Patent ID: 12220808

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

The invention is described more fully hereinafter with references to the accompanying drawings, in which exemplary embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure is thorough, and will fully convey the scope of the invention to those skilled in the art. It will be understood that for the purposes of this disclosure, “at least one of each” will be interpreted to mean any combination the enumerated elements following the respective language, including combination of multiples of the enumerated elements. For example, “at least one of X, Y, and Z” will be construed to mean X only, Y only, Z only, or any combination of two or more items X, Y, and Z (e.g., XYZ, XZ, YZ, X). Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals are understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.

Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a conveyance system20and method for automatically moving one or more items21between a structure at a source location26and a destination28using a robot30with an end effector32are disclosed.

One example of the conveyance system20of the present disclosure is shown inFIG.1for automatically moving one or more parts22between a bin24at a source location26and a destination28using a robot30with an end effector32, and where the parts22may be loose or not fixed in specific locations in the bin24. As used in this disclosure, a bin24may include any box, rack, tray, or other carrier for holding parts22. It should be appreciated that the term “part”22as discussed throughout the subject disclosure, including the claims, may encompass various types of objects including, but not limited to, raw materials, housings, and component pieces in any stage of manufacture, assemblies or sub-assemblies in any stage of construction, and finished pieces or assemblies. A variety of different items21may be accommodated and moved by the same conveyance system20, using the same or different end effectors32. It should also be appreciated that the term “item”21may refer to a part22, a bin24, or any other physical item including, but not limited to a tool, part, fixture, raw material, housing, component piece in any stage of manufacture, assembly or sub-assembly in any stage of construction, finished pieces or assemblies, a box, rack, tray, or other carrier.

As best shown inFIG.1, a first vision system34may identify a part22within the bin24at a source location26and determine a pick location, and a pick orientation of the part22. A second vision system38may determine the location and orientation of a destination28, which may be inside or outside of the bin24. The destination28may be any place where one or more parts are to be moved, including, for example: fixtures or carriers for manufacturing or inspection, shipment, etc.; racks or packages for storage or conveyance; conveyors; fixtures or assemblies in any stage of manufacture. The destination28may be fixed in position and orientation. The destination28may be variable in position and/or orientation, such as for parts being placed on an assembly as it moves along an assembly line. Additionally, the destination28for each of a series of parts22may be different, for example in cases where a rack, or other such assembly is loaded with a plurality of parts22, with each part22in a separate compartment or location on the rack.

Each of the vision systems34,38may be any type of machine vision system, including one or more cameras36or other imaging devices and including but not limited to 2D, 2.5D, and 3D systems capable of identifying and locating a part22in 3-dimensional space, having x, y, and z coordinates, as well as a 3-dimensional orientation of roll, pitch, and yaw. One example of such a machine vision system is the camera system manufactured by Cognex. Such identifying and locating may be done using direct observations and measurements, through comparisons with one or more reference images, through any other method or combination of methods.

The conveyance system20includes a robot30having an end effector32to pick the part22from the bin24, move the part22along a path40, and place the part22at the destination28. The end effector32may be an advanced effector (e.g., tooling), or any other effector capable of moving an item21including, but not limited to, a grasp, clamp, and a suction device. The system also includes a trajectory planning controller42for planning a best path40for the robot30to follow in moving the item21between the source location26and the destination28.

Each of the vision systems34,38may include one or more cameras36located at fixed positions, as shown onFIG.1. Alternatively or additionally, the first vision system34may include a camera36that is located on the robot30, as shown onFIG.2. More specifically, the camera36may be located on or near a free or distal end of the robot30. The camera36may be located on the end effector32of the robot30or on another part of the robot30, such as a joint or a structural component near the end effector32. Such a robot-mounted camera36may be used instead of or in addition to one or more cameras36at fixed positions. Alternatively or additionally, the second vision system38may include a camera36that is located on the robot30. In one embodiment, the vision systems34,38may share one or more cameras36that are mounted on the robot30. In other words, the vision systems34,38may each be configured to use a shared camera mounted on the robot. Such a configuration may include one of the vision systems34,38passing an image signal from the shared camera to the other one the vision systems34,38. Alternatively, an image from the shared camera may be provided to each of the vision systems34,38from the shared camera or from another device, such as a signal splitter.

