Robot system with reconfigurable end effector assembly

Abstract

The end effector assembly includes a main cantilever, a frame rail coupled thereto, and at least one branch rail movably coupled to the frame rail by a swing branch lock. A swing arm is movably coupled to the at least one branch rail by a swing arm lock. Each of the swing branch lock and the swing arm lock further includes a clamp configured to movably fix the branch rail to the frame rail or movably fix the swing arm to the branch rail. A pivot extends through the clamp and is configured to rotationally fix the clamp in place. A swing plate is fixed to the pivot and is configured to engage a configuration tool. A locking fastener extends through the swing plate and into the pivot and is configured to lock and unlock the clamp in place.

Description

Technical Field

[0001] The present invention relates to a robotic system having a reconfigurable end effector assembly. Background Art

[0002] The statements in this section merely provide background information related to the present invention and may not constitute prior art.

[0003] Multi-axis industrial robots include articulated arms joined by joints. Each arm segment is driven by one or more joint motors. A typical industrial robot is controlled by six different control axes. The control axes work together to enable the robot to rotate relative to a fixed or moving base, extend / retract a first arm, raise / lower a second arm, and rotate and rotate / translate the joints of a wrist disposed at the distal end of the second arm. Additional arms can be used in a series arrangement according to the design, and the end effector attached to the wrist can be manipulated to perform a desired work task.

[0004] The term "end effector" refers to a specific end attachment or segment that can reliably grip, transport, orient, and release a workpiece according to the design of the robot. Some end effector assemblies are formed by a grid-like array of elongated beams and / or tracks, to which a set of tool branches suspending end tools (such as suction cups or grippers of the type used to move metal or glass sheets in manufacturing equipment) are attached. Traditionally, prior to performing a specified work task, each tool branch and end tool are manually adjusted to a predetermined configuration by an operator. Summary of the Invention

[0005] An end effector assembly includes a main cantilever, a frame rail coupled thereto, and at least one branch rail movably coupled to the frame rail by a swing branch lock. A swing arm is movably coupled to at least one branch rail by a swing arm lock. The swing branch lock and the swing arm lock each further include a clamp, a pivot, a swing plate, and a locking fastener. The clamp is configured to movably fix the branch rail to the frame rail, or movably fix the swing arm to the branch rail. The pivot extends through the clamp and is configured to rotatably fix the clamp in place. The swing plate is fixed to the pivot and is configured to engage a configuration tool. The locking fastener extends through the swing plate and into the pivot and is configured to lock and unlock the clamp in place.

[0006] In some embodiments, the end effector is disposed at the distal end of the swing arm. The end effector defines a first side of the end effector assembly for engaging with a workpiece. The swing branch lock and the swing arm lock are configured to be engaged by a configuration tool on a second side of the end effector assembly opposite the first side. Additionally, the swing branch lock is movable relative to the frame rail between an unlocked state and a locked state to fix the branch rail in place relative to the frame rail. The swing arm lock is movable along the branch rail between an unlocked state and a locked state to fix the swing arm in place relative to the branch rail. Further, the clamp of the swing arm lock is fixed to the second swing arm clamp. The second swing arm clamp includes a pair of distal openings such that unlocking the clamp of the swing arm enables the swing arm lock to move in at least a primary direction, a secondary direction, and a third direction. The swing branch lock further includes a rotatable joint fixed to the pivot on a side opposite the locking fastener. Additionally, the swing branch lock further includes an extension leg for receiving a portion of a tube, wherein the extension leg extends along a protruding axis disposed perpendicular to the pivot axis.

[0007] The end effector assembly having a main cantilever includes a flexible covering assembly fixed thereto. The frame rail is coupled to the main cantilever such that the flexible covering assembly has a portion of a hose extending along at least a portion of the frame rail. At least one branch rail is movably coupled to the frame rail by a swing branch lock. The swing branch lock has an extension leg for receiving a wound portion of the flexible covering assembly. The swing arm is movably coupled to at least one branch rail by a swing arm lock. The swing arm lock includes at least one fitting for receiving the flexible covering assembly fixed thereto.

[0008] In some embodiments, at least one fitting fluidly couples the flexible covering assembly to an end effector disposed on the swing arm. The at least one fitting is a pneumatic fitting that is in fluid communication with a fluid passage formed through the swing arm. Additionally, the wound portion of the flexible covering assembly is disposed around a spring-loaded reel. Further, the swing arm lock is movable along the branch rail between an unlocked state and a locked state to fix the swing arm in place relative to the branch rail. The swing branch lock is movable relative to the frame rail between an unlocked state and a locked state to fix the branch rail in place relative to the frame rail. Further, an end effector is disposed at the distal end of the swing arm. The end effector defines a first side of the end effector assembly for engaging with a workpiece. The swing branch lock and the swing arm lock are configured to be engaged by a configuration tool on a second side of the end effector assembly opposite the first side. Additionally, the swing branch lock further includes a rotatable joint disposed opposite the extension leg.

[0009] The end effector assembly includes a main cantilever having a flexible covering assembly fixed thereto. A frame rail is coupled to the main cantilever, and the flexible covering assembly has a portion extending along at least a part of the frame rail. At least one branch rail is movably coupled to the frame rail by a swing branch lock. The swing branch lock has an extension leg for accommodating a wound portion of the flexible covering assembly. A swing arm is movably coupled to the at least one branch rail by a swing arm lock. The swing arm lock includes at least one fitting for accommodating a proximal end of the flexible covering assembly fixed thereto. The swing branch lock and the swing arm lock each further include a clamp, a pivot, a swing plate, and a locking fastener. The clamp is configured to movably fix the branch rail to the frame rail or movably fix the swing arm to the branch rail. The pivot extends through the clamp and is configured to rotatably fix the clamp in place. The swing plate is fixed to the pivot and is configured to engage a configuration tool. The locking fastener extends through the swing plate and into the pivot and is configured to lock and unlock the clamp in place.

