Off-line teach assist apparatus and on-line control apparatus

Claim 2

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a predetermined work path to perform a series of operations with respect to a workpiece moving along said work path, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for precomputing signals representing movement of said arm between said different locations relative to the workpiece accounting for projected workpiece movement and corresponding to movement at the maximum dynamic capabilities of said manipulator arm; and means for storing said precomputed signals for use as command signals in controlling movement of said arm in a playback cycle with a moving workpiece.

Claim 3

The combination of claim 1 further comprising means responsive to said command signals for controlling movement of said arm in correlation with a moving workpiece during a playback cycle.

Claim 4

The combination of claim 2 further comprising workpiece encoder means for developing position signals corresponding to workpiece movement along said predetermined work path.

Claim 5

The combination of claim 3 wherein said controlling means comprises: arithmetic computation means for generating position, velocity and acceleration control signals in accordance with said command signals and a predetermined series of control words, each of said control words including a predetermined number of data bits to define operation of said arithmetic computation means; and means for generating said predetermined series of control words in a predetermined sequence.

Claim 6

The combination of claim 4 wherein said arithmetic computation means comprises means for generating a predetermined number of sequential position, velocity and acceleration control signals.

Claim 7

The combination of claim 5 wherein said command signals include an interpolation interval code to define a predetermined number of interpolation intervals, said controlling means further comprising means responsive to said interpolation interval code for generating an interpolation interval control signal.

Claim 8

The combination of claim 6 wherein said sequential control signal generating means is responsive to said interpolation interval control signal, said predetermined number of interpolation intervals defining said predetermined number of sequential control signals.

Claim 9

The combination of claim 7 wherein said sequential control signal generating means is responsive to two successive command signals, said predetermined number of sequential control signals representing movement of said manipulator arm between the manipulator arm positions represented by said two successive command signals.

Claim 10

The combination of claim 7 wherein each of said stored command signals includes a workpiece positional signal corresponding to projected workpiece movement.

Claim 11

The combination of claim 9 wherein said sequential control signal generating means generates an artificial workpiece position signal and control signals for each of said axes.

Claim 12

The combination of claim 10 wherein said controlling means further comprises means for detecting a predetermined state of equality between said positional signal generated by said workpiece encoder means and said artificial workpiece position signal.

Claim 13

The combination of claim 11 wherein said interpolation interval control signal generating means is responsive to said detecting means.

Claim 14

The combination of claim 12 wherein said interpolation interval control signal is a digital signal advanced by one digital data state upon each occurrence of equality between said workpiece encoder positional signal and said generated workpiece position control signal.

Claim 15

The combination of claim 4 wherein said command signals include mode data signals representing operational modes including an acceleration mode or a constant velocity mode, said controlling means further comprising means for decoding said mode data signals to generate an acceleration control output or a velocity control output.

Claim 16

The combination of claim 14 wherein said arithmetic computation means further comprises means for generating a predetermined number of sequential command signals representing acceleration of said manipulator arm in response to said acceleration control output and representing constant velocity of said manipulator arm in response to said velocity control output.

Claim 17

In a programmable manipulator apparatus for performing work operations with respect to a workpiece movable along a predetermined workpiece path, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected position of said manipulator arm in said plurality of manipulator axes and a corresponding projected workpiece position, said projected manipulator arm position being calculated in a teaching phase in accordance with a predetermined projected workpiece velocity and a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of: means for reading out said command signals in a predetermined manner; means responsive to two successive command signals for generating a predetermined number of sequential position, velocity and acceleration control signals for each of said manipulator axes; and means responsive to said control signals for moving said manipulator arm to said projected position in accordance with movement of said workpiece.

Claim 18

In a programmable manipulator apparatus for performing work operations with respect to a workpiece movable along a predetermined workpiece path, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected position of said manipulator arm in said plurality of manipulator axes and a corresponding projected workpiece position, said projected manipulator arm position being calculated in a teaching phase in accordance with a predetermined projected workpiece velocity and a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of: means for reading out said command signals in a predetermined manner; means responsive to two successive command signals for generating a predetermined number of sequential position, velocity and acceleration control signals for each of said manipulator axes; and means responsive to said control signals for moving said manipulator arm to said projected position in accordance with movement of said workpiece.

Claim 19

The combination of claim 16 wherein said series of command signals represents a predetermined sequence of work operations with respect to a workpiece.

