Claims:
1. A system configured to enable automatic product testing, said system comprising:
a robot end-effector configured at the end of a robotic arm of a robot, said robot end-effector comprising at least two mechanical fingers that provide a minimal gripping force on at least a part of the product;
an incoming conveyor configured to transport said product to be tested from a first location to a second location, said incoming conveyor comprising a singling cylinder configured to restrict mobility of a subsequent product until said robot picks up said product from picking zone, said incoming conveyor further comprising a rotary system and a mechanical guide plate used for proper positioning of said product.

2. The system of claim 1, wherein said system further comprises an ON-Reset-Trip mechanism that enables circuit breaker to be tested to be automatically configured in ON state, Reset state, and Trip state in each cycle, wherein the ON-Reset-Trip mechanism comprises any or a combination of an ON cylinder, a Reset cylinder, a Trip cylinder, a load/unload cylinder, and a clamp cylinder.

3. The system of claim 1, wherein the minimal gripping force is determined based on mass of product part that is to be moved, friction co-efficient between material of which said fingers are made and material of which said product part is made, and gravitational acceleration constant.

4. The system of claim 1, wherein said robot end-effector comprises a fix plate and a moving plate that are operatively coupled with each other.

5. The system of claim 1, wherein said product is a circuit breaker.

6. The system of claim 1, wherein said incoming conveyor further comprises a scanner configured to scan a code printed on said product so as to determine if said product passed the test at previous station.

7. The system of claim 1, wherein the system further comprises a pass and fail conveyor configured to receive a test passed product from said robot, and transport said product to subsequent station.

8. The system of claim 1, wherein the system comprises an integrated control system comprising a controller that is operatively coupled with a test bench such that upon said controller issuing a command to a Programmable Logic Controller (PLC), said PLC controls said robot.

9. The system of claim 1, wherein said robot is configured with a machine learning algorithm based on which said robot self-learns operation and process of said product testing in view various faults and errors, and process operation of testing said product and subsequent products based on such self-learning.

10. The system of claim 9, wherein said self-learning is based on re-positioning of said robot, reaction of said robot during power failure, reaction of robot when the incoming conveyor is full, and reaction of said at least two mechanical fingers when air supply drops.
, Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of circuit breaker, and more specifically, relates to a smart system comprising of Industrial Robot and Test bench for performing automatic product testing.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] An electronic circuit breaker is used to interrupt an electric circuit under an abnormal condition, such as a power surge or a ground fault. An electronic circuit breaker is rated at predetermined which indicates the threshold current passing through the breaker which will trip the breaker, causing it to interrupt the electric circuit. The tester of the present invention is particularly suited for testing circuit breakers having threshold current ratings of between 63 and 1600 Amperes, though the tester may find applications involving the testing of other circuit breakers as well.
[0004] Circuit breakers require testing to ensure proper functioning of the circuit breaker in which the test bench is coupled with circuit breaker to test the functionality of the circuit breaker. Problems are diagnosed based on the test, and the circuit breaker is repaired or replaced as needed.
[0005] Some present-day testers are large and unwieldy, typically comprising a suitcase-sized box (e.g., eighteen inches by twelve inches by six inches). These testers perform many tests on the circuit breakers, some of which may not be necessary to provide a reasonable diagnosis of the functionality of the circuit breaker. The size and complexity of these testers makes them difficult to use and transport in many applications, particularly when the maintenance personnel must travel to the work site.
[0006] One portable tester performs a “dry” test and a primary injection test. The dry test subjects the breaker to simulated phase overload and simulated ground fault tests. Primary injection testing verifies the wiring outside of the circuit breaker. However, both tests are not necessary for all testing situations. Also, this tester fails to test the continuity of the current transformer within the circuit breaker which, it has been found, yields a great deal of test data regarding the condition of a circuit breaker.
[0007] Also, Magnetic Testing is most important and crucial testing for MCCB. As per IEC 60898 clause 9.10, this test is must to be conducted to confirm product specification. Magnetic Testing is one of the bottleneck station in MCCB production line and this test is performed on 2 test bench and by 2 operators. There is often safety concern received from Production that Operator finger get cut/pressed/light burn during Magnetic Testing.
[0008] Currently, a product to be tested needs to be placed manually in “ON” condition on a fixture, needs to be slided mannually, and needs to be clamped by test fixture and Barcode Scan. However, such manual technique of testing imposes restrictions for production outputs. For example, 200 Nos. / 1 Test Bench / Shift imposing bottleneck situation at a station. Further, manual safety is also a major concern for example, safety issues such as burning/ electric shock/ finger pressed due to manual techniques.
[0009] What is observer in existing literature is that there is no availability of a standard gripper available to grip the product. Further, there is no standard incoming conveyor is available to pick the product from incoming conveyor. Furthermore, there is no standard system available to make ON-OFF-Reset the product in test bench fixture.
[00010] Accordingly, what is needed is a smart system comprising of Industrial Robot and Test bench for performing automatic product testing.
[00011] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[00012] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about”. Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[00013] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[00014] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[00015] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