[0010] In some embodiments, the swing arm lock is movable along the branch rail between an unlocked state and a locked state to fix the swing arm in place relative to the branch rail. The swing branch lock is movable relative to the frame rail between an unlocked state and a locked state to fix the branch rail in place relative to the frame rail. Further, an end effector is disposed at a distal end of the swing arm. The end effector defines a first side of the end effector assembly for engaging a workpiece. The swing branch lock and the swing arm lock are configured to be engaged by a configuration tool on a second side of the end effector assembly opposite the first side. Additionally, the swing branch lock further includes a rotatable joint fixed to the pivot on a side opposite the locking fastener.

[0011] Many applicable fields will be apparent from the description provided herein. It should be understood that the description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the invention in any way.

[0013] Figure 1 is a perspective view of a robotic system including an end effector assembly according to the present invention;

[0014] Figure 2 is Figure 1 a perspective view of the end effector assembly of

[0015] Figure 3 is Figure 1 a perspective view of the end effector assembly of

[0016] Figure 4 is along Figure 3Cross-sectional view of the swing branch lock of the end effector assembly taken along section line 4-4;

[0017] Figure 5 is along Figure 3 Cross-sectional view of the swing arm lock of the end effector assembly taken along section line 5-5;

[0018] Figure 6 is a cross-sectional view of an alternative swing arm lock of the end effector assembly;

[0019] Figure 7 is usable as Figure 1 Perspective view of a configuration tool that is part of a robotic system, showing the gripper in the disengaged state;

[0020] Figure 8 is usable as Figure 1 Perspective view of a configuration tool that is part of a robotic system, showing the gripper fingers in the engaged state;

[0021] Figure 9 Perspective view of a configuration tool moving towards the swing branch lock of the end effector assembly;

[0022] Figure 10 Perspective view of a configuration tool coupled to the swing branch lock of the end effector assembly;

[0023] Figure 11 Perspective view of a configuration tool moving towards the swing arm lock of the end effector assembly;

[0024] Figure 12 Perspective view of a configuration tool coupled to the swing arm lock of the end effector assembly;

[0025] Figure 13 is for Figure 1 Perspective view of the flexible pneumatic covering member assembly of the end effector assembly; and

[0026] Figure 14 is as Figure 13 Cross-sectional view of a spring-loaded tube reel as an alternative to a coiled tube. Detailed Description

[0027] The following description is merely illustrative in nature and is not intended to limit the invention, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals refer to like or corresponding parts and features. Additionally, unless otherwise noted, directions such as "top", "side", "back", "lower", and "upper" are for illustrative purposes and are not intended to require a specific orientation. These directions are provided only as a reference framework relative to the examples provided, but may be changed in other applications.

[0028] Referring to the accompanying drawings, in which like reference numerals designate like parts throughout the drawings, Figure 1 a robotic system 10 is schematically shown. The robotic system 10 includes a multi-axis industrial robot 12, a configuration tool 14, and a reconfigurable end effector assembly 16, which will be described in detail below. The overall operation control of the robotic system 10 can be achieved via a controller 18. The robotic system 10 also includes a configuration rack 20, for example, which will be discussed in more detail below.

[0029] The controller 18 can be configured as a host (e.g., a digital computer) specifically programmed to execute steps or instructions. To this end, the controller 18 includes sufficient hardware to perform the required method steps, that is, it has sufficient memory 22, a processor 24, and other associated hardware, such as a high-speed clock, analog-to-digital and / or digital-to-analog circuits, timers, input / output circuits and related devices, signal conditioning and / or signal buffering circuits. The memory 22 includes sufficient tangible non-transitory memory, such as magnetic or optical read-only memory, flash memory, etc., as well as random access memory, electrically erasable programmable read-only memory, etc. The controller 18 receives and records the measured joint positions (arrow 26) from at least one position sensor 28, and also monitors the forces applied by or applied to the end effector assembly 16 during the process of configuring the end effector assembly 16 and when operating on a given workpiece (not shown). The controller 18 generates or receives an input signal (arrow 30), which notifies the controller 18 of the required work task to be performed on the corresponding workpiece, and outputs a control signal (arrow 32) to the robot 12 to command the required actions from the robot 12.

[0030] The robot 12 can be configured as a 6-axis industrial robot and can include a fixed or movable base 34 and a plurality of robot joints 36, at least some of which are Figure 1 shown. The various joints 36 couple segments of the robot 12 or are serially coupled, including a first or lower robot arm 38, a second or upper robot arm 40, and a wrist 42, which together provide a desired range of motion and the degrees of freedom of control required to perform the assigned work task. It is contemplated that the robot 12 can include more or fewer robot arms and wrists. Examples of such work tasks performed by the robot 12 include grasping, lifting, positioning, and placing metal or glass plates, as well as many other possible tasks, such as painting and welding. As previously described, the joint position sensors 28 can be positioned relative to each joint 36 and are configured to measure and report the measured joint positions (arrow 26) to the controller 18. Additionally, one or more force sensors (not shown) can also be positioned relative to the joints 36 and are used to provide force or torque feedback to the controller 18, which can avoid applying excessive force to the workpiece or the end effector assembly 16.