Claim 20

The combination of claim 16 wherein said control signals represent manipulator arm movement in said manipulator axes including constant acceleration portions and constant velocity portions.

Claim 21

The combination of claim 16 wherein said predetermined number of sequential control signals represent the projected dynamic manipulator arm movement between the positions represented by successive command signals with respect to the workpiece.

Claim 22

The combination of claim 16 wherein said control signal generating means comprises: arithmetic computation means for generating position, velocity and acceleration control signals in accordance with said command signals and a predetermined series of control words, each of said control words including a predetermined number of data bits to define operation of said arithmetic computation means; and means for generating said predetermined series of control words in a predetermined sequence.

Claim 23

The combination of claim 20 wherein said command signals include an interpolation interval code to define a predetermined number of interpolation intervals, said control signal generating means further comprising means responsive to said interpolation interval code for generating an interpolation interval control signal.

Claim 24

The combination of claim 21 wherein said control signal generating means is responsive to said interpolation interval control signal, said predetermined number of interpolation intervals defining said predetermined number of sequential control signals.

Claim 25

The combination of claim 16 wherein said control signal generating means comprises means for calculating said velocity control signals from the projected manipulator arm position of said two successive command signals and means for calculating said acceleration control signals from the velocity at the projected manipulator arm positions corresponding to said two successive command signals.

Claim 26

The combination of claim 16 wherein said control signal generating means comprises means for calculating said position control signals from said velocity control signals and the projected manipulator arm position corresponding to one of said two successive command signals.

Claim 27

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having encoder means for said axes operative to develop position signals corresponding to the actual position of said arm and being arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm during an initial teaching operation with a stationary workpiece to different positions corresponding to the desired operations of the manipulator relative to the stationary workpiece; means for calculating signals representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm; and means for storing said calculated arm position signals for use as command signals in controlling movement of said arm in a playback cycle with a moving workpiece.

Claim 28

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having encoder means for said axes operative to develop position signals corresponding to the actual position of said arm and being arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm during an initial teaching operation with a stationary workpiece to different positions corresponding to the desired operations of the manipulator relative to the stationary workpiece; means for calculating signals representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm; and means for storing said calculated arm position signals for use as command signals in controlling movement of said arm in a playback cycle with a moving workpiece.

Claim 29

The combination of claim 25, which includes means responsive to said command signal for moving said arm to said different positions relative to a moving workpiece during a subsequent playback cycle, and means for adjusting said arm moving means for variations in the actual velocity of said moving workpiece from said predetermined velocity during said subsequent playback cycle.

Claim 30

The combination of claim 25 further comprising means responsive to said command signals for controlling movement of said arm in correlation with a moving workpiece during a playback cycle.

Claim 31

The combination of claim 27 further comprising workpiece encoder means for developing position signals corresponding to workpiece movement along said reference axis, said movement controlling means including means for dividing the resultant difference between successive stored command signals into a number of increments equal to a predetermined number of artificial command signals, means for multiplying each of said increments by a variable integer increasing by one with each successive one of said artificial command signals, and means for combining said series of multiplied increment products with the preceding stored command signal to produce said series of artificial command signals.

Claim 32

The combination of claim 28 wherein said stored command signals include a projected workpiece movement positional signal, said means for controlling movement of said arm further comprising means for comparing said position signals corresponding to workpiece movement with said artificial command signals, and said dividing means further comprising counter means responsive to said comparing means and advanced by the coincidence of said aritificial command signals and said position signals corresponding to workpiece movement for controlling the generation of successive artificial command signals.

Claim 33

The combination of claim 27 further comprising workpiece reference axis encoder means for developing position signals corresponding to workpiece movement along said reference axis, said stored command signals including a workpiece reference axis positional signal corresponding to projected workpiece movement, said movement controlling means including means for detecting a predetermined state of equality between said positional signals of said workpiece encoder means and said artificial workpiece reference axis command signals, and means controlled by said detecting means for generating a predetermined number of artificial command signals for controlling movement of said arm in correlation with said moving workpiece.

Claim 34

The combination of claim 30 wherein said artificial command signal generating means further comprises: a multiplier responsive to a control input and arranged to multiply the resultant difference between successive command signals by a series of fractions according to said control input, the denominator of each of said fractions being equal to said predetermined number of artificial command signals, the numerator being a variable integer increasing by one with each successive one of said artificial command signals; and means for combining said series of products of multiplied difference signals and fractions with the preceding command signal to produce said series of artificial command signals, said control input being generated by said detecting means.

