System for diagnosis of robot state

1. A robot data transfer method comprising the following steps:

collecting data from sensors on each of a plurality of robots in real-time;

transferring the data from a controller of each of the robots to a first data collection device in real-time;

buffering the data in the first data collection device using a multi-segment queuing mechanism with a retention policy, wherein the data is retained according to the retention policy based on at least one of a triggering event, priority, duration, size, transfer rate and data transformation to optimize throughput or data storage requirements; and

transferring the data from the first data collection device to a second data collection device based on the retention policy.

2. The method according to claim 1 , further comprising the step of analyzing the data in the second data collection device to determine a need for maintenance or optimization of the robots.

3. The method according to claim 1 , further comprising the step of generating a report from the second data collection device, wherein the report includes at least one of a mechanical health, a process health, a system health, and a maintenance notification.

4. The method according to claim 1 , wherein the first data collection device is a logical device within the controller of the robot.

5. The method of claim 1 , wherein the first data collection device is a physical storage device, external to the controller of the robot.

6. The method of claim 1 , wherein the second data collection device is a network server, the network server connected to the first data collection device via a functional network.

7. The method of claim 1 , wherein the second data collection device is formed local to the first data collection device, the second data collection device in direct communication with the first data collection device.

8. The method according to claim 1 including the following steps:

the data transferred to the first data collection device is buffered in the data storage with capability of maintaining data for some duration; and

the first data collection device transfers the data entirely to the second data collection device in response to one of an event from the robot controller or external device, and an internally triggered event on the first data collection device.

9. The method according to claim 1 including the following steps:

the data transferred to the first data collection device is buffered in the data storage with capability of maintaining data for some duration; and

the first data collection device queues the data into priority segments and interrupts a lower priority segment data transfer and transfers the data from a higher priority segment to the second data collection device or the server.

10. The method of claim 1 , wherein the data includes at least one of a joint travel distance, a component operational load, a component operational temperature, component high speed emergency stops, and joint reverse travel condition.

11. A robot analytical and prognostic reporting method comprising the following steps:

collecting data from sensors on each of a plurality of robots in a first data collection device;

buffering the data in the first data collection device using high priority and low priority queueing segments and a retention policy, wherein the data is retained according to the retention policy based on at least one of a triggering event, priority, duration, size, transfer rate and data transformation to optimize throughput or data storage requirements;

transferring the data from the first data collection device to and storing the data in a second data collection device, based on the retention policy, the second data collection device being remote to or local to the first data collection device;

analyzing the data in the second data collection device;

generating a report from the second data collection device, the report based on the analysis of the data by the second data collection device;

identifying a determination for a robot controller parameter change, anomaly, or failure in the report; and

distributing the report to at least one recipient.

12. The method according to claim 11 wherein the recipient is at least one of a smart device, a server, application software, an email, a personal computer, and a robot teaching device.

13. The method according to claim 11 , further comprising the step of generating a work order based on the analysis of the data.

14. The method of claim 11 , wherein the data includes at least one of a joint travel distance, a component operational load, a component operational temperature, component high speed emergency stops, and joint reverse travel condition.

15. A robot analytical and optimization reporting system comprising:

at least one robot, the robot having a programmable controller configured to collect dynamic data from sensors on the robot;

a first data collection device in electrical communication with the controller of the at least one robot, the first data collection device configured to receive the dynamic data from the controller, and to buffer the dynamic data in a multi-segment queue for a duration determined by a retention policy, wherein the data is retained according to the retention policy based on at least one of a triggering event, priority, duration, size, transfer rate and data transformation to optimize throughput or data storage requirements;

a second data collection device in communication with the first data collection device, the second data collection device configured to receive the dynamic data from the first data collection device, and to analyze the dynamic data; and

a recipient in communication with the second data collection device for receiving the analysis of the dynamic data.

16. The system of claim 15 , wherein the first data collection device is a logical device within a memory of the controller of the robot.

17. The system of claim 15 , wherein the first data collection device is a physical storage disk, formed separately from the controller.

18. The system of claim 15 , wherein each of the controller, the first data collection device, the second data collection device, and the recipient is in communication with a functional network.

19. The system of claim 15 , wherein the second data collection device is formed local to the first data collection device.