SUMMARY
[00016] The present disclosure relates to the field of circuit breaker, and more specifically, relates to a smart system comprising of Industrial Robot and Test bench for performing automatic product testing.
[00017] Embodiments of the present disclosure provide an efficient, effective, reliable, and improved robot integrated smart system for automatic product testing. Further, the present invention provides a smart system comprising of Industrial Robot and Test bench for performing automatic product testing.
[00018] Accordingly, an aspect of the present disclosure relates to a system configured to enable automatic product testing. The system includes a robot end-effector configured at the end of a robotic arm of a robot. The robot end-effector comprising at least two mechanical fingers that provide a minimal gripping force on at least a part of the product.
[00019] The system further includes an incoming conveyor configured to transport said product to be tested from a first location to a second location. The incoming conveyor comprising a singling cylinder configured to restrict mobility of a subsequent product until said robot picks up said product from picking zone. The incoming conveyor further includes a rotary system and a mechanical guide plate used for proper positioning of said product.
[00020] In an aspect, the system can further include an ON-Reset-Trip mechanism that enables circuit breaker to be tested to be automatically configured in ON state, Reset state, and Trip state in each cycle, wherein the ON-Reset-Trip mechanism comprises any or a combination of an ON cylinder, a Reset cylinder, a Trip cylinder, a load/unload cylinder, and a clamp cylinder.
[00021] In an aspect, the minimal gripping force is determined based on mass of product part that is to be moved, friction co-efficient between material of which said fingers are made and material of which said product part is made, and gravitational acceleration constant.
[00022] In an aspect, the robot end-effector includes a fix plate and a moving plate that are operatively coupled with each other
[00023] In an aspect, the product is a circuit breaker.
[00024] In an aspect, the incoming conveyor further comprises a scanner configured to scan a code printed on said product so as to determine if said product passed the test at previous station.
[00025] In an aspect, the system further includes a pass and fail conveyor configured to receive a test passed product from said robot, and transport said product to subsequent station
[00026] In an aspect, the system further includes an integrated control system comprising a controller that is operatively coupled with a test bench such that upon said controller issuing a command to a Programmable Logic Controller (PLC).
[00027] In an aspect, said robot is configured with a machine learning algorithm based on which said robot self-learns operation and process of said product testing in view various faults and errors, and process operation of testing said product and subsequent products based on such self-learning.
[00028] In an aspect, said self-learning is based on re-positioning of said robot, reaction of said robot during power failure, reaction of robot when the incoming conveyor is full, and reaction of said at least two mechanical fingers when air supply drops.
[00029] In contrast to the conventional circuit breaker testing methodologies, the present disclosure provides a smart system comprising of Industrial Robot and Test bench for performing automatic product testing.
[00030] The inventors of the present application noted various issues in existing manual testing of products (circuit breakers). Below provided are few such problems in the existing manual testing and the solution to solve these problems as provided in the present invention.
a) Early Detection of Fail breaker in Previous Station:
Problem Definition: There is more cycle time if the product is not passed from previous station.
Problem Solution: A barcode Scanner is attached with incoming conveyor. During Robot Pick-up, it scanned the product and confirm whether it is passed or fail in previous station. If Fail, then Robot Pick it and Place it to Fail conveyor immediately.
b) Pass Fail Conveyor Interlocking:
Problem Definition: Robotic System used get collide with breaker when Pass / Fail Conveyor is Full.
Problem Solution: A Proximity sensor installed to detect in case Product is present. Robotic System is used to get paused in case Conveyor is getting full. An Additional Sensor also installed to provide warning to operator (previous Station) that conveyor is going to Full.
c) Singling System:
Problem Definition: Ideally, Robot is used to pick one breaker from incoming conveyor. Many times it is observed; Robot is unable to pick breaker due to load from queue products.
Problem Solution: 2 Cylinder is installed such a way that one cylinder will be actuated when another will be de-actuated. Hence, Product flows one at a time only.
d) Product Present in Fixture
Problem Definition: Many times it is observed; Robot went to place the product to Test bench fixture where product is already present, and thereby causing collision.

