, e.g. on the ground, while the collaborative robot <NUM> continues to be operative. This operation may be carried out either when the safe mode of the carrying robot <NUM> is deactivated or when the safe mode comprises moving the carrying robot <NUM> at reduced speed.

<FIG> schematically represents a top view of one example of a robot system <NUM> for carrying out work in a working area <NUM>. The working area <NUM> is here exemplified as an assembly area for vehicles, such as a final assembly area along an assembly line. In <FIG>, one semi-finished vehicle <NUM> is positioned in the working area <NUM>. It is however emphasized that the invention according to the present disclosure may be implemented in other types of working areas, including assembly of other transportation equipment, household appliances and electronic goods.

In <FIG>, the vehicle <NUM> is constituted by an empty car body or coachwork. Collaborative assembly work, such as installations of dashboards, seats etc., is carried out on the vehicle <NUM>.

The robot system <NUM> comprises at least one collaborative robot <NUM> and at least one carrying robot <NUM> configured to carry the collaborative robot <NUM> and move the collaborative robot <NUM> within the working area <NUM>. The carrying robot <NUM> and the collaborative robot <NUM> may each be of the type illustrated in <FIG>.

In the example of <FIG>, the robot system <NUM> comprises three carrying robots 10a, 10b, 10c and three collaborative robots 12a, 12b, 12c (also collectively referred to with reference numerals <NUM> and <NUM>, respectively). However, the numbers of carrying robots <NUM> and collaborative robots <NUM> may be varied.

Each carrying robot <NUM> may operate in a safe mode. The safe mode may either comprise a complete standstill of the carrying robot <NUM> or a limitation of the movement speeds of the carrying robot <NUM>. Force sensors may also be provided on each carrying robot <NUM> to further improve safety.

The robot system <NUM> further comprises a detection arrangement <NUM>. The detection arrangement <NUM> is configured to detect whether or not a person <NUM> is within a dangerous region <NUM>. In this example, the detection arrangement <NUM> is illustrated by a camera monitoring the working area <NUM>. However, the detection arrangement <NUM> may be of any type to detect whether or not a person <NUM> is within a dangerous region <NUM>. The detection arrangement <NUM> may also be configured to detect the position of each person <NUM> within the working area <NUM>.

The robot system <NUM> further comprises a control system <NUM>. The control system <NUM> is in signal communication with the detection arrangement <NUM>, the carrying robots <NUM> and the collaborative robots <NUM>. The control system <NUM> is configured to command one or more of the carrying robots <NUM> to activate a safe mode when the detection arrangement <NUM> detects that a person <NUM> is within the dangerous region <NUM>. The control system <NUM> is also configured to command one or more of the carrying robots <NUM> to deactivate the safe mode when the detection arrangement <NUM> detects that no person <NUM> is within the dangerous region <NUM>. Since the collaborative robots <NUM> are not harmful to humans, the collaborative robots <NUM> may continue to operate even when the detection arrangement <NUM> detects that a person <NUM> enters a dangerous region <NUM>.

What is considered to constitute a dangerous region <NUM> may vary depending on implementation. According to one example, the entire working area <NUM> may be considered to constitute a dangerous region <NUM>. In this case, the control system <NUM> may command each carrying robot <NUM> within the working area <NUM> to activate the safe mode when the detection arrangement <NUM> detects that a person <NUM> is within the working area <NUM>. In <FIG>, the person <NUM> is within a safe area <NUM> next to the working area <NUM> and no person <NUM> is within the working area <NUM>. Thus, each carrying robot <NUM> operates in the normal working mode when the working area <NUM> is considered to constitute a dangerous region <NUM>.

According to a further example, dangerous regions <NUM> may be constituted by the working spaces or ranges of each carrying robot <NUM>, i.e. a safety region in proximity to each carrying robot <NUM>. In this case, the control system <NUM> may only activate the safe mode of carrying robots <NUM> to which a person <NUM> is proximate. Thus, the safe mode may be inactive for all carrying robots <NUM> (i.e. the carrying robots <NUM> may operate in the normal working mode) when it is detected that a person <NUM> is within the working area <NUM> but not within any of the dangerous regions 28a, 28b, 28c (also collectively referred to with reference numeral <NUM>) associated with the carrying robots <NUM>.

One possible approach is to consider the working spaces associated with the carrying robots <NUM> to constitute dangerous regions <NUM> if all carrying robots <NUM> within the working area <NUM> are fixed to the ground. In this situation, the working spaces of the carrying robots <NUM> are limited. The carrying robots <NUM> may then adopt the normal working mode if no person <NUM> is within the working area <NUM>. If a person <NUM> is within a dangerous region 28a, 28b, 28c of one of the carrying robots <NUM>, this carrying robot <NUM> may adopt the safe mode (e.g. either reduced speed or standstill) and the remaining carrying robots <NUM> within the working area <NUM> may adopt the normal working mode or an intermediate working mode. An intermediate working mode may impose some restrictions on the movements on the carrying robot <NUM>, but not as hard restrictions as in the safe mode.