[0031] Regarding the end effector assembly 16, the structure may include a main cantilever 44 and a grid-like end effector array 46. The end effector array 46 in the illustrated embodiment includes one frame rail 48 orthogonally arranged with respect to the longitudinal axis 50 of the main cantilever 44. However, it is contemplated that the end effector array 46 may include more than one frame rail 48. In the depicted embodiment, the frame rail 48 has a substantially cylindrical shape. The end effector array 46 may further include a plurality of tool branches 52 movably coupled to the frame rail 48. However, the end effector array 46 may alternatively have only a single tool branch 52. Each tool branch 52 includes a branch rail 54 and a tool module 56 that projects from and extends radially outward from the frame rail 48. The various branch rails 54 are slidably and rotatably attached to the frame rail 48. In other words, as will be described in more detail below, the branch rail 54 is movably coupled to the frame rail 48. Separate tool modules 56 are suspended from or movably coupled to the branch rail 54. The frame rail 48 is in turn coupled to the main cantilever 44 via a mechanical coupler 58.

[0032] Now referring to Figure 2 , the main cantilever 44 may include a double-sided tool changing device assembly 60 having opposing tool changing devices 62, 64. The term "tool changing device" refers to a manual or automatic component capable of quickly changing a robotic end effector. Such devices typically include integrated power and communication ports, couplers, and equipment required to function as an end tool, such as a gripper or vacuum chuck 66. In the depicted embodiment, the tool changing device assembly 60 is specifically configured to provide simultaneous engagement of the main cantilever 44 with the robot 12 and the configuration rack 20, the latter being schematically shown in Figure 1 .

[0033] For the purposes of the present invention, the configuration rack 20 may be fixed relative to the floor or suspended from a vertical surface such as a machine column or a wall. The configuration rack 20 has a predetermined position in a Cartesian (e.g., XYZ) reference frame and thus provides a calibration reference point for zeroing the robot 12 during reconfiguration of the end effector assembly 16. For example, when transitioning from a first configuration to another configuration, the robot 12 couples the tool changing device 64 to the configuration rack 20 and releases the tool changing device 62. When the robot 12 reconfigures the end effector assembly 16, the position of each of the locking mechanisms (e.g., the swing branch locking mechanism 74 and the swing arm locking mechanism 70) described below in free space is known to the controller 18 due to the known position in the reference frame provided by the configuration rack 20. In the event that the configuration of the end effector assembly 16 becomes ambiguous during operation (e.g., due to a collision event or a power failure), the end effector assembly 16, while suspended from the configuration rack 20, can be manually set to a calibration setting in which the positions of the various end effectors and locking mechanisms are known, after which the configuration starts from the zeroing setting.

[0034] The branch rail 54 with the attached tool module 56 can be automatically repositioned by the robot 12 using the configuration tool 14 and instructions executed by the controller 18. Thus, the tool branch 52 can be arranged as needed to allow the tool module 56 or more precisely the respective end effectors 66 of the tool module 56 to be attached to a given workpiece or otherwise interact with the given workpiece. In a non-limiting example of a body panel, the respective end effectors 66 shown in the figures are configured as pneumatic suction cups or grippers typically used to secure and move an automotive or other body panel (without damaging the decorative display surface). However, other end effectors 66 such as pliers, clamps, or nozzles can be used. Thus, the specific construction of the end effectors 66 can vary. In each tool branch 52, the swing arm 68 is coupled between the end effector 66 and the branch rail 54 by a swing arm locking mechanism 70, and the branch rail 54 is coupled to the frame rail 48 by a swing branch locking mechanism 74, as will be described in more detail below.

[0035] The end effector assembly 16 can be reconfigured to interact with workpieces having different sizes, shapes, and / or surface profiles relative to each other or other workpieces and constructed of different materials. For example, a workpiece can be considerably larger and more uniform than other workpieces, allowing different configurations of the same end effector assembly 16. Any number of possible workpieces may be encountered in a given manufacturing operation, and thus the end effector assembly 16 can be reconfigured by the robot 12 to operate individually on any of them as needed.

[0036] The controller 18 is aware of the specific workpiece via an input signal ( Figure 1The arrow 30) operates, such as through manual selection by an operator, to detect the RFID tag or any other suitable identification process. Then the controller 18 automatically selects the corresponding configuration from its memory 22. After the end effector assembly 16 has been stored on the configuration rack 20 via the tool changing device 64, the robot 12 then releases the end effector assembly 16 via the tool changing device 62 and moves to attach the configuration tool 14 (see Figure 7 ) to its wrist 42 or other suitable end link at a suitable workstation (not shown) via another tool changing device 142 mounted on the configuration tool 14 in order to configure the end effector assembly 16. Such a workstation can be embodied as a fixture that allows the configuration tool 14 to be held in a calibrated position (i.e., a position easily accessible to the wrist 42). All of this occurs while the end effector assembly 16 remains attached to the configuration rack 20. Additionally, since the locking / unlocking features of the swing arm lock 70 and the swing branch lock 74 are accessible from the opposite direction of the end tool 66, this embodiment allows the end effector assembly 16 to be configured by the robot 12 without any "flipping" on the configuration rack 20,

[0037] Once the end effector assembly 16 has been fully configured for the task at hand using the configuration tool 14, the robot 12 automatically stores the configuration tool 14 at its workstation, detaches the configuration tool 14 from the wrist 42 by releasing the tool changing device 142 on the configuration tool 14, moves to pick up the newly configured end effector assembly 16 by simultaneously engaging the tool changing device 62 and releasing the tool changing device 64, removes the end effector assembly 16 from the configuration rack 20, and begins operating on the workpiece. The ability of the robot 12 to reconfigure the end effector assembly 16 (without flipping the end effector assembly 16) allows it to be used for a wide range of possible workpieces and in various different environments without concern for space limitations. In this way, manufacturing flexibility and efficiency can be increased while reducing processing costs and system downtime.

[0038] Continuing to refer to Figure 2 , the end effector assembly 16 includes at least one frame rail 48 disposed perpendicular to the cantilever axis 50 of the main cantilever 44, wherein each tool module 56 is coupled to a radially extending branch rail 54. In an exemplary embodiment where the end tool 66 is a pneumatic gripper, a flexible pneumatic hose or covering assembly 400 can be disposed along the main cantilever 44 and routed to each end tool 66, as will be described in more detail below.