Problem Solution: A sensor installed in Test Bench Fixture to detect whether any product is present or not. If present, robot will never place breaker inside it.
e) IOT (Queue based prioritize logic for maximum utilization):
Problem Definition: More cycle time due to improper allocation of job.
Problem Solution: The algorithm is developed such a way that it can predict how much cycle time required to perform for particular rating. Hence, based on its predictive database, it allocated the job with its Queue based prioritize logic, causing maximum utilization of cycle time.
f) Gripper will be close in case Air Pressure Drop
Problem Definition: Product used gets dropped from gripper due to Air pressure drop.
Problem Solution: Double Acting Cylinder valve is used to ensure Gripper is closed all at a time.
g) Data logging & Report Generation
Data used to get captured during Robot Operation. This Data can be defined as Barcode information, start time, End time, pass data, Fail data. It also generates Daily Production Report.
h) Safety Feature
A fence is installed surrounding Robot area to rid away from human. 2 industrial Limit Switch ins installed at Fence Door to ensure safety of operator. In case Door get opened- Robot Power will get cut immediately.
i) Bypass Provision:
This provision is given to Maintenance team to bypass any Test bench in case if maintenance required.
j) PLC-HMI-SCANNER_SQL-ROBOT-CRIO Communication.
• PLC: Entire system is connected with chain of Industrial Devices. Each device used to perform certain tasks. PLC used to act here as a master brain to control all of the devices.
• HMI: It used to give entire information, alarm, warning regarding Robotic System.
• Barcode Scanner: This Barcode Scanner is used connected with HMI via RS232 communication. It used to send Barcode Information to SQL Server.
• SQL: It is a database where all information is getting stored.
• C-RIO: It is a NI based high speed controller used to switching electrical variacs to control Magnetic test bench. It used give signals to Robot in case Test bench is idle, busy etc.
• ROBOT- It is 6 Axis Robot to perform pick –place operations.
[00031] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[00032] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein:
[00033] FIG. 1 illustrates an ON-RESET-TRIP mechanism in currently available manual testing process.
[00034] FIG. 2 illustrates an exemplary implementation of said ON-RESET-TRIP mechanism, in accordance with an exemplary embodiment of the present disclosure.
[00035] FIG. 3 illustrates an exemplary double acting cylinder calculation, in accordance with another exemplary embodiment of the present disclosure.
[00036] FIG. 4 illustrates exemplary 2 finger based gripper, in accordance with another exemplary embodiment of the present disclosure.
[00037] FIG. 5 illustrates an exemplary implementation of 2 finger based gripper, in accordance with another exemplary embodiment of the present disclosure.
[00038] FIG. 6 illustrates an exemplary design of incoming conveyor with singling system.
[00039] FIG. 7 illustrates an exemplary implementation of design of Incoming conveyor with singling system, in accordance with another exemplary embodiment of the present disclosure.
[00040] FIG. 8 illustrates an exemplary pass conveyor, in accordance with another exemplary embodiment of the present disclosure.
[00041] FIG. 9 illustrates an exemplary fail conveyor, in accordance with another exemplary embodiment of the present disclosure.
[00042] FIG. 10 illustrates an exemplary Axis Industrial Robot.
[00043] FIG. 11 illustrates an exemplary Yaskawa GP7.
[00044] FIG. 12 illustrates an exemplary Yaskawa GP7 Parameters.
[00045] FIG. 13 illustrates an exemplary integrated control system, in accordance with another exemplary embodiment of the present disclosure.
[00046] FIG. 14 illustrates an exemplary artificial intelligence, in accordance with another exemplary embodiment of the present disclosure.
[00047] FIG. 15 illustrates exemplary images depicting pick from incoming conveyor and place to test bench, in accordance with another exemplary embodiment of the present disclosure.
[00048] FIG. 16 illustrates exemplary image depicting place to test bench, in accordance with another exemplary embodiment of the present disclosure.
[00049] FIGs. 17-18 illustrates exemplary images depicting place to pass test bench and place to fail conveyor, in accordance with another exemplary embodiment of the present disclosure.
[00050] FIG. 19 illustrates an exemplary product stuck in critical zone, in accordance with another exemplary embodiment of the present disclosure.
[00051] FIGs. 20-21 illustrate exemplary images depicting convention homing process and intelligent homing process, in accordance with another exemplary embodiment of the present disclosure.
[00052] FIG. 22 illustrates an exemplary smart integration of robotic system, in accordance with another exemplary embodiment of the present disclosure