As shown inFIG.3, an example application of the conveyance system20of the present invention may be to replace a manual operation of loading and unloading vehicle fascias onto paint bucks, or racks used in paint processes. For example, the process of loading the paint bucks may require a crew, with persons alternating between picking from the walk-in bin (at floor level) and placing the parts in a buck (at hip level) and by transferring the part to each other in order to relieve the ergonomic stressors. As shown inFIG.3, the conveyance system20of the present invention may replace the manual loading and unloading of vehicle fascias to and from paint bucks and may allow the combined operation to be performed with fewer persons per shift. The bins24may be located within a general window area, which may be a predetermined tolerance value from a predetermined nominal position or boundary. The bins24may not need to be secured or placed in an exact location, and therefore may not require locating fixtures. The parts22may be fixed within the bins24, such as by fixtures formed in the bins24, and the number of parts within a bin24may vary. The conveyance system20of the present disclosure may accommodate several different types of parts, such as for different vehicle models. For example, a conveyance system20may accommodate 17 or more different types of parts. According to an aspect, the conveyance system20may require both the source and the destination to be stationary. Alternatively, the conveyance system20may allow the loading and unloading of bucks which are moving in up to two different directions simultaneously, such as may result from being moved along a curved segment of conveyor track. The conveyance system20of the present disclosure may provide for faster and/or more consistent cycle times in loading or unloading parts22when compared to the manual loading and unloading operations of the prior art and may allow for a direct labor reduction from 5 persons per shift to 1 person per shift.

As shown inFIG.3, the conveyance system20may be used to control a robot30to move one or more parts22into and out of a machine44. The robot30may pick one or more parts22from a source location26, which may be, for example, a first bin24holding raw, or unfinished parts22, and carry the parts22to the machine44for processing, after which the robot30may remove pick the finished parts22to a destination28, which may be, for example, a second bin24for transporting the finished parts22to another area. In the example shown inFIG.3, the robot30may load and unload right-hand (RH) and left-hand (LH) parts22for simultaneous processing by the machine44. The conveyance system20may accommodate some variation in the placement of the bins24used for the source location26and the destination28. Such variation may allow the source and destination bins26,28to be located anywhere within a window of space in each direction from a nominal position. Therefore, the bins24do not need to be secured in a precise location and may not require a locating fixture. The robot30may accommodate for variations in the location and tolerances of the parts22. According to an aspect, the conveyance system20may inspect the finished parts22, to ensure that the finished parts22were properly processed by the machine44before the parts22are allowed to be processed further. Such an inspection may be, for example, a hole inspection to verify that holes are properly made in the parts22. According to a further aspect, conveyance system20may accommodate a variation in the number of parts22or bins24located at the source location26and/or the destination28, such as variations in the stack height, and may automatically pick or place parts22from the top of a stack of bins24. Such a system20may replace a current manual loading and unloading operation and may occupy the same or a smaller square footage footprint on a building floor. The example shown inFIG.3may allow a reduction from 1 to 0 direct labor on each shift to perform the loading and unloading of parts22from the machine44.

As shown inFIG.4, an example application of the conveyance system20of the present invention may be to replace a manual operation of loading and unloading baskets46of parts22into and out of a machine44. In the example shown, the machine44is a washer with an input belt48for receiving baskets46of dirty parts22and an output belt50for removal of baskets46cleaned parts22. Parts22to be washed arrive in a basket46and are placed in a defined position on a rack inside the basket46. The operator may load a basket46from a source location26onto the input belt48and may then unload the basket46from the output belt50by moving the basket46to a destination28. The baskets46, with parts22may require the use of a mechanical aid such as a crane52to lift in order to be compliant with health and safety regulations. The use of a crane52may be difficult and/or cumbersome to use and may not be embraced by staff. The operator loading and unloading the machine44may perform quality, quantity, and data logging tasks on the parts22.

The process of manually loading and unloading a washing machine44may involve the following steps:Step 1: The operator takes the basket46off a standing/fixed delivery carriage54and places the basket46on the input belt48on the right side of the washing machine44.Step 2: The operator takes the basket46off the output belt50on the left side of the washing machine44and places the basket46on a stationary carriage56in a defined area with. Stack height may vary depending on how many baskets46are already in place on the carriage56.