Conversely, if one or more of the carrying robots <NUM> is mobile and not fixed to the ground, e.g. when one or more of the carrying robots <NUM> travel on a track (not illustrated) within the working area <NUM>, the entire working area <NUM> may be considered to constitute a dangerous region <NUM>.

The carrying robots <NUM> may move to a storage area <NUM> within the working area <NUM> (both when being fixed to the ground and when being mobile) to collect parts and fill magazines. This may be done in the normal working mode of the carrying robots <NUM>, e.g. between shifts or at lunch break. This may also be done at reduced speed when a person <NUM> is within a dangerous region <NUM> of a carrying robot <NUM> (or when a person <NUM> is within the working area <NUM>, if the working area <NUM> is considered to constituted a dangerous region <NUM>) if the safe mode imposed on the carrying robot <NUM> comprises limiting the speed of the carrying robot <NUM>.

A carrying robot <NUM> may for example lift a collaborative robot <NUM> from the ground at a first position and move the collaborative robot <NUM> to a second position where the collaborative robot <NUM> is put on the ground. In case a carrying robot <NUM> is arranged to move on a track or similar, the safe mode of the carrying robot <NUM> may also be imposed on the track, e.g. a stopping or speed limitation of the track movement.

A collaborative robot <NUM> may also be mounted to a carrying robot <NUM> such that the carrying robot <NUM> always carries the collaborative robot <NUM>. In this case, the carrying robot <NUM> may either be fixed to the ground or be movable within the working area <NUM>, such as by means of a track.

<FIG> illustrates that the carrying robot 10b lifts the collaborative robot 12b into the vehicle <NUM>. Thus, a person <NUM> and the collaborative robot 12b may carry out collaborative work inside the vehicle <NUM>. At the same time, a further collaborative robot 12c carries out external work on the vehicle <NUM>.

Collaborative robots typically has a small workspace. By providing a detection arrangement <NUM> and arranging a carrying robot <NUM> to carry and move a collaborative robot <NUM> according to the present disclosure, the effective workspace of the collaborative robot <NUM> can be increased without compromising safety. This enables, for example, an increased automation and efficiency of operations carried out in the working area <NUM>.

<FIG> schematically represents a block diagram of one example of a control system <NUM>. The control system <NUM> is configured to supervise a working area <NUM> according to the present disclosure. The control system <NUM> comprises a data processing device <NUM> and a memory <NUM> having computer program stored thereon. The computer program comprises program code which, when executed by the data processing device <NUM>, causes the data processing device <NUM> to perform the steps of: determining whether or not a person <NUM> is within a dangerous region <NUM>, 28a, 28b, 28c based on detection data <NUM> from the detection arrangement <NUM>, commanding the respective carrying robot(s) <NUM> to activate a safe mode upon determining that a person <NUM> is within the dangerous region <NUM>, 28a, 28b, 28c, and commanding the respective carrying robot(s) <NUM> to deactivate the safe mode upon determining that no person <NUM> is within the dangerous region <NUM>, 28a, 28b, 28c.

One or more sensor of the detection arrangement <NUM> provides real-time detection data <NUM> to the control system <NUM> from which the data processing device <NUM> can determine at least the presence of a person <NUM> within a dangerous region <NUM>. The control system <NUM> may also be configured to determine the position of one or more persons <NUM> within the working area <NUM>. The control system <NUM> may optionally also be configured to detect movements, accelerations, speeds or velocity of any person <NUM> within the working area <NUM> and/or to detect further potentially harmful objects within the working area <NUM>, including mobile workstations.

The detection data <NUM> may for example be constituted by image data. In this case, the data processing device <NUM> of the control system <NUM> may perform image processing of the detection data <NUM> in order to determine whether or not a person <NUM> is within the dangerous region <NUM>.

Claim 1:
Method for supervising a working area (<NUM>) in which a collaborative robot (<NUM>, 12a-c) and a carrying robot (<NUM>, 10a-c) are arranged to operate, wherein the method comprises:
- arranging the carrying robot (<NUM>, 10a-c) to carry and move the collaborative robot (<NUM>, 12a-c) within the working area (<NUM>), the carrying robot (<NUM>, 10a-c) comprising at least one automatically controlled, reprogrammable, multipurpose manipulator programmable in three or more axes, and the collaborative robot (<NUM>, 12a-c) being designed for direct interaction with a human to perform collaborative work with the human;
- monitoring the working area (<NUM>);
- detecting whether or not a person (<NUM>) is within a dangerous region (<NUM>, 28a-c), the dangerous region (<NUM>, 28a-c) being a space around the carrying robot (<NUM>, 10a-c) in which there is a potential risk of collision between the carrying robot (<NUM>, 10a-c) and the person (<NUM>);
- activating a safe mode of the carrying robot (<NUM>, 10a-c) upon detecting that a person (<NUM>) is within the dangerous region (<NUM>, 28a-c);
- deactivating the safe mode of the carrying robot (<NUM>, 10a-c) upon detecting that no person (<NUM>) is within the dangerous region (<NUM>, 28a-c); and
- operating the collaborative robot (<NUM>, 12a-c) irrespective of whether a person (<NUM>) within the dangerous region (<NUM>, 28a-c) is detected or not.