Claim 35

The combination of claim 27 further comprising workpiece reference axis encoder means for developing position signals corresponding to workpiece movement along said reference axis, said calculating means comprising means reponsive to said workpiece reference axis encoder means for calculating projected workpiece position signals for each of said initial teaching positions of said manipulator arm based on maximum projected workpiece movement and the maximum dynamic capabilities of the manipulator arm, and means for storing said projected workpiece position signals.

Claim 36

The combination of claim 25 wherein said calculating means further comprises: means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps to Cartesian coordinates of the free end of said arm; means for translating said resulting Cartesian coordinates to account for the projected movement of said workpiece in terms of positional displacement units along said reference axis during the projected elapsed time for said arm to traverse the distance between successive taught positions on said workpiece at the maximum dynamic capabilities of said arm; and means for reconverting said translated Cartesian coordinates into new position signals corresponding to different angular positions of said arm in said plurality of axes.

Claim 37

The combination of claim 33 wherein said translating means comprises: means for determining the projected time interval T 1-2 for the arm to traverse the distance between successive taught points P 1s and P 2s on the stationary workpiece at a projected arm velocity of V, a projected arm acceleration +a and a projected arm deceleration -a, and means for modifying the Cartesian coordinates of P 2s by a quantity which is defined by a first factor equal to the accumulated program position, ΣD 1 , up to program step 1 corresponding to P 1s in terms of a number of basic displacement units of workpiece position and the distance D 1-2 traversed by the workpiece during movement of the arm between P 1s and P 2s in terms of a number of basic displacement units of workpiece position.

Claim 38

The combination of claim 34 wherein said determining means comprises: means for calculating T 1 , the time for the manipulator arm to accelerate at the rate +a from the projected workpiece velocity Vc to the velocity V M ; means for calculating T 2 , the time for the manipulator arm to decelerate at the rate -a from the velocity V M to the velocity Vc; and means for calculating T M , the time for the manipulator arm to move the distance, ΔS 1-2 -1/2V M (T 1 +T 2 ), at the velocity V M , where ΔS 1-2 is the distance between the points P 1s and P 2s .

Claim 39

The combination of claim 35 wherein said manipulator arm velocity V M is equal to the maximum manipulator arm velocity V MAX minus the projected workpiece velocity Vc.

Claim 40

The combination of claim 35 wherein said projected time interval T 1-2 is equal to the sum of the times T 1 , T 2 and T M .

Claim 41

The combination of claim 37 wherein said modifying means comprises means for calculating said distance D 1-2 on the basis of the time T 1-2 and the projected workpiece velocity V c .

Claim 42

The combination of claim 34 wherein said determining means comprises: means for calculating T.sub.θn for each of the manipulator axes, where T.sub.θn is the minimum projected time interval for each axis of the manipulator to accomplish the movement between P 1s and P 2s ; and means for comparing the Tθn values for the manipulator axes and determining the greatest T.sub.θn to define T 1-2 .

Claim 43

The combination of claim 25 which includes means responsive to said command signal for moving said arm to said desired location relative to a workpiece which is moving at a velocity which is different from said projected velocity during a subsequent playback cycle.

Claim 44

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals correponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; and means for translating said resulting Cartesian coordinates to account for the projected movement of said workpiece in terms of positional displacement units along said reference axis during the projected elapsed time for said arm to traverse the distance between successive taught positions on said workpiece at the maximum dynamic capabilities of said arm.

Claim 45

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals correponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; and means for translating said resulting Cartesian coordinates to account for the projected movement of said workpiece in terms of positional displacement units along said reference axis during the projected elapsed time for said arm to traverse the distance between successive taught positions on said workpiece at the maximum dynamic capabilities of said arm.

Claim 46

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes, and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; means for calculating the time interval required for said arm to traverse the distance between successive taught positions when the workpiece is moving at a predetermined velocity and said arm is moving at the maximum dynamic capabilities; and means controlled by said calculating means for translating said resulting Cartesian coordinates to account for movement of said workpiece along said reference axis during said calculated time interval.

Claim 47

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes, and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; means for calculating the time interval required for said arm to traverse the distance between successive taught positions when the workpiece is moving at a predetermined velocity and said arm is moving at the maximum dynamic capabilities; and means controlled by said calculating means for translating said resulting Cartesian coordinates to account for movement of said workpiece along said reference axis during said calculated time interval.