As illustrated inFIG.4, the carriage56may be fixed, being stationary and located in a general predetermined location window, shown as a taped rectangle on the floor, but the carriages56do not need to be located or secured in a precise position such as by using a mechanical carriage fixing device. The loading and unloading operations are not time-critical. The cycle time of the machine may allow for some variation in when the baskets46are loaded and unloaded. The loading and loading operations may require careful handling. The baskets46may vary in weight and height to accommodate different numbers and types of parts22. Due to the physical constraints of the machine44and the carriages54,56, fencing for a traditional robot cell around the machine44may not be feasible.

As shown inFIG.4, the conveyance system20including a robot30may be used to load and unload baskets46of parts22from the washing machine44. The system20may locate a basket46from the standing/fixed delivery carriage54and may pick the basket46with an end effector32on the robot30, which may place the basket46on the input belt48(dirty parts) of the washing machine44. The system20may detect and locate a basket46on the output belt50of the washing machine44and may move the basket46onto stack on a carriage56. The conveyance system20may use cameras36accommodate baskets46that vary in size and weight and which are not fixed in a specific location. The conveyance system20may perform quantity, quality inspection, and data logging tasks. The conveyance system20may allow baskets to be stacked at different positions on a carriage56which may vary according to the existing load on that carriage56. The system20may provide for loading and unloading cycle times of less than 80s to prevent any bottleneck at the loading or unloading steps. The robot30may have TUV certified skin technology and may recognize and/or inform humans in the working area. In this way, the robot30may be able to operate without protective fencing.

FIGS.4and5provide schematic views of the conveyance system20of the present disclosure as used for the example application of loading and unloading baskets46of parts22from a washing machine44.

As shown inFIG.4, a first vision system34including at least one camera36may identify a basket46including its precise pick location and pick orientation in the source location26, which may be delivery carriage54holding a stack of one or more baskets46. The robot30may pick the basket46from the source location26and move the basket46to the input belt48of the washing machine44. A camera36may not be required to cover the input and/or output belts48,50, as those locations may be fixed, and their status as empty or loaded with a basket46may be communicated to the conveyance system20from the machine44. The conveyance system20may also perform the step of unloading the washing machine44by picking up a basket46from the output belt50and placing that basket at a destination location28, which may be the top of a stack of other baskets46upon a carriage56. The precise location and orientation of the destination28may vary according to the exact location of the carriage and/or the height of the stack of baskets46and may be determined by the second vision system38using one or more cameras36. The system20may provide adaptive trajectory planning to determine the best path to move the baskets46.

As illustrated inFIG.5, the system20may include a trajectory planning controller42for planning a best path40for the robot30to follow in moving an item21, which may be a basket46, between the source location26and the destination28. One or more cameras36may provide a 3-dimensional view to detect the exact position of a basket46. The system20may also detect the number and shape of individual parts22in the basket46. The trajectory planning controller42may perform several functions in the system20, which may include, for example, 2D inspection of a basket46and parts22therein; 3D perception and localization; perception and load & force measurement; production process sequencing, providing a production graphical user interface (GUI); calibration and configuration software; and Production process specific motion planning and control, including the control of the end effector32, also called end-of-arm-tooling (EOAT). The robot30may be a standard type used in industry for automation tasks, and the end effector32may be configured to grasp the standard basket46of different weights.

The trajectory planning controller42may provide adaptive trajectory planning using the information provided by the vision systems (pick part and place part), as well as predetermined or fixed locations to calculate the best trajectory for the robot to follow in picking and placing the item21. The robot30may be directly controlled by a robot controller60which may handle safety functions, movement control, and control of the end effector32. The trajectory planning controller42may coordinate and communicate with a robot operating system (ROS) driver62. The trajectory planning controller42may also be operatively connected to a machine controller64, such as the controller of the washing machine44. This connection to the machine controller64may allow the system20to know when items may be loaded onto or removed from the machine44. The operative connections between devices may include electrical, radio, optical, light-based, and/or mechanical interconnections and may be wired or wireless.

The robot30may be equipped with touch sensors65, which may include pressurized air pads on the end effector32or gripper, which may allow the robot30to be used without the need for fencing. A touch sensor controller66, such as an air skin controller, may be used to monitor the status of one or more touch sensors65on the robot30, and may be operatively connected to a safety circuit of the robot controller60. In order to allow the robot30to operate without traditional safety fencing, such a touch sensor configuration may require safety performance level E and may require the robot30to be able to react to all humans on the shop floor including operators, visitors, supplier staff, etc.. The touch sensor controller66may also be operatively connected to the adaptive system controller42.

