Dual installation for automatic repair systems

Abstract

A dual mounted end effector system is described, the end effector system being mounted on a powered manipulator to prepare a surface of an object. The system includes a first tool configured to contact and prepare the surface of the object and a second tool configured to contact and prepare the surface of the object. The system also includes a force control member. The force control member is configured to align with the first tool in a position to contact and prepare the surface of the object in a first state, and to align with the second tool in a position to contact and prepare the surface of the object in a second state.

Description

Background Art

[0001] The automotive industry often needs to prepare the surface of vehicle parts or replacement parts (e.g., bumpers) for various purposes (e.g., paint), or repair the surface of automotive parts or replacement parts due to defects caused during painting or coating. Typical surface preparation processes include, for example, physically grinding the automotive surface or "scraping". Typical repair operations often include, for example, sanding and polishing. Surface preparation and repair of defects on the surface can utilize different tools. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] The present disclosure may be more fully understood by considering the following detailed description of various embodiments of the present disclosure in conjunction with the accompanying drawings, in which:

[0003] Figure 1 A side perspective view of a surface preparation system including a smart end effector tool to scrape a surface of an object is shown according to one embodiment.

[0004] Figure 2 A side perspective view of a smart end effector tool is shown.

[0005] FIG. 3A to FIG. 3D An embodiment of a dual-mount end effector system is shown.

[0006] 4A to 4D A block diagram of an embodiment of a dual-mount end effector system is shown.

[0007] Figure 5A and Figure 5B An embodiment of an end effector assembly having a nozzle is shown.

[0008] Figure 6 A block diagram of an embodiment of a surface preparation system is shown.

[0009] Figure 7 A block diagram of an embodiment of a dual-mount end effector system is shown.

[0010] Figure 8 A method of using a dual mounted end effector in an embodiment of the present invention is shown.

[0011] In the accompanying drawings, similar reference numerals indicate similar elements. Although the above-identified drawings, which may not be drawn to scale, set forth various embodiments of the present disclosure, other embodiments as mentioned in the detailed description are also conceivable. In all cases, the present disclosure describes the currently disclosed disclosure in the manner of representation of exemplary embodiments rather than by expressing limitations. It should be understood that those skilled in the art may devise many other modifications and embodiments that fall within the scope and essence of the present disclosure. DETAILED DESCRIPTION

[0012] The present disclosure provides an automated system and method for working on an object surface (e.g., scraping, sanding, polishing, etc.) using an end effector with a dual-mounted tool. The present invention provides an automated surface preparation system, which includes an end effector with a dual-mounted tool and a powered manipulator. The dual-mounted tool is mounted on the powered manipulator. Each tool includes a functional component that is configured to contact and prepare the surface of an object; one or more sensors that are configured to detect working status information of the end effector tool and possibly a dispenser for a fluid when the functional component contacts and prepares the surface of the object; and a control circuit that is used to receive signals from the sensors and process these signals to generate status information of the end effector tool.

[0013] In some embodiments, the automated surface preparation system can be initialized by communicating the end effector tool with its mechanical arm to update the corresponding status information of each of the end effector and the dual installation tool. When the end effector tool contacts and prepares the surface of the object, one or more onboard sensors can detect the working status information of the installed tool to generate a tool status signal. The control system can process the tool status signal from the sensor to generate real-time status information, notifications and instructions, and transmit the notifications and instructions to the robot controller, which in turn can adjust the motion parameters of the mechanical arm and the control parameters of the end effector tool itself based on the real-time status information and the notifications and instructions from the end effector and the dual installation tool.

[0014] Figure 1 and Figure 2 An automated surface preparation system such as that discussed in commonly owned U.S. Provisional Patent Application No. 62 / 781,874 filed on December 19, 2018 is shown. Figure 1 and Figure 2 However, as shown in Figures 3 to Figure 8 As discussed, embodiments of the present invention relate to many similar machine components.