Claim 48

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; means for calculating the time interval required for said arm to traverse the distance between successive taught locations when said arm is moving at the maximum dynamic capabilities throughout said time interval and said workpiece is moving along said reference axis at a predetermined velocity; and means controlled by said calculating means for translating said resulting Cartesian coordinates to account for movement of said workpiece along said reference axis during said calculated time interval.

Claim 49

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; means for calculating the time interval required for said arm to traverse the distance between successive taught locations when said arm is moving at the maximum dynamic capabilities throughout said time interval and said workpiece is moving along said reference axis at a predetermined velocity; and means controlled by said calculating means for translating said resulting Cartesian coordinates to account for movement of said workpiece along said reference axis during said calculated time interval.

Claim 50

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; means for calculating the path of movement and the minimum time which are required for said arm when moving at predetermined dynamic parameters in order to position said arm at the taught location relative to the workpiece when the workpiece is moving at a predetermined velocity; and means controlled by said calculating means for translating said resulting Cartesian coordinates to values corresponding to said taught location relative to a moving workpiece.

Claim 51

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; means for converting said position signals corresponding to different angular positions of said arm in said plurality of axes for successive taught steps into corresponding Cartesian coordinates; means for calculating the path of movement and the minimum time which are required for said arm when moving at predetermined dynamic parameters in order to position said arm at the taught location relative to the workpiece when the workpiece is moving at a predetermined velocity; and means controlled by said calculating means for translating said resulting Cartesian coordinates to values corresponding to said taught location relative to a moving workpiece.

Claim 52

The combination of claim 44 wherein said predetermined velocity of said workpiece is the maximum allowable velocity of said workpiece when said arm is moving at its maximum velocity.

Claim 55

The method of claim 46 further comprising the step of selectively advancing the workpiece during the initial teaching operation to the approximate position corresponding to the position of the workpiece accounting for projected workpiece movement.

Claim 58

In programmable manipulator apparatus for performing work operations with respect to a workpiece movable along a predetermined workpiece path, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected dynamic manipulator parameters of said manipulator arm in said plurality of manipulator axes with respect to a corresponding projected workpiece position, said projected manipulator arm positions being calculated in a teaching phase in accordance with a predetermined projected workpiece velocity and a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of: means for reading out said command signals in a predetermined manner; means responsive to two successive command signals for generating a predetermined number of sequential positions, velocity and acceleration control signals for each of said manipulator axes; and means responsive to said control signals for moving said manipulator arm in accordance with movement of said workpiece.

Claim 59

In programmable manipulator apparatus for performing work operations with respect to a workpiece movable along a predetermined workpiece path, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected dynamic manipulator parameters of said manipulator arm in said plurality of manipulator axes with respect to a corresponding projected workpiece position, said projected manipulator arm positions being calculated in a teaching phase in accordance with a predetermined projected workpiece velocity and a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of: means for reading out said command signals in a predetermined manner; means responsive to two successive command signals for generating a predetermined number of sequential positions, velocity and acceleration control signals for each of said manipulator axes; and means responsive to said control signals for moving said manipulator arm in accordance with movement of said workpiece.

Claim 60

In a programmable manipulator having a manipulator arm movable in a plurality of axes and arranged adjacent a predetermined work path to perform a series of work operations on a workpiece moving along said work path, the combination of: means having stored therein a first series of program work operation command signals representing positions of said manipulator arm in said plurality of axes and a second series of track alarm command signals representing positions of said manipulator arm, each of said track alarm command signals representing a predetermined static point on the workpiece at corresponding workpiece positions; means for detecting a predetermined improper operating mode of said manipulator arm with respect to said workpiece; means for controlling the sequential read out of said first series of program work operations in accordance with movement of said workpiece; means responsive to said first and second series of command signals for moving said manipulator arm to the positions represented by said command signals; and means responsive to said detecting means for controlling the read out of said second series of track alarm command signals.