After processing by the washing machine44, a camera36may identify a destination location28being a desired stack of baskets46upon a carriage56and which may vary in height as additional baskets46are added to the stack.

The conveyance system20of the present disclosure may provide the following functions: transporting a basket46accounting for variations in the precise special arrangement (x, y, z, roll, pitch, yaw) of both the pick and the place operations; identifying the general source and destination location26,28(x, y, z, yaw) from a stack of one or more baskets46at each location26,28; type identification of baskets46(height, weight, insert feature & geometry); identifying interactions between baskets46(tangled or various other interactions matching predetermined criteria, such as being caught upon another item21and which may be known as easy to take apart); recognizing and reporting a damaged basket46.

The conveyance system20may also provide for identification and information sharing regarding the items21being moved, such as, for example by reading a bar code on the baskets46, and may also identify individual parts22within a basket46, such as by their shape and size in 3-D space, and/or by their positioning within an insert in the basket46. It may provide a mode in which the robot30drains fluid from the carriage56, such as, for example, by moving the carriage56to a designated dumping location and opening a drain valve or by tilting the carriage56.

The conveyance system20may automatically calibrate to account to changes in the environment, such as temperature and/or lighting, and may provide for environmental awareness, such as for crash detection and awareness. In other words, the cameras36of the conveyance system20may detect persons or other hazards, and may direct the robot30to avoid any such hazards. The conveyance system20may provide for increased system reliability and may allow for different sequencing or sorting baskets46, such as, for example, in normal or special operation modes.

The present disclosure also provides a method for automatically moving one or more items21between a structure at a source location26and a destination28using a robot30with an end effector32. The items21may be individual parts22or assemblies of parts22or other things such as a basket46for holding several parts22. The structure may be a bin24for holding parts22. The structure may also be, for example, a cart or a stack or a conveyor for holding or moving parts22or baskets46. The method includes the steps of identifying a part22having a non-fixed location and orientation upon the structure at the source location26using a first vision system34; determining the precise pick location and pick orientation of the part22upon the structure using the first vision system34; and determining the location and orientation of a destination28using a second vision system38. The first and second vision systems34,38may be a combined vision system and may use one or more of the same cameras36. The method also includes the step of performing adaptive trajectory planning to determine the best path40between the source location26and the destination28. According to an aspect, the step of performing adaptive trajectory planning may include the sub-steps of planning a plurality of possible paths40between the source location26and the destination incorporating geometrical information of the robot and source location26and the pick orientation and the destination28which may include the target location and the target orientation; and determining a best path40between the source location26and the destination28by simulating the plurality of possible paths40between the source location26and the destination28. One example of such an active trajectory planning is ROS (Robotic Operating System).

The method proceeds with the steps of picking the item21from the source location26by the end effector32on the robot30; moving the item21along the best path40by the robot30; placing the item21at the destination28by the end effector32on the robot30. The method may also include the step of checking the item21for quality and/or other characteristics by one or more of the first vision system34and the second vision system38.

According to an aspect, the destination28may have a fixed position and orientation. According to another aspect, the destination28may have a varying position, and/or orientation or one which is not fixed in space. According to another aspect, the item21may be disposed loosely or in a fixed position within a bin24at the source location26.

According to an aspect, the first vision34system may be a 2D vision system and the method may further comprise the step of comparing by the first vision system34an image of the item21to a reference image to determine the source location26and the orientation of the item21at the source location26, also called the pick orientation. According to another aspect, the first vision system34may be a 3D vision system, which may be capable of directly determining the source location26and pick orientation. According to an aspect, the system20may be used for two or more distinct pick-and-place operations such as, for example loading and unloading a machine44as shown inFIG.4.

According to an aspect, the second vision system38may be a 2D vision system and the method may further comprise the step of comparing by the second vision system38an image of the item21to a reference image to determine the location and orientation of the destination28. According to another aspect, the second vision system38may be a 3D vision system, which may directly determine the location orientation of the destination28.