[0015] Figure 1A side perspective view of an automated surface preparation system 100 according to one embodiment is shown, the automated surface preparation system including an intelligent end effector 20 to which a tool can be attached and used to scrape an object surface 2. The surface preparation system 100 also includes a robotic arm 10. The robotic arm 10 includes a plurality of arm segments 12a to 12c connected by joints 13a to 13c. The intelligent end effector 20 is functionally connected to a mounting interface 14 located at the distal end of the robotic arm 10. The mounting interface 14 can be designed based on certain mounting standards and can be compatible with various end effectors based on the same mounting standards. In some embodiments, the mounting interface 14 may include various mechanical and electrical devices to functionally connect the end effector 20 to the robotic arm 10. For example, the mounting interface may include any suitable fastening device to mechanically mount the intelligent end effector 20 to the robotic arm 10; the mounting interface may include any suitable electrical connector to transmit electrical signals between the tool and the robotic arm or to provide power from the robotic arm to the tool.

[0016] The robot controller 16 is used to execute the robot arm command program to control the movement of the robot arm 10, so that the movement trajectory of the intelligent end effector 20 can be precisely controlled. In some embodiments, the robot arm command program can control the movement of the robot arm via a set of motion parameters (including, for example, the position, orientation, and speed of the arm segments and joints). The object surface 2 can be, for example, an automatic component surface (e.g., a bumper). The robot controller 16 can control the movement of the robot arm so that the end effector 20 can control a tool for contacting and moving around the object surface to prepare (e.g., scraping, grinding, sanding, polishing, etc.) the object surface 2. In some embodiments, the robot controller 16 may include an optional power interface to its power supply to provide power in the form of electricity, air pressure, etc. to the end effector tool.

[0017] Figure 2 According to one embodiment, Figure 1 1 is a side perspective view of the smart end effector 20. The smart end effector 20 includes a mounting interface 22 to mount the end effector 20 to the mounting interface 14 of the robot arm 10. The tool 20 is controlled by the motion of the robot arm 10 to adjust its position, orientation, movement trajectory, etc. while traveling around the object surface 2. Figure 2 In the depicted embodiment, the smart end effector 20 includes a device configured to contact and scrape Figure 1 The functional component 26 includes a scraping pad 26a and a motor 26b to move the scraping pad 26b to scrape or grind the surface of the object. In some embodiments, the scraping pad may include an abrasive pad. The abrasive pad can grind the surface of the object, for example, by oscillating, vibrating or moving in a certain trajectory under a certain pressure against the surface of the object.

[0018] The end effector 20 also includes one or more sensors to detect the working status information of the functional component 26 while the functional component is working or about to work on the object surface 2. The relevant working status information may include, for example, displacement information between the functional component 26 and the object surface 2; mapping information of the object surface 2 including surface position, plane, orientation, etc.; physical contact information between the functional component 26 and the object surface 2, including, for example, contact pressure information, vibration information, etc. Figure 2 In the depicted embodiment, the end effector 20 includes a pressure sensor 23, a flexure sensor 24, and an ultrasonic sensor 25 to detect relevant working status information. There may also be at least some cameras or other optically based sensors for determining whether the end effector or tool is properly positioned. It should be understood that other suitable sensors may be used to obtain the desired working status information of the end effector 20. In addition, multiple sensors may be distributed at various locations of the end effector 20 and the functional component 26 to monitor their working status.

[0019] The pressure sensor 23 may be positioned adjacent to the scraping pad 26a to monitor the physical contact pressure between the scraping pad 26a and the object surface 2. Figure 2 In the depicted embodiment, the pressure sensor 23 is disposed between the scratch pad 26a and the mounting plate 21 of the scratch pad 26a. In some embodiments, the pressure sensor 23 may be positioned between the scratch pad 26a and the object surface 2 or other suitable positions, as long as the physical contact pressure between the scratch pad 26a and the object surface 2 can be monitored in real time.

[0020] A flexure sensor 24 is provided to measure the precise displacement between the tool and the object surface and to continuously map the object surface 2, for example, to obtain a 2D perspective representation or contour of the object surface 2. The flexure sensor 24 includes one or more flexure sensing elements 24a, which extend toward the object surface 2 and have corresponding distal ends 24e to contact the object surface 2, thereby providing contact measurement results for precise displacement and continuous surface mapping. In some embodiments, the flexure sensing elements 24a may be analog resistive, and their resistance may vary with their deflection amount. The analog signal from the flexure sensing element 24a may be amplified and sampled by the control circuit 28 in real time to generate surface mapping data for the object surface 2. However, although the flexure sensor is described as an implementation option for measuring the displacement between the tool and the object surface, other sensor technologies are clearly envisioned, including other linear distance sensors, particularly non-contact distance sensors.