Claim 61

In a programmable manipulator having a manipulator arm movable in a plurality of axes and arranged adjacent a predetermined work path to perform a series of work operations on a workpiece moving along said work path, the combination of: means having stored therein a first series of program work operation command signals representing positions of said manipulator arm in said plurality of axes and a second series of track alarm command signals representing positions of said manipulator arm, each of said track alarm command signals representing a predetermined static point on the workpiece at corresponding workpiece positions; means for detecting a predetermined improper operating mode of said manipulator arm with respect to said workpiece; means for controlling the sequential read out of said first series of program work operations in accordance with movement of said workpiece; means responsive to said first and second series of command signals for moving said manipulator arm to the positions represented by said command signals; and means responsive to said detecting means for controlling the read out of said second series of track alarm command signals.

Claim 62

In a programmable manipulator having a manipulator arm controllable in a plurality of axes and arranged adjacent a workpiece moving along a predetermined work path to perform a predetermined series of work operations on a workpiece moving along said work path, said manipulator arm including a work head for selective contact with said workpiece, the combination of: means for positioning said arm at different positions relative to a stationary workpiece during an initial teaching operation; means for calculating signals representing a predetermined change in orientation of said manipulator arm relative to the workpiece for work operations in contact with and tracking the workpiece movement, said predetermined change in orientation being calculated to change the orientation of said manipulator arm by said predetermined orientation change between the initial contact of said manipulator arm and the workpiece and the projected termination of the workpiece contact; and means for storing said calculated signals for use as command signals in controlling movement of said arm in a playback cycle to perform said predetermined series of work operations on the workpiece.

Claim 63

In a programmable manipulator having a manipulator arm controllable in a plurality of axes and arranged adjacent a workpiece moving along a predetermined work path to perform a predetermined series of work operations on a workpiece moving along said work path, said manipulator arm including a work head for selective contact with said workpiece, the combination of: means for positioning said arm at different positions relative to a stationary workpiece during an initial teaching operation; means for calculating signals representing a predetermined change in orientation of said manipulator arm relative to the workpiece for work operations in contact with and tracking the workpiece movement, said predetermined change in orientation being calculated to change the orientation of said manipulator arm by said predetermined orientation change between the initial contact of said manipulator arm and the workpiece and the projected termination of the workpiece contact; and means for storing said calculated signals for use as command signals in controlling movement of said arm in a playback cycle to perform said predetermined series of work operations on the workpiece.

Claim 64

In a programmable manipulator having a manipulator arm movable in a plurality of axes and arranged adjacent a predetermined work path to perform a series of work operations on a workpiece moving along said work path, the combination of: means having stored therein a first series of program work operation command signals representing positions of said manipulator arm in said plurality of axes and one or more series of escape path signals representing positions of said manipulator arm, each of said series of escape path command signals representing a series of manipulator arm positions to withdraw said manipulator arm away from said workpiece to a predetermined position; means actuable by an operator for generating an escape mode signal; means for controlling the sequential read out of said first series of program work operations in accordance with movement of said workpiece; means responsive to said first series of command signals and said escape path command signals for moving said manipulator arm to the positions represented by said command signals; and means responsive to said escape mode generating means for controlling the read out of a predetermined one of said series of escape path command signals in accordance with the number of the work operation command signals at which said escape mode generating means is actuated.

Claim 65

In a programmable manipulator having a manipulator arm movable in a plurality of axes and arranged adjacent a predetermined work path to perform a series of work operations on a workpiece moving along said work path, the combination of: means having stored therein a first series of program work operation command signals representing positions of said manipulator arm in said plurality of axes and one or more series of escape path signals representing positions of said manipulator arm, each of said series of escape path command signals representing a series of manipulator arm positions to withdraw said manipulator arm away from said workpiece to a predetermined position; means actuable by an operator for generating an escape mode signal; means for controlling the sequential read out of said first series of program work operations in accordance with movement of said workpiece; means responsive to said first series of command signals and said escape path command signals for moving said manipulator arm to the positions represented by said command signals; and means responsive to said escape mode generating means for controlling the read out of a predetermined one of said series of escape path command signals in accordance with the number of the work operation command signals at which said escape mode generating means is actuated.