FIG.6shows a fenceless robot system100in accordance with some embodiments, and in which the robot30is configured to move in proximity to a person without a safety fence preventing the person from contacting the robot30. The fenceless robot system100may be similar to the conveyance system20shown inFIGS.1-5and may include many of the same components. The example fenceless robot system100shown inFIG.6includes a vision controller70receiving signals from one or more cameras36for sensing a position and orientation of an item21, such as a basket46in a stack upon a carriage56or a precise location of a carriage56as a destination for the robot30to place the basket46. The input belt48may be a predetermined destination28for the robot to place baskets46to be processed by the washing machine44. The output belt50may be a predetermined source location26for the robot30to pick and remove baskets46after processing by the washing machine44. In some embodiments, and as shown inFIG.6, the input belt48and the output belt50of the washing machine44may be integrated at a single, combined location. In some embodiments, one or more of the stacks of baskets46may function as a source location26for the robot30to pick baskets46of dirty parts to be loaded into the washing machine44, and one or more other stacks of baskets46may be a destination26for the robot30to place baskets46of clean parts coming out of the washing machine44. In some embodiments, the stack may include up to ten (10) baskets46. It should be appreciated that the washing machine44is merely an example application and that the fenceless robot system100may be used for many other different applications.

The fenceless robot system100includes a trajectory planning controller42, configured to plan a path for the robot30to follow in moving an item21, such as a basket46, between the source location26and the destination28. The trajectory planning controller42may include a ROS (Robotic Operating System). Alternatively or additionally, the trajectory planning controller42may include another proprietary or open hardware and/or software system configured to plan the path or paths for the robot30to follow.

A proximity sensor74is configured to detect a person in proximity to the robot30. The proximity sensor74may include, for example, a laser scanner, a LIDAR sensor, or one or more optical cameras, which may be combined with a machine vision processor configured to detect presence and /or location of a person. In some embodiments, and as shown inFIG.6, the proximity sensor74may be configured to sense a person within an inner zone80containing the robot30or an outer zone82outside of the reach of the robot30. In some embodiments, such as the arrangement shown inFIG.6, the proximity sensor74may be located adjacent to the robot30. In other embodiments, the proximity sensor74may be spaced away from the robot30.

As also shown inFIG.6, one or more touch sensors65are disposed on surfaces of the robot30and on surfaces surrounding the end effector32. The touch sensors65are configured to detect a contact between an external object, such as a person, and the surface of the robot30or the surface surrounding the end effector32. A touch sensor controller66is configured to monitor the touch sensors65and to report the detection of a contact with an external object. In some embodiments, one or more of the touch sensors65include a bladder configured to deform and to generate a change in fluid pressure in response to contacting the external object. For example, each of a plurality of bladders (not shown) may cover a region of the surface of the robot30or the surface surrounding the end effector32. Alternatively or additionally, one or more of the touch sensors65may include a rigid or semi-rigid panel configured to be displaced by contact with an external object, and the displacement of the panel may be cause a corresponding bladder to be squeezed, generating a corresponding increase in fluid pressure, which may be sensed. The touch sensors65may be, for example, Airskin product from Blue Danube Robotics.

In some embodiments, a visual indicator68, such as a multi-colored light, is configured to indicate a contact between the external object and the surface of the robot30or the surface surrounding the end effector32. The visual indicator68may be disposed within or projected upon a region of the surface of the robot30or the surface surrounding the end effector contacted by the external object. In some embodiments, each of the touch sensors65may include a corresponding visual indicator68which may change between different appearances to indicate various status conditions regarding the touch sensor65. For example, a solid blue light may indicate that the touch sensor65is in working condition and is actively waiting to detect a contact with an external object; a flashing red light may indicate that the touch sensor65is currently detecting contact with an external object; and a solid red light may indicate that the touch sensor65previously detected contact with an external object and is holding its state until it receives a reset signal.

A safety Programmable Logic Controller (safety PLC)80is configured to monitor the touch sensor and the proximity sensor and to stop the robot30in response to an error condition by the touch sensor65, the touch sensor controller66, and/or the proximity sensor74. The error condition may include sensing a person within one of the predefined zones76,78, detecting a contact between the robot30or the end effector32and an external object, or an internal or external failure of any hardware or software of the touch sensor65, the touch sensor controller66, and/or the proximity sensor74. The safety PLC80may include integrated safety functions, safety-certified hardware and software, redundant and/or self-checking circuits to verify proper operation of the touch sensor65, the touch sensor controller66, and/or the proximity sensor74. The safety PLC80may include, for example, a safety-rated PLC by Siemens or Allen-Bradley.