[0021] An ultrasonic sensor 25 is provided to measure the relative position of the end effector 20 relative to the object surface 2 and continuous mapping of the object surface. The relative position can be measured by an echolocation process, in which sound waves can be transmitted from the ultrasonic sensor 25, bounced off the object surface 2 and received by the ultrasonic sensor 25, where the time difference is used to calculate the distance between the end effector 20 and the object surface 2. The positioning signal of the ultrasonic sensor 25 can be sent to the control circuit 28 to determine the real-time displacement between the end effector 20 and the object surface 2. In some embodiments, the ultrasonic sensor 25 can provide position and mapping information at a relatively coarse level, which can be further refined by measurements from the flexure sensor and / or pressure sensor.

[0022] Figure 1 and Figure 2 The system of shows a single end effector for a robotic assembly. However, many operations require the use of multiple tools, such as using a sanding or other sanding tool to remove imperfections to smooth a surface before sanding or polishing, or using a wiping tool to clean or clear a surface. However, for operations such as Figure 1 or Figure 2 The system requires first removing a functional component, attaching a second functional component, and then verifying that the second functional component is properly attached and communicating with the system controller.

[0023] In contrast, the embodiments described herein illustrate an end effector with dual mounted tools so that a single robotic arm can switch between a first tool and a second tool based on the needs of a particular operation. Alternatively, the robot can switch between a first tool and a second tool in response to a command received from an operator.

[0024] FIG. 3A to FIG. 3D An embodiment of a dual mounted end effector system 320 on a robotic arm 300 is shown. Figure 3A A system view of a robotic arm 300 is shown. Figure 3B A view of the end effector system in a use position is shown. The robot arm 300 may have a cable mounting configuration 302. The robot arm 300 has a dual mounted end effector system 320 mounted on a mounting plate 350. The robot arm 300 may rotationally move the end effector system 320 using a rotating plate 310 and vertically move the end effector system using a joint 315 to position a first tool 330 or a second tool 340 to interact with a workpiece. Each of the first tool 330 and the second tool 340 has a connector 332, 342, respectively, connected to the end effector unit 320a, 320b, respectively.

[0025] Figure 3BThe end effector system 320 is shown in one of two use positions, wherein the second tool 340 is in position to engage the workpiece. As discussed with respect to FIG4 , the system 320 uses a single force control to operate both the first tool 330 and the second tool 340. The first and second use positions align one of the tools 330, 340 parallel to the force control.

[0026] Figure 3C A side view of end effector system 320 is shown. Figure 3D A front view of the end effector system 320 is shown, illustrating how the end effectors 320a, 320b are positioned relative to the force control member 360 and the mounting plate 350.

[0027] Figure 4A and Figure 4B Shown is a block diagram of an end effector system according to an embodiment described herein. Figure 4A An exploded view of the end effector system 400 is shown. The end effector system 400 can be moved in any of a variety of suitable orientations by the robotic arm using a vertical translation joint 410. The end effector system 400 can be rotationally moved by movement of a plate 415. The end effector system 400 is mounted to the robotic arm by one or more mounting plates 450.

[0028] The first end effector motor 420a is coupled to the first tool 430 through a tool connector 432 that interacts with the main shaft 422a. The end effector motor 420a is coupled to the force control 460 through a first mount 436. The first mount 436 is also coupled to the first housing 434.

[0029] The second end effector motor 420b is coupled to the second tool 440 via a tool connector 442 that interacts with the spindle 422b. The end effector motor 420b is coupled to the force control 460 via a second mount 446. The second mount 446 is also coupled to a second housing 446. The housings 436, 446 can be used to prevent dust and debris from contacting the motors 420a, 420b.

[0030] Figure 4B The assembled end effector system 400 is shown connected to the robotic arm 402 with the housings 436 , 446 removed for clarity.