Claim 66

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle while the workpiece is moving along a predetermined path, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to a stationary workpiece; predict means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions and accounting for projected playback workpiece movement without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said predict means comprising means for determining the projected minimum execution time required in each of said axes for the manipulator arm to accomplish said projected path of movement between each of said initial teaching positions accounting for projected workpiece movement and without exceeding said predetermined dynamic parameters, and means for comparing said minimum projected execution times in each of said axes to determine the axis requiring the largest projected execution time for each movement between teaching positions, said predict means utilizing said largest execution time to determine said projected path of movement between each of said initial teaching positions; and means for storing said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 67

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle while the workpiece is moving along a predetermined path, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to a stationary workpiece; predict means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions and accounting for projected playback workpiece movement without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said predict means comprising means for determining the projected minimum execution time required in each of said axes for the manipulator arm to accomplish said projected path of movement between each of said initial teaching positions accounting for projected workpiece movement and without exceeding said predetermined dynamic parameters, and means for comparing said minimum projected execution times in each of said axes to determine the axis requiring the largest projected execution time for each movement between teaching positions, said predict means utilizing said largest execution time to determine said projected path of movement between each of said initial teaching positions; and means for storing said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 68

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle while the workpiece is moving along a predetermined path, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to a stationary workpiece defining a predetermined playback work cycle; predict means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions and accounting for projected playback workpiece movement without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said predict means comprising means for determining the limit axis for each movement of said manipulator arm between said successive teaching positions, said limit axis being defined as that axis requiring the greatest execution time during the projected path of movement of said manipulator arm between each of said successive initial teaching positions accounting for projected workpiece movement and without exceeding said predetermined dynamic parameters, said predict means utilizing each of said limit axis determinations to calculate said projected path of movement between each of said teaching positions to perform said projected playback work cycle in minimum projected execution time with respect to a workpiece moving at a projected velocity; and means for storing said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 69

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle while the workpiece is moving along a predetermined path, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to a stationary workpiece defining a predetermined playback work cycle; predict means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions and accounting for projected playback workpiece movement without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said predict means comprising means for determining the limit axis for each movement of said manipulator arm between said successive teaching positions, said limit axis being defined as that axis requiring the greatest execution time during the projected path of movement of said manipulator arm between each of said successive initial teaching positions accounting for projected workpiece movement and without exceeding said predetermined dynamic parameters, said predict means utilizing each of said limit axis determinations to calculate said projected path of movement between each of said teaching positions to perform said projected playback work cycle in minimum projected execution time with respect to a workpiece moving at a projected velocity; and means for storing said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 70

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent to a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said arm at different locations relative to the workpiece during an initial teaching operation; means for precomputing signals representing movement of said arm between said different locations relative to said workpiece corresponding to movement at the maximum dynamic capabilities of said manipulator arm; and means for storing said precomputed signals for use as command signals in controlling movement of said arm in a playback cycle.

Claim 71

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent to a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said arm at different locations relative to the workpiece during an initial teaching operation; means for precomputing signals representing movement of said arm between said different locations relative to said workpiece corresponding to movement at the maximum dynamic capabilities of said manipulator arm; and means for storing said precomputed signals for use as command signals in controlling movement of said arm in a playback cycle.

Claim 72

The combination of claim 55 further comprising means responsive to said command signals for controlling movement of said arm during a playback cycle.

Claim 73

The combination of claim 56 wherein each of said command signals has associated therewith an execution time signal representing the execution time as a number of basic timing units that corresponds to the movement of said manipulator arm represented by said associated command signals.

Claim 74

The combination of claim 57 wherein said playback controlling means comprises playback timing means for generating playback timing signals at a predetermined rate corresponding to said basic timing units, said playback controlling means being responsive to said timing signals to control movement of said manipulator arm represented by said command signals at the execution time represented by said associated execution time signal.

Claim 75

The combination of claim 58 wherein said controlling means comprises: arithmetic computation means for generating position, velocity and acceleration control signals in accordance with said command signals and a predetermined series of control words, each of said control words including a predetermined number of data bits to define operation of said arithmetic computation means; and means for generating said predetermined series of control words in a predetermined sequence.

Claim 76

The combination of claim 59 wherein said arithmetic computation means comprises means for generating a predetermined number of sequential position, velocity and acceleration control signals.

Claim 77

The combination of claim 60 wherein said command signals include an interpolation interval code to define a predetermined number of interpolation intervals, said controlling means further comprising means responsive to said interpolation interval code for generating an interpolation interval control signal.

Claim 78

The combination of claim 61 wherein said sequential control signal generating means is responsive to said interpolation interval control signal, said predetermined number of interpolation intervals defining said predetermined number of sequential control signals.

Claim 79

The combination of claim 62 wherein said sequential control signal generating means is responsive to two successive command signals, said predetermined number of sequential control signals representing movement of said manipulator arm between the manipulator arm positions represented by said two successive command signals.