DETAILED DESCRIPTION
[00053] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[00054] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[00055] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[00056] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.
[00057] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[00058] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[00059] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[00060] The present disclosure relates to the field of circuit breaker, and more specifically, relates to a smart system comprising of Industrial Robot and Test bench for performing automatic product testing.
[00061] Embodiments of the present disclosure provide an efficient, effective, reliable, and improved robot integrated smart system for automatic product testing. Further, the present invention provides a smart system comprising of Industrial Robot and Test bench for performing automatic product testing.
[00062] Accordingly, an aspect of the present disclosure relates to a system configured to enable automatic product testing. The system includes a robot end-effector configured at the end of a robotic arm of a robot. The robot end-effector comprising at least two mechanical fingers that provide a minimal gripping force on at least a part of the product.
[00063] The system further includes an incoming conveyor configured to transport said product to be tested from a first location to a second location. The incoming conveyor comprising a singling cylinder configured to restrict mobility of a subsequent product until said robot picks up said product from picking zone. The incoming conveyor further includes a rotary system and a mechanical guide plate used for proper positioning of said product
[00064] In an aspect, the system can further include an ON-Reset-Trip mechanism that enables circuit breaker to be tested to be automatically configured in ON state, Reset state, and Trip state in each cycle, wherein the ON-Reset-Trip mechanism comprises any or a combination of an ON cylinder, a Reset cylinder, a Trip cylinder, a load/unload cylinder, and a clamp cylinder.
[00065] In an aspect, the minimal gripping force is determined based on mass of product part that is to be moved, friction co-efficient between material of which said fingers are made and material of which said product part is made, and gravitational acceleration constant.
[00066] In an aspect, the robot end-effector includes a fix plate and a moving plate that are operatively coupled with each other
[00067] In an aspect, the product is a circuit breaker.
[00068] In an aspect, the incoming conveyor further comprises a scanner configured to scan a code printed on said product so as to determine if said product passed the test at previous station.
[00069] In an aspect, the system further includes a pass and fail conveyor configured to receive a test passed product from said robot, and transport said product to subsequent station
[00070] In an aspect, the system further includes an integrated control system comprising a controller that is operatively coupled with a test bench such that upon said controller issuing a command to a Programmable Logic Controller (PLC), said PLC controls said robot.
[00071] In an aspect, said robot is configured with a machine learning algorithm based on which said robot self-learns operation and process of said product testing in view various faults and errors, and process operation of testing said product and subsequent products based on such self-learning.
[00072] In an aspect, said self-learning is based on re-positioning of said robot, reaction of said robot during power failure, reaction of robot when the incoming conveyor is full, and reaction of said at least two mechanical fingers when air supply drops.
[00073] In contrast to the conventional circuit breaker testing methodologies, the present disclosure provides a smart system comprising of industrial robot and test bench for performing automatic product testing.
[00074] Existing technologies do not include a standard gripper to grip the product. The present invention provides a customized 2 finger based robotic gripper to perform gripping operation.
[00075] Existing technologies do not include a standard incoming conveyor to pick the product from incoming conveyor. The present invention provides a conveyor to perform pick operation.
[00076] Existing technologies do not include a standard system available to make ON-OFF-Reset the product in test bench fixture. The present invention provides a customized solution implemented to automate same operation which is done in manual.
[00077] In an exemplary embodiment, the present invention is about the smart machine learning of robotic system. This system can be broadly defined in 7 major categories as follows:
1. ON-RESET-TRIP mechanism
2. Robot end-effector
3. Incoming conveyor
4. Pass and fail conveyor
5. GP7-motoman robot
6. Integrated control system
7. Machine Learning (ARTIFICIAL INTELLIGENCE)
[00078] ON-RESET-TRIP mechanism: FIG. 1 illustrates an ON-RESET-TRIP mechanism in currently available manual testing process. Breaker needed to make ON, Reset and Trip at every cycle. Average Manual Cycle is 14 numbers per product. FIG. 2 illustrates an exemplary implementation of said ON-RESET-TRIP mechanism to automate the same cycle, in accordance with an exemplary embodiment of the present disclosure.