[0031] exist Figure 4A and Figure 4B430, 440. In one embodiment, tools 430, 440 are the same tool, for example, both are grinding tools, both are polishing tools, both are wiping tools, both are sanding tools, or both are other tools. In addition, one or both tools can be an imaging tool, a spray tool, or a fluid (such as water or polishing agent) applicator. Having two available tools can increase the operating time of the robot before requiring operator intervention and / or until the robot needs maintenance (such as replacing a disc, replacing a polishing pad, etc.). For example, when the first tool 430 is worn, the robot arm 402 can rotate the end effector system 400 by rotating the plate 415, so that the second tool 440 is in place and continues to operate. However, in another embodiment, tools 430, 440 are different. For example, tools 430 and 440 can both be sanding tools, but their abrasive grain size or surface area is different. Alternatively, tools 430 and 440 can be different tools, such as a denibber 430 and a sander 440. Any suitable combination of tools may be appropriate and are contemplated as being part of this disclosure.

[0032] in addition, Figure 4A and Figure 4B The embodiment of shows a system with two tools. However, in another embodiment, such as Figure 4C and Figure 4D In the embodiments shown in , a third tool and a fourth tool are also added along an axis perpendicular to the axis of the motors 420a, 420b. The third tool and the fourth tool can be paired with a second force control member positioned perpendicular to the force control member 460. Alternatively, the third tool and the fourth tool can be paired with the force control member 460 as long as the third tool and the fourth tool or the force control member 460 can be rotated so that the third tool and the fourth tool are parallel to the force control member 460 during operation. In addition, although in 4A to 4D Two or four tools are shown in the configuration, but it is expressly contemplated that additional tools may be arranged on the power manipulator arm, coupled to the force control unit.

[0033] Figure 5A and Figure 5BAn embodiment of an end effector assembly having a nozzle is shown. The end effector assembly 500 has a first end effector 520a coupled to a first tool 530 using a connector 532. The first tool 530 can obtain an operational benefit from a fluid present on a working surface. Thus, in one embodiment, a nozzle 538 is mounted to a mounting plate 550 via a nozzle mount 539. The nozzle 538 can be connected to a water source or a polish source and dispense water or polish, depending on the operational needs. Similarly, a second end effector 520b is coupled to a second tool 540 using a connector 542. The second tool can also be associated with a second nozzle 548, which can dispense a working fluid, such as a coolant, a grinding aid, oil, soap, water, and / or a polish.

[0034] Systems such as those described in FIGS. 3 to 5 provide operational benefits by being coupled to a single end effector of a robotic arm. The multi-tool design allows the process to be dynamically modified to accommodate changing or unexpected operating conditions without having to replace the tool head or reposition other robots with the required tools. The embodiments of the end effector assembly described herein include a motor with a modular connection system, thereby allowing the tools to be interchanged by connecting the tool to a spindle associated with the end effector motor using a connection mechanism. This allows various tools to be connected to the same assembly without having to change the end effector for different tools. However, direct connections between end effector motors are also envisioned. Integrating various tools in the same assembly and control system significantly reduces system complexity, reduces the time required for dynamic reconfiguration, and potentially reduces the number of robots required to complete process operations.

[0035] Figure 6 6 shows a block diagram of a surface preparation system 600 according to one embodiment, the surface preparation system including an end effector system 610 functionally connected to a powered robotic arm 620 for preparing a surface of an object. Figure 6 As shown, several end effector systems 610 can be coupled to a single robotic arm 620. For example, two end effector systems 610 can be coupled to a force control member so that each end effector system 610 is rotated 180° relative to each other. This allows a single force control member to operate either end effector system 610.

[0036] In another embodiment, more than two end effector systems 610 may be coupled to a single powered robot arm 620. For example, another set of end effector systems 610 may be mounted 180° from each other and perpendicular to the first set of end effector systems 610. A single force controller may operate all four end effector systems by rotating 90° between each end effector system so that the end effector system 610 coupled to the target tool is aligned with the force controller.