[0039] Referring to Figures 2 to 4, each tool branch 52 includes a swing branch lock 74 having a rotatable coupling 72 for securing the branch rail 54 to the frame rail 48. In the illustrated embodiment, the swing branch lock 74 is movable between a locked state and an unlocked state. In the locked state, the swing branch lock 74 fixes the position of the branch rail 54 relative to the frame rail 48, and thus the branch rail 54 remains stationary relative to the frame rail 48. When the swing branch lock 74 is in the unlocked state, the branch rail 54 can be translated along the frame rail 48 in the direction indicated by arrow 76, rotated about the frame rail 48 in the direction indicated by arrow 78, and rotated about the pivot 103 at the joint 72 (see Figure 4 ) in the direction indicated by arrow 79. In this way, in response to a command (arrow 32) from the controller 18, any number of different configurations of the tool module 56 can be set by the robot 12 as needed. As discussed in detail below, the configuration tool 14 can be used to move the swing branch lock 74 between the locked state and the unlocked state. Due to its rounded cross-section (e.g., circular cross-section), when the swing branch lock 74 is in the unlocked state, the frame rail 48 allows the swing branch lock 74 to rotate about the frame rail axis 80. Also due to the joint 72, when the swing branch lock 74 is in the unlocked state, the swing branch lock 74 can swing about the frame rail 48. Additionally, when set in the unlocked state, the swing branch lock 74 can slide along the frame rail axis 80. By way of example only, Figure 3 shows an alternative configuration having one of the branch rails 54 (e.g., the first branch rail 55), which rotates to be juxtaposed next to another branch rail 54 (e.g., the second branch rail 57) due to the rotation of the swing branch lock 74 about the axis of the pivot 103 at the joint 72.

[0040] In Figure 4 the illustrated embodiment shown, the swing branch lock 74 includes a clamp 82 for clamping the frame rail 48, a pivot 103 for rotatably securing the branch rail 54 to the clamp 82, a swing plate 107 for engaging the configuration tool 14, and a captured fastener 96 for tightening and releasing the swing branch lock 74. In particular, the clamp 82 is configured as a wound clamp having a clamp arm 84 adjacent to a clamp base 86. The clamp 82 can clamp and release on the frame rail 48 by clamping and / or releasing the clamp arm 84 and the clamp base 86. The clamp 82 defines a clamp groove 88 configured, shaped, and sized to receive a portion of the frame rail 48. The clamp groove 88 may have a concave shape to allow the frame 48 to sit on the clamp arm and base 84, 86.

[0041] The captured fastener 96 can be used to adjust the distance between the clamp arm 84 and the clamp base 86. As a non-limiting example, the fastener 96 can be a screw, a bolt, or any other suitable fastener for moving the clamp arm and bases 84, 86 toward and away from each other. In the illustrated embodiment, for example, the captured fastener 96 is secured within the swing plate 107 via a retaining ring 123. In this way, when unclamping, the captured fastener 96 rotates freely, but the pivot 103 can be axially pushed away to unlock the clamp 82 without causing the captured fastener 96 to push the configuration tool 14 back.

[0042] It should be understood that rotating the fastener 96 causes the clamp arm 84 to move toward or away from the clamp base 86, thereby tightening or loosening the clamp 82 relative to the frame rail 48. Specifically, rotating the fastener 96 in a first rotational direction (e.g., clockwise) locks the clamp 82, and rotating the fastener 96 in the opposite direction (e.g., counterclockwise) unlocks the clamp 82. When the clamp 82 is locked, the branch rail 54 is fixed relative to the frame rail 48 and thus remains stationary relative to the frame rail 48. When the clamp 82 is unlocked, the branch rail 54 can translate, rotate, and swing relative to the frame rail 48. The clamp 82 can also be configured as a two-piece clamp with one hinge, a three-piece clamp with a double hinge, or any other suitable clamp design.

[0043] The swing branch lock 74 can further define a plurality of lugs or tabs 97 that provide features for the configuration tool 14 to engage and adjust the swing branch lock 74, as described in more detail below. At least one of the tabs 97 can include a centering feature for robot 12 alignment control. The swing branch lock 74 additionally includes an extension leg 98 for holding at least a portion of the flexible pneumatic cover assembly 400 (e.g., see Figure 3 ).

[0044] Continuing to refer to Figure 2 and now referring to Figure 5 , the swing arm 68 is angled obliquely relative to the branch rail 54 to facilitate interaction of the end effector 66 with the workpiece. In the illustrated embodiment, the swing arm lock 70 can move between a locked state and an unlocked state. In the locked state, the swing arm lock 70 fixes the position of the swing arm 68 relative to the branch rail 54, and thus the swing arm 68 remains stationary relative to the branch rail 54. When the swing arm lock 70 is in the unlocked state, the swing arm 68 can translate along the branch rail 54 in the direction indicated by arrow 100, can rotate about the branch rail 54 in the direction indicated by arrow 102, and can rotate about the pivot 104 (see Figure 5) rotates and can rotate about a third axis 94 in the direction indicated by arrow 95. In this way, in response to a command from the controller 18 (arrow 32), any number of different configurations of the tool module 56 can be set by the robot 12 as needed. Due to its rounded cross-section (e.g., circular cross-section), when the swing arm lock 70 is in the unlocked state, the branch rail 54 allows the swing arm lock 70 to rotate about the branch rail axis 105. Additionally, when set in the unlocked state, the swing arm lock 70 can slide along the branch rail axis 105. As discussed in detail below, the configuration tool 14 can be used to move the swing arm lock 70 between the locked and unlocked states.