In some embodiments, and as also shown inFIG.6, the fenceless robot system100includes a processing status indicator86adjacent to a processing location88, such as a combined source location26and destination28. The processing status indicators86are configured to indicate a condition of one or more items21located at the processing location88. For example, the processing status indicators86may indicate one of a plurality of different condition states of the one or more items21located at the processing location88. In some embodiments, the processing status indicators86each comprise a lighted indicator having one of a plurality of different colors or patterns, with each of the different colors or patterns indicating a corresponding one of the different condition states.

For example, the processing status indicator86may be illuminated red to indicate the processing location88being in an active state corresponding to the robot30actively using the processing location88as a source location26or as a destination28. The processing status indicator86may be illuminated purple to indicate the processing location88being in a ready state corresponding to items21at the processing location88being in a queue to be used by the robot30in the future. The processing status indicator86may be illuminated blue to indicate the processing location88being in an inactive state corresponding to items21at the processing location88that are not yet processed for use by the robot30. The processing status indicator86may be illuminated green to indicate the processing location88being in a completed state corresponding to the processing location88holding items that have finished being processed by the robot30and which are ready to be taken away from the fenceless robot system100. The colors and states of the processing status indicators86are merely examples, and other colors and/or state condition may be used or indicated by the status indicators86.

One or more of the processing locations88may be dedicated source locations26where items21are picked and removed by the robot30. Alternatively or additionally, one or more of the processing locations88may be dedicated destinations28where items21are placed by the robot30. In the example shown inFIG.6, several different processing locations88are provided as regions or fixtures for placement of a carriage56holding a stack of one or more baskets46.

FIGS.6-7show a schematic diagrams of the fenceless robot system100according to some embodiments of the present disclosure. Specifically,FIGS.6-7show a plurality of zones92,94,96,98concentrically surrounding the robot30. The plurality of zones92,94,96,98includes a restricted access zone92which may be designated for exclusive operation of the robot30. In some embodiments, and as shown inFIG.7, the restricted access zone92may extend around the robot30and have a radius of 733 mm. The plurality of zones92,94,96,98also includes an inner safety zone94surrounding the restricted access zone92and extending between 733-1466 mm from the center of the robot30. The plurality of zones92,94,96,98also includes an outer safety zone96surrounding the inner safety zone94and extending between 1466-2200 mm from the center of the robot30. The plurality of zones92,94,96,98also includes a limited access zone98outside of the outer safety zone96having limited access or use restrictions. For example, the limited access zone98may be designated as a “no-storage zone” where storage of carriages56or other items is prohibited in order to ensure a clear line of sight between the proximity sensor74and the other ones of the plurality of zones92,94,96,98.

In some embodiments, and as shown inFIG.7, the inner zone76is subdivided into the restricted access zone92and the inner and outer safety zones94,96, and the peripheral zone78defines the limited access zone98. In some embodiments, and as shown inFIG.7, the robot30is configured to limit the speed of the end effector32in one or more of the plurality of zones92,94,96,98in response to detecting a human within or in proximity to the inner zone76. For example, the robot30may be configured to move the end effector32at a speed of up to 500 mm/s within the restricted access zone92if no humans are present, and the robot30may limit the speed of the end effector32within the restricted access zone92to 350 mm/s in response to detecting a human within or in proximity to the inner zone76. The robot30may be configured to move the end effector32at a speed of up to 350 mm/s within the inner safety zone94regardless of whether a human is present within or in proximity to the inner zone76. The robot30may be configured to move the end effector32at a speed of up to 250 mm/s within the outer safety zone96if no humans are present, and the robot30may limit the speed of the end effector32within the outer safety zone96to 50 mm/s in response to detecting a human within or in proximity to the inner zone76.

In some embodiments, the end effector32may not be limited to the lower limited speed for some motions which have a lower risk of presenting a hazard to a human in proximity to the robot30, such as motions toward the center of the robot30.