[0037] Each smart end effector 610 includes a plurality of sensors 612 (e.g., sensor 1, ... sensor N) to detect its working status information relative to the object surface 602. The plurality of sensors 612 may include, for example Figure 2 One or more pressure sensors of the pressure sensor 23, Figure 2 one or more of the flexure sensors 24, Figure 2 The raw signal from the sensor 612 (e.g., analog sensor signal) is processed by the processor unit 614 (e.g., Figure 2 The processor unit 614 may include an analog-to-digital converter (ADC) component to sample the analog sensor signal and convert the analog sensor signal into a digital signal. The processor unit 614 may also include a digital signal processing component to process and extract the digital signal to generate real-time tool status information, notifications or instructions, and transmit the generated information to the robot controller and / or force controller.

[0038] In some embodiments, the real-time tool status information generated by the processor unit 614 of the tool may include, for example, the current position information of the tool relative to the surface of the object. The real-time tool status information may also include, for example, the contact pressure indicating whether the tool is properly contacting the surface of the object, the real-time change of the displacement between the surface of the object and the tool, etc.

[0039] In some embodiments, the processor unit 614 may combine the positioning data from the ultrasonic sensor 25, the surface mapping data from the flexure sensor 24, and the pressure data from the pressure sensor 23 to reconstruct the object surface 2 and derive the path of the end effector tool to travel on the object surface 602 and prepare (e.g., scrape, grind, sand, or polish) the object surface 602. In some embodiments, the processing unit 614 only modifies the existing robot path to take into account the change between the planned path and the actual position of the workpiece. In some embodiments, the real-time notifications generated by the processor unit 614 of the tool may include, for example, position notifications (e.g., notifying the robot controller that the tool is at the edge of the object surface), safety notifications (e.g., notifying the robot controller that the contact pressure is above an upper limit), etc.

[0040] In some embodiments, the instructions generated by the processor unit 614 of the tool may include, for example, tool operation instructions on how to control the operation of the tool, motion instructions for instructing the robot controller to adjust the position of the tool, or the movement trajectory or speed of the tool, etc. The tool operation instructions may include, for example, on / off instructions for the robot controller to turn the tool on / off, motor control instructions for the robot controller to control the operation of the motor of the tool, etc. For example, when the processor unit 614 determines that the contact pressure is above the limit, the processor unit 614 may send an instruction to the robot controller to instruct the robot arm to move away from the surface of the object. When the processor unit 614 determines that the tool is approaching the surface of the object, the processor unit 614 may send an instruction to the robot controller to instruct the robot arm to reduce the speed of the tool movement. When the processor unit 614 determines that there is a process event that requires immediate action or stop (for example, the tool is contacted by an unidentified protrusion on the surface of the object), the processor unit 614 may send an emergency stop instruction to the robot controller to stop the operation of the tool.

[0041] Real-time status information, notifications, or instructions from the smart end effector tool 610 may be sent to the robot controller 16 via the tool control interface 616 and the robot control interface 626. The robot controller 16 may then use the real-time status information to simultaneously update the motion parameters of the robotic arm so that the movement trajectory of the smart end effector tool 310 may be precisely controlled. The robot controller 628 may also control the surface preparation system 600 accordingly by taking action based on the notification or following the instructions from the smart end effector tool 610. In some embodiments, the robot controller 628 may receive real-time status information, notifications, or instructions from the smart end effector tool, interpret the received information, check whether the notification or instruction is compatible with the preset rules, and implement the instructions accordingly. For example, the robot controller 628 may provide the tool with a movement vector for position adjustment of the tool relative to the surface of the object; the robot controller 628 may instruct the robotic arm and / or the force control unit to provide an appropriate force to press the tool against the surface of the object; the robot controller 628 may provide an emergency stop command to the tool to stop when the robot controller determines an emergency situation, etc.

[0042] Figure 7 A block diagram of an embodiment of a dual-mount end effector system is shown. System 700 can be configured to connect to a powered robot arm, for example, via mounting plate 722 .

[0043] The system 700 includes an end effector system 710. The end effector system 710 is a dual mounting system that supports a first tool 712 and a second tool 714. In one embodiment, only one of the first tool 712 and the second tool 714 is operable at a time. In one embodiment, the first tool 712 and the second tool 714 are arranged so that the tools are rotated 180° relative to each other. However, other configurations are also possible. Each of the first tool 712 and the second tool 714 may have an associated sensor, such as a pressure sensor, a flexure sensor, an ultrasonic sensor, or other suitable sensor, for obtaining desired working status information.