[0045] Now referring to Figure 5 , the swing arm lock 70 includes a pair of winding clamps 90, 106 for clamping the swing arm 68 to the branch rail 54, a pivot 104 for rotatably fixing the swing arm 68 to the winding clamp 106, a swing plate 108 for engaging with the configuration tool 14, and a locking fastener 112 for tightening and releasing the swing arm lock 70. In particular, the winding clamp 106 can be clamped and / or released by a pair of split flanges (i.e., split flange base 114, split flange arm 116) above a pair of semi-circular distal opposite ends (e.g., upper distal opposite end 113 and lower distal opposite end 115) of the winding clamp 90, which in turn are fixed above the branch rail 54.

[0046] As described above, the swing arm 68 can carry the end tool 66. When in the locked state, the swing arm 68 can be tightened to the winding clamp 106, but when in the unlocked state, it rotates freely with the fastened pivot 104. To this end, the pivot 104 can extend through openings in the split flange base 114 and the split flange arm 116 and terminate at the swing plate 108. The locking fastener 112 can movably couple the split flange base 114 to the split flange arm 116. As a non-limiting example, the locking fastener 112 can be a screw, bolt, or any other suitable fastener (including external threads). In the illustrated embodiment, for example, the locking fastener 112 is a captured fastener fixed within the swing plate 108 via a retaining ring 124. In this way, when unclamped, the locking fastener 112 rotates freely, but the pivot 104 can be axially pushed away to release the swing arm lock 70, rather than causing the captured fastener 112 to push the configuration tool 14 back.

[0047] The locking fastener 112 further includes a shaft 126 and a head 128 coupled to the shaft 126. The head 128 is arranged to project from the swing plate 108, while the shaft 126 is partially disposed within a blind hole 130 extending through the pivot 104. The blind hole 130 of the pivot 104 is internally threaded and configured, shaped, and sized to mate with the external threads of the shaft 126. Thus, rotating the locking fastener 112 causes the split flange base 114 and the split flange arms 116 to move together or move apart, thereby tightening or loosening the winding clamps 90, 106 relative to the branch rail 54 and the swing arm 68 simultaneously. Specifically, rotating the locking fastener 112 in a first rotational direction (e.g., clockwise) screws the locking fastener 112 into the pivot 104 and locks the winding clamp 106, while rotating the locking fastener 112 in the opposite direction (e.g., counterclockwise) screws the locking fastener 112 out of the pivot 104 and unlocks the winding clamp 106.

[0048] Additionally, at least one pneumatic fitting 132 may be coupled to the swing arm 68 to fluidly couple the flexible pneumatic covering assembly 400 to the end effector 66 disposed on the swing arm 68. The pneumatic fitting 132 may be in fluid communication with a fluid passage 134 formed through the swing arm 68. The swing plate 108 may further define a plurality of lugs or tabs 136 that provide features for the configuration tool 14 to engage and adjust the winding clamp 106, as described in more detail below. At least one of the tabs 136 may include a centering feature for alignment control of the robot 12.

[0049] Now referring Figure 6 to, another exemplary swing arm lock 270 for the reconfigurable end effector assembly 16 includes a winding clamp 306 for clamping the swing arm 268 to the branch rail 54, a pivot 304 for rotatably securing the swing arm 268 to the winding clamp 306, a swing plate 308 for engaging the configuration tool 14, and a locking fastener 312 for tightening and releasing the swing arm lock 270. Referring to the drawings, where like reference numerals represent like components, the winding clamp 306 may be clamped and / or released on the branch rail 54 by clamping and / or releasing a pair of split flanges (i.e., split flange base 314, split flange arms 316) of the winding clamp 306, as described previously with reference to the swing lock 70. However, instead of using upper and lower distal ends to rotate or tilt the end effector 66 about a third axis 395, the swing arm lock 270 straddles a pair of spherical halves 372, 374 disposed on the branch rail 54. Tapered reliefs or chamfers 376 on the end faces of the inner surface of the winding clamp 306 correspond to the front and rear ends on each of the spherical halves 372, 374 to allow the swing arm 268 to lean forward or tilt on the branch rail 54 in the direction indicated by arrow 394.

[0050] Specifically referring Figure 7 and 8, the configuration tool 14 includes an axially extending tool assembly 140 and a tool changing device 142 coupled to the tool assembly 140 via an axially extending support rail 144. The tool assembly 140 includes a tool body 146, which may include parallel plates 148 each shaped as a rectangle or other polygon. Each parallel plate 148 is mounted to (and extends from) a first end plate 150 toward a second end plate 152. The first and second end plates 150, 152 are part of the tool body 146 and may be rectangular. The first end plate 150 may be larger in area than the second end plate 152 to facilitate configuring the end effector assembly 16.

[0051] The nut runner 154 can rotate about a nut runner axis 156 (i.e., the drill axis) and extends through the second end plate 152 and is used to adjust the swing arm lock 70 and the swing branch lock 74. In the present disclosure, the term "nut runner" means a drive torque wrench capable of rotating and transmitting torque using pneumatic, electric, or hydraulic power. The nut runner 154 can be driven by a servo motor and controlled for precise and consistent rotation.

[0052] Additionally, the tool assembly 140 includes a gripper 158, which is coupled to the tool body 146 at a location closer to the second end plate 152 than the first end plate 150. The gripper 158 is parallel to the nut runner 154 and includes a gripper actuator 160 and a plurality of gripper fingers 162 movably coupled to the gripper actuator 160. The gripper actuator 160 can be an electric or pneumatic actuator, and when the configuration tool 14 is mounted to the wrist 42, the tool changing device 142 can direct electrical power or pneumatic fluid for controlling the gripper 158. In the illustrated embodiment, the gripper 158 includes two fingers 162. However, the gripper 158 can include more than two fingers 162. Regardless of the number, the gripper fingers 162 can be in a first or disengaged position ( Figure 7 ) and a second or engaged position ( Figure 8 ) relative to each other. When set in the first position ( Figure 7 ), the gripper fingers 162 are closer to each other than in the second position ( Figure 8 ). The gripper fingers 162 can be coupled to the gripper actuator 160 via a sliding member 164. The sliding member 164 is coupled to the gripper fingers 162 and can be actuated by the gripper actuator 160 to move the gripper fingers 162 between the first and second positions.