[00079] Robot end-effector: In manual testing, breaker needed to pick, move, and place manually at every operation. According to the present invention, a robot end effector can be defined as a device that is used at the end of a robotic arm. 2 Nos. of mechanical finger is used to develop this end effector.
[00080] Minimal Gripping Force: The calculation of the minimal gripping force that the robot gripper must apply will include the mass of the part that must be moved, the friction coefficient between the finger material and the part material and the gravitational acceleration constant.
F: Gripping force [N]
u: Coefficient of static friction
m: Mass of the part [kg]
g: Gravitational acceleration [9.81 m/s^2]
a: Acceleration (if it is significant)
To make sure the part doesn’t slip during static prehension, the gripping force should be higher than the weight of the part itself.
F > m (g + a) /u *(safety factor), F > 30 N (Calculated Force to grip product) (FOS = 1.5)
[00081] Double Acting Cylinder: FIG. 3 illustrates an exemplary double acting cylinder calculation, in accordance with another exemplary embodiment of the present disclosure. The force exerted by double acting pneumatic cylinder on outstroke can be expressed as (1). The force exerted on in-stroke can be expressed as F = P p (d12 - d22) / 4, F = 37.75 N, Where,
d1 = full bore piston diameter (m)
d2 = piston rod diameter (m)
P = air pressure
F = Force
[00082] FIG. 4 illustrates exemplary 2 finger based gripper, in accordance with another exemplary embodiment of the present disclosure. FIG. 5 illustrates an exemplary implementation of 2 finger based gripper, in accordance with another exemplary embodiment of the present disclosure.
[00083] Incoming conveyor: Non-powered roller conveyors or Gravity Conveyors are the most economical and common method of conveying unit loads. The conveyors are typically mounted on a slight decline angle, therefore using gravity to assist product movement, especially for long distances. This conveyor is designed to transfer the product from previous station to next station. It works as FIFO basis. A singling system is developed to restrict previous products until Robot pick the breaker from picking zone. This allows only one product to be picked at a time. A rotary system and mechanical guide plate used for proper positioning of product. This positioning is very important because with this reference, product is placed in test bench fixture. Any miss-alignment will cause damages to fixture and robot gripper.
[00084] A barcode Scanner is integrated in incoming conveyor. This scanner scans the product barcode and this barcode data used to transfer SQL Database. Test bench used to retrieve the barcode information from the same SQL server. An algorithm is used to check whether the scanned product is passed in previous station. If not tested, then it triggers to robot to place it to fail conveyor.
[00085] FIG. 6 illustrates an exemplary design of incoming conveyor with singling system. FIG. 7 illustrates an exemplary implementation of design of Incoming conveyor with singling system, in accordance with another exemplary embodiment of the present disclosure.
[00086] Pass and Fail Conveyor: Motorized conveyor is used to transfer tested and passed product from test bench to next station. This conveyor is used to get start automatically once robot placed it on it. This conveyor is used to get stopped when it is full and given a warning alarm to operator to empty it. Gravity conveyor is used to transfer tested but failed product from test bench to previous station. Robotic System is used to get stopped when it is full and given a warning alarm to operator to empty it. FIG. 8 illustrates an exemplary pass conveyor, in accordance with another exemplary embodiment of the present disclosure. FIG. 9 illustrates an exemplary fail conveyor, in accordance with another exemplary embodiment of the present disclosure.
[00087] GP7-Motoman Robot: Yaskawa make GP7-Motoman model is used for this application. It is Ideal for high-speed assembly and handling applications, the new GP7 robot is fast, compact and efficient. It offers the highest payload, fastest speed and highest wrist allowable moment in its class. The GP-series robots offer improved acceleration/deceleration control for all robot positions resulting in overall improved productivity. The small footprint, slim arm design allows for minimum installation space and minimizes interference with peripheral devices. This enables the GP-series robots to be placed in close proximity to work pieces and other robots to create flexible, high-density layouts. Installation is quick and efficient. A single cable is all that is needed to connect the manipulator to the controller, resulting in easy setup and reduced expenses for maintenance and spare parts inventory.
[00088] Some general specifications are highlighted in below:
Nos of Axis- 6
Payload – 7 kg
Reach – 927mm Horizontal + 1693mm Vertical
Repeatability- +/- 0.03mm
[00089] FIG. 10 illustrates an exemplary Axis Industrial Robot, in accordance with another exemplary embodiment of the present disclosure. FIG. 11 illustrates an exemplary Yaskawa GP7, in accordance with another exemplary embodiment of the present disclosure. FIG. 12 illustrates an exemplary Yaskawa GP7 Parameters, in accordance with another exemplary embodiment of the present disclosure.