[0044] The system 710 also has one or more movement mechanisms 718 that allow the tools 712, 714 to be moved into position relative to the workpiece. In one embodiment, the tool 712 or 714 needs to be aligned and parallel to the force control member 720 to operate. In one embodiment, the movement mechanism 718 can rotate to move the end effector system 710 so that the tool 712 or 714 is in position when needed.

[0045] The system 700 includes a material source 730 configured to provide a material to a work surface, for example using one or more nozzles 716. The provided material may be water 732, a surfactant 734, a polish 736, or another suitable fluid 738, depending on the operation.

[0046] In one embodiment, tool selection mechanism 740 selects whether tool 712 or tool 714 should be aligned with force control member 720. Tool selection mechanism 740 may make a selection in response to a user selection (e.g., via a user interface). In another embodiment, tool selection mechanism 740 may make a selection based on the parameters of a given repair. For example, based on known defects, a first sanding tool may be required, and then a polishing tool may be applied. Based on the repair process, tool selection mechanism 740 may select a polishing tool when necessary.

[0047] In one embodiment, the end effector tool detector 750 is configured to detect the current tool aligned with the force control member 720. The end effector tool detector 750 can detect the current tool by detecting information from sensors associated with each of the tools 712, 714. For example, in one embodiment, each tool has an associated motor that may not be powered or otherwise in an "on" state when not aligned with the force control member 720. Similarly, other sensor information may also be used to report whether the tool is aligned. Therefore, the end effector tool detector can detect whether the tool is aligned based on sensor and / or power usage information.

[0048] The end effector tool switcher 760 may generate a signal that the end effector system 710 needs to change position to align the desired tool with the force control 720 based on whether and which tool is aligned with the force control.

[0049] The end effector position actuator 770 actuates the movement mechanism 718 to align the desired tool 712 or 714 with the force control member 720 to perform the desired operation.

[0050] A single end effector system 710 having two tools 712 and 714 has been described. However, it is expressly contemplated that in one embodiment, there is a second end effector system 710 having a third tool and a fourth tool. The third tool and the fourth tool may also be positioned 180° relative to each other. The second end effector system 710 may be positioned at an offset relative to the first system, wherein the offset is large enough so that the first tool does not affect the operation of the third tool on the workspace when not in operation. In one embodiment, the two systems 710 are positioned so that approximately 90° rotation of the moving mechanism 718 causes one of the four tools to align with the force control member 720. However, the rotation between each of the four tools may require greater or less rotation, depending on the size of the tools and the clearance required to ensure that the unused tools do not improperly engage the work surface.

[0051] Figure 8 3 to 4. A method of using a dual mounted end effector in an embodiment of the present invention is shown. Method 800 may be used with respect to FIG. 3 to 4. Figure 7 Any of the systems described may be used with another suitable dual mounted end effector system.

[0052] In block 810, the end effector system is in a first position. The first position may be, for example, a first tool aligned with a force control member.

[0053] In block 820, an input is received that a new tool is needed. In one embodiment, the input may be received, for example, from an operator interacting with a user interface. In another embodiment, the input may come from a set of repair instructions to be executed by the automated repair system.

[0054] In block 830, the end effector system is actuated. Actuation may include moving the end effector system from a first position to a second position such that the tool is aligned with the force control member. In one embodiment, the end effector assembly includes a first tool and a second tool, each tool being mounted to the force control member. In one embodiment, the first tool and the second tool are positioned 180° apart from each other. In such embodiments, actuating the end effector system may include rotating the end effector system until the first tool or the second tool is aligned with the force control member.

[0055] In one embodiment, the end effector assembly includes four tools, each of which is mounted to a force control member. In one embodiment, the four tools are oriented so that they are approximately 90° apart from each other. However, depending on the amount of space required for the tools to operate freely, the tools may be closer or further apart. For example, two grinding tools may be positioned closer to each other than two sanding tools. The four tools may be rotated so that each tool is aligned with the force control member in turn. In another embodiment, a four-tool end effector assembly requires two force control members, each of which has two tools positioned 180° apart, wherein the two force control members are mounted perpendicular to each other so that the four tools form a general "X" shape.