[0053] The gripper fingers 162 of the gripper 158 are configured to grasp the tab 97 of the swing branch lock 74 to hold the swing branch lock 74, thereby allowing the configuration tool 14 to move (translate or rotate) the tool branch 52 relative to the frame rail 48. In particular, to release the swing branch lock 74, the configuration tool 14 is automatically commanded to grasp the swing plate 107 on the tab 97, and then the nutter 154 rotates counterclockwise the locking fastener 96 to push the pivot 103, which in turn pushes the branch rail 54. In turn, this allows the robot 12 to slide and rotate the tool branch 52 about the frame rail 48 and to swing the branch rail 54 about the axis of the pivot 103, in combination for moving the end effector 66 to a desired position. Similarly, to lock the swing branch lock 74 upon reaching the desired position and while the configuration tool 14 remains engaged, the nutter 154 rotates the locking fastener 96 clockwise to pull the pivot 103 and the branch rail 54 to thereby lock the branch rail 54 into the desired configuration. In turn, the split flanges 84, 86 of the winding clamp 82 are clamped above the frame rail 48, thereby firmly locking the end effector assembly 16 in place. Since these steps can be performed simultaneously, the reconfiguration cycle time can be reduced.

[0054] Similarly, the gripper fingers 162 of the gripper 158 can grasp the tab 136 of the swing arm lock 70 to hold the swing plate 108, thereby allowing the configuration tool 14 to move (e.g., rotate or translate) the tool module 56 relative to the branch rail 54. In particular, to release the swing arm lock 70, the configuration tool 14 is automatically commanded to grasp the swing plate 108 on the tab 136, and then the nutter 154 rotates counterclockwise the locking fastener 112 to push the pivot 104, which in turn pushes the swing arm 68. In turn, this allows the robot 12 to slide and rotate the tool module 56 about the branch rail 54 and to swing and tilt the swing arm 68 about the axis of the pivot 104 and a third axis 94, respectively, in combination for moving the end effector 66 to a desired position. Similarly, to lock the swing arm 68 upon reaching the desired position and while the configuration tool 14 remains engaged, the nutter 154 rotates the locking fastener 112 clockwise to pull the pivot 104 and the swing arm 68 together to thereby lock the swing arm 68 into the desired configuration. In turn, this causes the split flanges 114, 116 of the winding clamp 106 to be clamped above the upper and lower distal ends 113, 115 of the winding clamp 90 and, in turn, above the branch rail 54, thereby firmly locking the end effector assembly 16 in place. Since these steps can be performed simultaneously, the reconfiguration cycle time can be reduced.

[0055] The tool changing device 142 of the configuration tool 14 can be any suitable mechanical coupling similar to the tool changing device 62 on the main boom 44, which allows the robot 12 to pick up the configuration tool 14 and includes a guide pin 166 or other suitable coupling device that enables the robot 12 to engage the configuration tool 14 with the wrist 42. The tool changing device 142 can also include electric and pneumatic ports capable of guiding electric power and pneumatic power and control signals to operate the nut runner 154 via a drive motor inside the nut runner 154. Once coupled to the wrist 42, the configuration tool 14 is locked in place, and electric power and / or pneumatic power is provided to the nut runner 154 as needed to rotate the drive bit 168, such as a hex bit. Thus, actuating the nut runner 154 causes the drive bit 168 to rotate. At least a portion of the nut runner 154 extends through the second end plate 152 in a direction away from the first end plate 150 such that the drive bit 168 is outside the tool body 146 and extends beyond the second end plate 152.

[0056] Referring Figure 9 and Figure 10 , to reconfigure the tool branch 52, when the gripper fingers 162 on the configuration tool 14 are held in the first position (i.e., the disengaged state), but are in a position ready to engage at least one of the tabs 97, the configuration tool 14 is first manipulated so that the nut runner 154 and its drive bit 168 engage the fastener 96 of the swing branch lock 74 wound around the frame rail 48. Specifically, when the gripper fingers 162 are in the first position (i.e., the disengaged state), the robot 12 moves the configuration tool 14 toward the swing branch lock 74 such that the drive bit 168 is aligned with the fastener 96, and the gripper fingers 162 of the gripper 158 are aligned with at least one of the tabs 97. The configuration tool 14 can be moved toward the swing branch lock 74 until the drive bit 168 is aligned with the fastener 96 and the gripper fingers 162 are aligned with at least one of the tabs 97. Then, as Figure 10 best shown, the gripper fingers 162 are then moved to the second position (i.e., the engaged state) to grip at least one of the tabs 97. As described above, the gripper fingers 162 can be actuated pneumatically or electrically.

[0057] Next, the controller 18 commands the nut runner 154 powerfully to engage the drive bit 168 with the fastener 96. The drive bit 168 can rotate (e.g., counterclockwise) to loosen the fastener 96 and release the swing branch lock 74 from the fixed engagement on the frame rail 48. With the gripper fingers 162 of the configuration tool 14 tightly gripping at least one of the tabs 97, the robot 12 can slide along the frame rail 48 and rotate the branch rail 54, and swing the branch rail 54 about the axis of the pivot 103 to the desired position or orientation. Thereafter, the nut runner 154 of the configuration tool 14 is commanded (by the controller 18) to rotate (e.g., clockwise) to tighten the fastener 96 so as to fix the swing branch lock 74 to the desired position on the frame rail 48. The controller 18 can also command the gripper fingers 162 to disengage (i.e., move to the first position) to release at least one of the tabs 97 and disengage the configuration tool 14 from the swing branch lock 74 to complete the reconfiguration operation.