Claim 84

In programmable manipulator apparatus for performing work operations with respect to a workpiece, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected dynamic manipulator parameters of said manipulator arm in said plurality of manipulator axes to accomplish said work operation, said projected manipulator arm positions being calculated in a teaching phase in accordance with a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of: means for reading out said command signals in a predetermined manner; means responsive to two successive command signals for generating a predetermined number of sequential position, velocity and acceleration control signals for each of said manipulator axes; and means responsive to said control signals for moving said manipulator arm in accordance with movement of said workpiece.

Claim 85

In programmable manipulator apparatus for performing work operations with respect to a workpiece, the programmable manipulator apparatus having a manipulator arm controllable in a plurality of manipulator axes and having stored therein a series of command signals, each of said command signals representing the projected dynamic manipulator parameters of said manipulator arm in said plurality of manipulator axes to accomplish said work operation, said projected manipulator arm positions being calculated in a teaching phase in accordance with a predetermined set of dynamic manipulator arm parameters including velocity and acceleration components, the combination of: means for reading out said command signals in a predetermined manner; means responsive to two successive command signals for generating a predetermined number of sequential position, velocity and acceleration control signals for each of said manipulator axes; and means responsive to said control signals for moving said manipulator arm in accordance with movement of said workpiece.

Claim 86

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to a workpiece; means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions relative to the workpiece without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said calculating means comprising means for determining the projected minimum execution time required in each of said axes for the manipulator arm to accomplish said projected path of movement between each of said initial teaching positions relative to the workpiece without exceeding said predetermined dynamic parameters, and means for comparing said minimum projected execution times in each of said axes for each of said movements between teaching positions to determine the axis requiring the largest projected execution time, said calculating means utilizing said largest execution time to determine said projected path of movement between each of said initial teaching positions; and means responsive to said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 87

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to a workpiece; means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions relative to the workpiece without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said calculating means comprising means for determining the projected minimum execution time required in each of said axes for the manipulator arm to accomplish said projected path of movement between each of said initial teaching positions relative to the workpiece without exceeding said predetermined dynamic parameters, and means for comparing said minimum projected execution times in each of said axes for each of said movements between teaching positions to determine the axis requiring the largest projected execution time, said calculating means utilizing said largest execution time to determine said projected path of movement between each of said initial teaching positions; and means responsive to said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 88

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to the workpiece defining a predetermined playback work cycle; means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said calculating means comprising means for determining the limit axis for each movement of said manipulator arm between said successive teaching positions, said limit axis being defined as that axis requiring the greatest execution time during the projected path of movement of said manipulator arm between each of said successive initial teaching positions without exceeding said predetermined dynamic parameters, said calculating means utilizing each of said limit axis determinations to calculate said projected path of movement between each of said teaching positions to perform said projected playback work cycle in minimum projected execution time; and means responsive to said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 89

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, the programmable manipulator having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and the programmable manipulator being arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said manipulator arm during an initial teaching operation to different locations relative to the workpiece defining a predetermined playback work cycle; means for calculating signals representing the projected path of movement of said manipulator arm corresponding to movement of said arm between said initial teaching positions without exceeding predetermined dynamic operating parameters for each of said axes of said manipulator arm, said calculating means comprising means for determining the limit axis for each movement of said manipulator arm between said successive teaching positions, said limit axis being defined as that axis requiring the greatest execution time during the projected path of movement of said manipulator arm between each of said successive initial teaching positions without exceeding said predetermined dynamic parameters, said calculating means utilizing each of said limit axis determinations to calculate said projected path of movement between each of said teaching positions to perform said projected playback work cycle in minimum projected execution time; and means responsive to said signals representing said projected path of movement for use as command signals in controlling movement of said manipulator arm in said operational playback work cycle.

Claim 94

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said arm at different locations relative to the workpiece during an initial teaching operation representing taught arm positions with respect to the workpiece; means for storing position signals during said initial teaching operation representing said taught arm positions; workpiece deviation sensing means for generating deviation signals representing the deviation of the workpiece in a playback cycle with respect to a predetermined workpiece orientation in said initial teaching operation; precomputing means responsive to said generated deviation signals and said stored position signals for generating precomputed command signals during said playback cycle representing positions of said arm accounting for projected workpiece movement and accounting for the deviations of the workpiece from the predetermined workpiece orientation during the teaching operations, said generated command signals representing movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm; and means responsive to said generated command signals for controlling movement of said manipulator arm during said playback cycle.

