BACKGROUND

The present inventions relate generally to robots, and more particularly, to a processing module located between the tool mounting surface of the robot and the end effector thereof.

Robots typically include a series of joints that allow an end effector to be moved from place to place to perform a variety of tasks. Often, one or more sensors are placed on or near the end effector to monitor the surroundings around the end effector in order to enable the end effector to perform various tasks. Robots also include a robot controller that collects data from and sends instructions to the joints, end effector and sensors. Typically, the robot controller may be located in or near the base of the robot or in a separate computer located a short distance from the robot, although it is also possible for the robot controller to be located remotely with communication between the robot and the controller occurring over a wide area network.

However, the location of the robot controller can result in decreased robotic performance in some situations. For example, where it is desired for the robot to perform real time operations, communication delays between sensors at the end effector and the robot controller can decrease performance of the robot. Sensors that transmit large amounts of data can also limit performance of a robot. For example, cameras transmitting video data require high-bandwidth transmission. Communication speed and bandwidth requirements between sensors and the robot controller can result in latency and jitter problems that degrade overall performance of the robot. Such problems can be further exacerbated as a greater number of sensors are added to the robot to provide additional functionality.

In addition to communication limitations, conventional arrangements for the robot controller and sensors can raise security and reliability risks. For example, as sensors become more and more sophisticated, it is common for such sensors to require additional software applications and drivers provided by third-party developers. However, loading this type of additional software onto the robot controller can present unexpected and uncontrolled risks that may be unacceptable.

Another problem with the increased number of sensors being used with robots is the difficulty in placing such sensors in a suitable and convenient location. Typically, the user of a robot may begin with an off-the-shelf end effector attached to the tool flange of the robot. As the user desires to add additional functionality to the robot, it may be necessary to add additional sensors to the robot. Typically, it is desirable to mount sensors close to the end effector since the operations of the robot are performed by the end effector. However, it can be difficult to find a location to mount the sensor at the end effector without interfering with the end effector or the surrounding environment. It can also be challenging and/or time-consuming to properly mount a sensor in a secure manner.

Still another problem with the number of sensors that may be used on a robot is the associated communication paths to the robot controller. Where cables are used to connect sensors to the robot controller, it is typical for each sensor to be connected to the robot controller with an individual cable. Thus, when multiple sensors are used at the end effector, an equivalent number of cables must be run to the robot controller. This can create routing difficulties and increase complexity of the system. Alternatively, where data is transmitted wirelessly from sensors to the robot controller, each sensor requires a separate signal pathway which can congest available bandwidth.

In view of the various needs for improvements in robot performance, it would be desirable to provide interchangeable modules between the robot tool flange and the end effector.

SUMMARY

Interchangeable modules are described that may be attached between the tool flange of a robot and the end effector. The modules include a processing module, a sensor module and a communications module. The modules can be attached to the robot tool flange in a stack with the end effector being attached to the end of the stack. The modules allow additional functionality to be easily added to a robot with minimal modifications to the robot or end effector.