[0058] Now referring to Figure 11 and 12 , to configure the swing arm 68 or adjust the position and / or orientation of the end effector 66 (e.g., vacuum gripper), when the gripper fingers 162 on the configuration tool 14 remain disengaged (i.e., in the first position) but are in a position ready to engage the locking fastener 112, the configuration tool 14 can be manipulated to engage the nut runner 154 and its drive bit 168 with the locking fastener 112 of the swing arm lock 70. Specifically, when the gripper fingers 162 are in the first position (i.e., disengaged state), the robot 12 moves the configuration tool 14 towards the swing arm lock 70 such that the drive bit 168 is aligned with the locking fastener 112, and the gripper fingers 162 of the gripper 158 are aligned with at least one of the tabs 136. The configuration tool 14 can be moved towards the swing arm lock 70 until the drive bit 168 is aligned with the head of the locking fastener 112 and the gripper fingers 162 are aligned with at least one of the tabs 136. Then, as Figure 12 best shown, the gripper fingers 162 are engaged (i.e., moved to the second position) to grip at least one of the tabs 136. As described above, the gripper fingers 162 can be actuated pneumatically or electrically.

[0059] Next, the controller 18 commands the nut runner 154, electrically, to engage the drive bit 168 with the locking fastener 112. The drive bit 168 can be rotated (e.g., counterclockwise) to loosen or push away the locking fastener 112 from the pivot 108. In turn, this action releases the swing arm lock 70 from the fixed engagement on the branch rail 54 while allowing the swing arm 68 to move relative to the swing arm lock 70. With the gripper fingers 162 of the configuration tool 14 tightly grasping at least one of the tabs 136, the robot 12 can slide and rotate the swing arm 68 along the branch rail 54, and tilt the swing arm 68 to a desired position or orientation about the upper and lower distal openings 113, 115 of the winding fixture 90. Additionally, the robot 12 can rotate the swing arm 68 and the end effector 66 (e.g., vacuum gripper) about the axis of the pivot 104. Thereafter, the nut runner 154 of the configuration tool 14 is commanded (via the controller 18) to rotate (e.g., clockwise) to tighten the locking fastener 112 to secure the swing arm lock 70 to a desired position on the branch rail 54 and to secure the swing arm 68 to a proper orientation relative to the swing arm lock 70. Then, the controller 18 can also command the gripper fingers 162 to disengage (i.e., move to a first position) to release the tabs 136 and disengage the configuration tool 14 from the swing arm lock 70 to complete the reconfiguration operation.

[0060] Now referring to Figure 2 and Figure 13 , a flexible pneumatic cover assembly 400 is disclosed for use with an end effector assembly 16 that directs gas (e.g., air) from the robot 12 and introduces or withdraws the gas to or from an end effector 66 (e.g., vacuum gripper). In particular, the pneumatic cover assembly 400 includes a plurality of coiled or helical pneumatic tubes 402 disposed at various locations along a plurality of tool branches 52, a main manifold 404 secured to the main cantilever 44, and a plurality of pneumatic fittings 406 disposed between the main manifold 404 and the tubes 402. In the exemplary embodiment described above where the end effector 66 is a pneumatic gripper, pneumatic tubes of various sizes can be used to convey pneumatic air or vacuum from the robot 12 through the tool changer assembly 60 and to the end effector 66 of the end effector assembly 16. The routing of the coiled or helical tubes 402 takes advantage of the spring-back ability of the tubes 402 such that when the tool branches 52 are reconfigured, the tubes 402 can be stretched and flattened back to their defined geometry and shape.

[0061] The flexible pneumatic covering assembly 400 can be arranged along the main boom 44 to establish a main manifold 404 between the main boom 44 and the frame rail 48. The main manifold 404 can further include a pair of pneumatic fittings 406 extending in either direction along the frame rail 48. The remaining fittings 406 and tubes 402 are daisy-chained to interconnect from the main manifold 404 to adjacent tool branches 52 and direct to each end effector 66. In particular, each swing branch lock 74 contains its own helical tube 402 disposed therearound, as Figure 13 best shown. Each helical tube 402 can be wound around the proximal end of the branch rail 54 for several turns. When the swing branch lock 74 is moved, the helical tube 402 can exhibit a diameter difference between the inner diameter of the coil and the outer diameter of the branch rail 54, thereby allowing the tube 402 to elongate or snap back. Each tube 402 can have a single input 408 and dual outputs 410, 412. The signal input 408 can be interconnected with the main manifold 404 or the fitting 406 of the aforementioned swing branch lock 74. The first output 410 can be interconnected with an additional swing branch lock 74 along the branch rail 54 (if any). The second output 412 can be routed via a tube 407 to the hollow interior of the branch rail 54. The tube 407 can also be interconnected with the end effector 66 via a smaller helical tube 409 that is wound around the swing arm 68 for several turns and terminates at a pneumatic fitting 411 on the swing arm 68 near the pivot 104. The fitting 411 has an air passage that is connected to the hollow interior 134 of the swing arm 68 and serves as a pneumatic conduit directly applied to the end effector 66.

[0062] The tube 402 can be further constrained along the branch rail 54 by the addition of a retaining feature 414, such as a straight pin that pierces the rear protrusion 415 of the swing branch lock 74. The retaining feature 414 ensures that the tube 402 remains outside the position of any moving part of the end effector assembly 16 (i.e., the tool module 56) or the configuration tool 14 during a reconfiguration operation. In one example, the retaining feature 414 can be an L-shaped hook extending from at least one side of the branch rail 54. In another example, the retaining feature 414 can be a straight pin that pierces the branch rail 54 near the swing branch lock 74, as shown.