[00090] Integrated Control System: Both Test bench is equipped with NI-CRIO controller. This controller gives command to a Programmable Logic Controller (PLC) via MODBUS TCP/IP protocol. PLC is used here as Master and Robotic System is used here as slave. PLC is used send signals to Robot for different logic. Different hand-shaking signals are used to confirm position completion, robot status etc. An HMI is integrated to get Barcode information over serial communication. HMI save this data in central SQL server. Both test bench used to fetch this data from the same table of SQL server. FIG. 13 illustrates an exemplary integrated control system, in accordance with another exemplary embodiment of the present disclosure.
[00091] Machine learning (artificial intelligence (AI)): Machine Learning / Artificial Intelligence are the most important part of the entire system. The machine learning is done such a way that Robot can make decisions on its own. VC++ Program is used in Robotics program. Please find some exemplary safety features of algorithm as described below:
? Robot can manage itself to move its Homing Position automatically if it gets stop/stuck in a critical zone in case of sudden power failure.
? Robot will get stopped in case Door get Opened.
? Robot will get stopped in case Pass / Fail conveyor is full.
? Robot will not open its gripper in case Air supply drop.
? Robot will not place the product in Test bench if product is present.
[00092] FIG. 14 illustrates an exemplary artificial intelligence, in accordance with another exemplary embodiment of the present disclosure.
[00093] FIG. 15 illustrates exemplary images depicting pick from incoming conveyor and place to test bench, in accordance with another exemplary embodiment of the present disclosure.
[00094] FIG. 16 illustrates exemplary image depicting place to test bench, in accordance with another exemplary embodiment of the present disclosure.
[00095] FIG. 17-18 illustrates exemplary images depicting place to pass conveyor and place to fail conveyor, in accordance with another exemplary embodiment of the present disclosure.
[00096] In an exemplary embodiment, the present invention by way of smart learning/machine learning/AI, solves many problems and tries to make the present invention further enhanced. For example, while the implementation of the present invention, in the first working demo of the system, it was observed that a breaker got stuck in to test bench pallet. FIG. 19 illustrates an exemplary product stuck in critical zone, in accordance with another exemplary embodiment of the present disclosure
[00097] FIG. 20 illustrates exemplary images depicting convention homing process, in accordance with another exemplary embodiment of the present disclosure. Root-cause of the problem, after investigation of this incident it is observed that it happened due to following reasons:
a) Power Failure just when Robot placed breaker inside Test Bench Pallet Fixture.
b) Then After Power ON when Homing is pressed by our supervisor. (Instruction were given to press HOME button during Robot Start up)
c) Then it gets stuck to test bench fixture. (Reason is attached in ppt)
d) Then Supervisor faced little difficulty to remove Robot Gripper from Test Bench Pallet Fixture. (It took almost 20 minutes)
e) After Robot came to Home position, then again it started working fine.
[00098] FIG. 21 illustrates exemplary images depicting convention homing process and intelligent homing process, in accordance with another exemplary embodiment of the present disclosure. FIG. 22 illustrates an exemplary smart integration of robotic system which helps to automatically solve the above recited issues, in accordance with another exemplary embodiment of the present disclosure
[00099] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the scope of the appended claims.
[000100] While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the scope of the disclosure, as described in the claims.
[000101] In the description of the present specification, reference to the term "one embodiment," "an embodiments", "an example", "an instance", or "some examples" and the description is meant in connection with the embodiment or example described The particular feature, structure, material, or characteristic included in the present invention, at least one embodiment or example. In the present specification, the term of the above schematic representation is not necessarily for the same embodiment or example. Furthermore, the particular features structures, materials, or characteristics described in any one or more embodiments or examples in proper manner. Moreover, those skilled in the art can be described in the specification of different embodiments or examples are joined and combinations thereof.
[000102] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
[000103] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[000104] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[000105] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[000106] The implementation of the present invention improves productivity: Before: 400 / Shift / 2 Test Bench and Present: 600 / Shift / 2
[000107] The implementation of the present invention saves manpower: 4