Claim 95

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a workpiece to perform a series of operations with respect to the workpiece during an operational playback work cycle, the combination of: means for positioning said arm at different locations relative to the workpiece during an initial teaching operation representing taught arm positions with respect to the workpiece; means for storing position signals during said initial teaching operation representing said taught arm positions; workpiece deviation sensing means for generating deviation signals representing the deviation of the workpiece in a playback cycle with respect to a predetermined workpiece orientation in said initial teaching operation; precomputing means responsive to said generated deviation signals and said stored position signals for generating precomputed command signals during said playback cycle representing positions of said arm accounting for projected workpiece movement and accounting for the deviations of the workpiece from the predetermined workpiece orientation during the teaching operations, said generated command signals representing movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm; and means responsive to said generated command signals for controlling movement of said manipulator arm during said playback cycle.

Claim 96

The combination of claim 71 wherein the workpiece moves along a predetermined work path during said playback work cycle.

Claim 97

The combination of claim 72 wherein said deviation signals represent the deviation of said workpiece in said playback work cycle with respect to the orientation of said workpiece about said work path, said deviation signals being equal for all of said taught arm positions.

Claim 98

The combination of claim 72 further comprising workpiece moving means for moving said workpiece along said work path and for orientating said workpiece along and with respect to said work path, said deviation signals representing incorrect registration of said workpiece with respect to said workpiece moving means and the deviation of said workpiece in directions orthogonal to said work path.

Claim 99

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a predetermined work path to perform a series of operations with respect to a workpiece moving along said work path, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; and means for precomputing signals during said initial teaching operation representing movement of said arm between said different locations relative to the workpiece accounting for projected workpiece movement and corresponding to movement at the maximum dynamic capabilities of said manipulator arm.

Claim 100

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having means for developing position signals corresponding to the actual position of said arm in said plurality of axes and arranged adjacent a predetermined work path to perform a series of operations with respect to a workpiece moving along said work path, the combination of: means for positioning said arm at different locations relative to a stationary workpiece during an initial teaching operation; and means for precomputing signals during said initial teaching operation representing movement of said arm between said different locations relative to the workpiece accounting for projected workpiece movement and corresponding to movement at the maximum dynamic capabilities of said manipulator arm.

Claim 101

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having encoder means for said axes operative to develop position signals corresponding to the actual position of said arm and being arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm during an initial teaching operation with a stationary workpiece to different positions corresponding to the desired operations of the manipulator relative to the stationary workpiece; means for calculating signals during said initial teaching operation representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm; means for storing said position signals representing said taught arm positions; and means responsive to said stored signals for controlling movement of said arm in correlation with a moving workpiece during a playback cycle, said movement controlling means comprising means for generating signals during said playback cycle representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm.

Claim 102

In a programmable manipulator provided with a manipulator arm which is movable in a plurality of axes, having encoder means for said axes operative to develop position signals corresponding to the actual position of said arm and being arranged adjacent a reference axis to perform a series of operations on a workpiece moving along said reference axis, the combination of: means for positioning said arm during an initial teaching operation with a stationary workpiece to different positions corresponding to the desired operations of the manipulator relative to the stationary workpiece; means for calculating signals during said initial teaching operation representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm; means for storing said position signals representing said taught arm positions; and means responsive to said stored signals for controlling movement of said arm in correlation with a moving workpiece during a playback cycle, said movement controlling means comprising means for generating signals during said playback cycle representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions at the maximum dynamic capabilities of said manipulator arm.

Claim 105

The method of claim 77 further comprising the step of selectively advancing the workpiece during the initial teaching operation to the approximate position corresponding to the position of the workpiece accounting for projected workpiece movement.

Claim 106

The method of claim 77 further comprising the step of generating signals during a playback cycle in response to said stored position signals and representing positions of said arm accounting for projected workpiece movement and corresponding to movement of said arm between said taught positions in the minimum projected elapsed time and at the maximum dynamic capabilities of said manipulator arm.

Claim 107

The method of claim 79 further comprising the step of controlling movement of said manipulator arm during the playback cycle in accordance with said generated signals and the position of the workpiece to perform said series of operations on the workpiece.