[0063] Referring to Figure 14 , another exemplary flexible pneumatic covering assembly 500 contains a spring-loaded tube reel 502 as an alternative to the simple helical tube 402. The tube reel 502 can advantageously elongate and / or flatten the tube into an actively defined geometry and shape, rather than passively relying on the snap-back ability of the tube material.

[0064] The spring-loaded tube reel 502 consists of a spool 504 having a hub 506. The reel 502 is coupled to a shaft 522 of a reel support 520. The spool 504 and the reel support 520 are assembled and held together by a retaining ring 505. A helical power spring 516 is mounted between the spool 504 and the reel support 520. The inner end of the power spring 516 is securely fixed to the hub 506 of the spool 504, while the outer end of the power spring 516 is fixed to a spring cap 518. After the power spring 516 is installed, the spring cap 518 is in turn fastened to the reel support 520 using fasteners (e.g., screws, bolts).

[0065] Although the reel support 520 is fixed to the rear projection 415 of the swing branch lock 74 via a plurality of fasteners (e.g., bolts, screws) through an adapter plate (not shown), the spool 504 rotates freely with the winding of the power spring 516. The reel support 520 also has a hollow core 526 that serves as a pneumatic conduit having a first end coupled to a pneumatic fitting 508 and a second opposite end coupled to another pneumatic fitting 514. The second fitting 514 receives the tube 530 wound on the spool 504. The fitting 514 is free to rotate to accommodate the rotation of the spool 504, which is caused by the elongation and flattening of the tube 530 during the automatic movement of the swing branch lock 74 for end effector reconfiguration. The power spring 516 helps to maintain the tube 530 in tension, and due to this tension, a retaining feature may not be required.

[0066] Embodiments of the present disclosure are described herein. The description is merely exemplary in nature and thus variations that do not depart from the gist of the present disclosure are considered to be within the scope of the present disclosure. The figures are not necessarily to scale; some features may be enlarged or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting but rather as a representative basis for teaching one skilled in the art to utilize the present invention in various ways. As will be understood by those of ordinary skill in the art, the various features shown and described with reference to any one of the figures may be combined with features shown in one or more other figures to produce embodiments not explicitly shown or described. Combinations of the features shown provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations.

Claims

1. An end effector assembly, which comprises: A main cantilever having a flexible covering assembly fixed thereto; A frame rail coupled to the main cantilever, the flexible covering assembly having a pneumatic hose, a portion of which extends along at least a portion of the frame rail; At least one branch rail movably coupled to the frame rail by a swing branch lock, wherein the flexible covering assembly further includes a wound portion of the pneumatic hose disposed along at least one branch rail, and the swing branch lock has an extension leg for receiving the wound portion of the pneumatic hose of the flexible covering assembly; And A swing arm movably coupled to the at least one branch rail by a swing arm lock, the swing arm lock including at least one fitting for receiving a proximal end of the flexible covering assembly fixed thereto, wherein the at least one fitting fluidly couples the flexible covering assembly to an end tool disposed on the swing arm, wherein the swing branch lock is movable relative to the frame rail between an unlocked state and a locked state to fix the branch rail in place relative to the frame rail, and wherein the swing branch lock further includes a rotatable joint disposed opposite the extension leg, and wherein when the swing branch lock is in the unlocked state relative to the frame rail, the branch rail can be translated in a first direction along the frame rail axis, can be rotated relative to the frame rail about the frame rail axis in a second direction, and can be swung relative to the frame rail about a pivot at the rotatable joint in a third direction, wherein the swing branch lock further includes: A clamp configured to movably fix the branch rail to the frame rail; A pivot extending through the clamp and configured to rotatably fix the clamp in place; A swing plate fixed to the pivot and configured to engage a configuration tool; and A locking fastener extending through the swing plate and into the pivot, wherein the locking fastener is configured to lock and unlock the clamp in place.

2. The end effector assembly according to claim 1, wherein the at least one fitting is a pneumatic fitting fluidly communicating with a fluid passage formed by the swing arm.

3. The end effector assembly according to claim 1, wherein the wound portion of the pneumatic hose of the flexible covering assembly is disposed around a spring-loaded reel.

4. The end effector assembly according to claim 1, wherein the swing arm lock moves along the branch rail between an unlocked state and a locked state to fix the swing arm in place relative to the branch rail.

5. The end effector assembly according to claim 1, further comprising an end tool disposed at a distal end of the swing arm, the end tool defining a first side of the end effector assembly for engaging a workpiece, wherein the swing branch lock and the swing arm lock are configured to be engaged by a configuration tool on a second side of the end effector assembly opposite the first side.

6. The end effector assembly according to claim 1, wherein the swing arm lock further comprises: A clamp configured to movably fix the swing arm to the branch rail; A pivot that extends through the clamp and is configured to rotatably secure the clamp in place; A swing plate that is fixed to the pivot and is configured to engage a configuration tool; And A locking fastener that extends through the swing plate and into the pivot, wherein the locking fastener is configured to lock and unlock the clamp in place.

7. The end effector assembly according to claim 6, wherein the clamp of the swing arm lock is fixed above a second swing arm clamp, wherein the second swing arm clamp includes a pair of distal opposing ends, and wherein unlocking the clamp of the swing arm allows the swing arm lock to move in at least a primary direction, a second direction, and a third direction.

8. The end effector assembly according to claim 1, wherein each helical pneumatic tube has a single input, a first output, and a second output, wherein the single input is interconnected with a main manifold or a fitting of a swing branch lock, the first output is interconnected with an additional swing branch lock along a branch rail, and the second output is routed to a hollow interior of the branch rail.

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