FIGS.9-10show perspective views of the fenceless robot system100according to some embodiments of the present disclosure.FIG.11shows a plan view of a washing machine44configured for manual loading and loading operation.FIG.12shows a plan view of the same washing machine44ofFIG.11configured to be loaded and unloaded by the fenceless robot system100.FIGS.13-15show images of components of the fenceless robot system100according to some embodiments of the present disclosure.FIG.13shows a frame structure104that surrounds the end effector (not shown) and which is used for mounting the touch sensors65surrounding the end effector.

In some embodiments, and as shown inFIG.11, a plurality of first panels110are disposed upon a part of the robot30, such as an arm. Each of the first panels110may be configured to detect a contact with an external object, such as a person, with a surface of the robot. In some embodiments, and as also shown inFIG.11, a plurality of second panels112are disposed upon or around a joint between the robot30and an end effector thereof. Each of the second panels112may be configured to detect a contact with an external object, such as a person, with a surface of the joint. In some embodiments, and as also shown inFIG.11, a plurality of third panels114are disposed around an end effector of the robot30. The third panels114may define a box shape with an open bottom for receiving the objects to be moved by the robot30. Each of the first panels110may be configured to detect a contact with an external object, such as a person, with a surface of the end effector. The system may include a visual indicator120showing a location of the contact between the external object and the surface of the robot30or the surface surrounding the end effector corresponding indicator. For example, the visual indicator120may take the form of a warning light on each of the panels110,112,114that illuminates in response to the corresponding one of the panels110,112,114detecting a contact. The visual indicator120may take other forms, such as a light or other indicator that is projected upon the surface at or near the location of a detected contact with an external object.

A method for moving an item21using a fenceless robot system100is also provided. The method comprises: picking an item from a source location26by an end effector32on a robot30; moving the item along a path to a destination28by the robot30; placing the item at the destination28by the end effector on the robot30; and stopping the robot30from moving in response to detecting contact between an external object and a surface of the robot30or a surface surrounding the end effector32. The robot30is configured to move in proximity to a person without a safety fence preventing the person from contacting the robot30.

In some embodiments, the method for moving an item21using a fenceless robot system100also includes indicating the contact between the external object and the surface of the robot30or the surface surrounding the end effector32by a visual indicator68in a region of the surface of the robot30or the surface surrounding the end effector32contacted by the external object.

In some embodiments, the robot30is capable of moving a payload, including the end effector30and the item21, having a mass of at least 100 kg. In some example embodiments, the robot30may be capable of moving an item21, such as a basket46full of parts having a combined mass of about 40 kg, however, the robot30may be configure to move items21having greater mass. In some embodiments, the robot30moves the item21at a speed greater than 200 mm/s. In some embodiments, the robot30moves the item21at a speed of up to 500 mm/s. In some embodiments, the robot30moves the item21at a speed of up to 700 mm/s.

In some embodiments, the method for moving an item21using a fenceless robot system100also includes detecting the person in one of a plurality of zones around the robot; and adjusting a speed of the robot30in response to detecting the person in one of the plurality of zones around the robot. In some embodiments, adjusting a speed of the robot30in response to detecting the person in one of the plurality of zones around the robot further comprises limiting the speed of the robot to a predetermined threshold speed; and the predetermined threshold speed is one of a plurality of different speeds depending on a location of the end effector32of the robot30.

In some embodiments, the method for moving an item21using a fenceless robot system100also includes detecting the person in one of a plurality of zones92,94,96,98around the robot30being a restricted access zone92; and immediately stopping the robot30from moving in response to detecting the person in the restricted access zone92.

In some embodiments, the method for moving an item21using a fenceless robot system100also includes detecting the person in one of a plurality of zones around the robot being an outer safety zone; and limiting a speed of the robot30in response to detecting the person in outer safety zone. In some embodiments, limiting the speed of the robot30in response to detecting the person in outer safety zone may comprise limiting the speed of the robot30in motions toward or across the outer safety zone while not limiting the speed of the robot30in motions away from the outer safety zone.

In some embodiments, the method for moving an item21using a fenceless robot system100also includes detecting the person in one of a plurality of zones around the robot being an inner safety zone located between the robot and the outer safety zone; and immediately stopping the robot from moving in response to detecting the person in the inner safety zone if the robot is moving toward or across the outer safety zone at a speed in excess of a predetermined threshold.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.