[0056] In box 840, the tool position is verified. Verification may include ensuring that the tool is properly aligned with the force control member. Verification may also include ensuring that the tool is properly connected to the motor. Verification may also include ensuring that the sensors associated with the tool are all operating properly. Verification may occur automatically, as indicated in box 842, or may include some operator intervention. Verification may be performed by the end effector system, as shown in box 846. Verification may also be performed by the powered manipulator 848.

[0057] A dual mounted end effector system is described, the end effector system being mounted on a powered manipulator to prepare a surface of an object. The system includes a first tool configured to contact and prepare the surface of the object and a second tool configured to contact and prepare the surface of the object. The system also includes a force control member. The force control member is configured to align with the first tool in a position to contact and prepare the surface of the object in a first state, and to align with the second tool in a position to contact and prepare the surface of the object in a second state.

[0058] The first tool may have a first motor configured to operate the first tool when the system is in the first position, and the second tool may have a second motor configured to operate the second tool when the system is in the second position.

[0059] The first motor and the second motor may be mounted to the force control member.

[0060] The first motor and the second motor may be mounted end to end such that the first tool and the second tool are approximately 180° apart.

[0061] The first tool may be selected from the group consisting of a sander, a polisher, a grinder, a sprayer, a fluid applicator, or a fluid removal tool. The first tool and the second tool may be the same. The first tool and the second tool may be different.

[0062] The end effector system may also have a third tool configured to contact and prepare the surface of the object and a fourth tool configured to contact and prepare the surface of the object. The third tool may be configured to operate when the end effector system is in the third position, and the fourth tool may be configured to operate when the end effector system is in the fourth position.

[0063] The system may further include a second force control coupled to a third motor, the third motor being configured to operate a third tool. The second force control is coupled to a fourth motor, the fourth motor being configured to operate a fourth tool.

[0064] The first tool may be coupled to the first motor via a first coupling that is removably coupled to a spindle of the first motor on a first end.The first coupling may be removably coupled to the first tool on a second end.

[0065] The first tool is selected from the group consisting of: a sander, a polisher, a grinder, a wiper.

[0066] The system may also include: one or more sensors configured to detect the working state of the end effector tool when the functional component contacts and prepares the surface of the object; and a control circuit for receiving signals from the sensors and processing the signals to generate state information of the end effector tool. The sensor may include at least one of a linear position sensor for obtaining position data, a pressure sensor for obtaining pressure data, and a sensor for obtaining surface mapping data.

[0067] The system may also include a mounting interface to functionally connect the end effector system to the powered robot arm.

[0068] The system may further include a nozzle configured to dispense a fluid onto the surface of the object. The fluid may be water, a surfactant, or a polish.

[0069] The control circuit may also include communication components to transmit signals between the control circuit and a control system of the powered manipulator.

[0070] An automated surface preparation system is provided that may include the end effector system of any embodiment described herein, the end effector system mounted on a powered robotic arm. The powered robotic arm may also include a microprocessor to execute a robotic control system. The powered robotic arm may be an automotive repair robot, and wherein the first tool is configured to contact and abrade a surface. Abrading the surface includes the first tool removing a layer of material from the surface. The layer of material may be a layer of paint, primer, electrocoat, or varnish on the surface.

[0071] A method for preparing a surface of an object using a surface preparation system is described. The method includes detecting an end effector system in a first position. The end effector system includes a first tool and a second tool. In the first position, the first tool is aligned with the surface of the object. The method also includes receiving input that the second tool is needed to prepare the surface of the object. The method also includes actuating a moving mechanism of the end effector system. Actuation includes moving the mechanism to align the second tool with the surface of the object. The method also includes verifying the position of the second tool. The steps of detecting, receiving, actuating, and verifying are performed by the end effector system in response to instructions generated by a processor associated with the end effector system.

[0072] The first tool may include a first motor and the second tool may include a second motor, and wherein the first motor and the second motor are mounted to the force control.

[0073] The first motor and the second motor may be installed 180° apart.

[0074] The end effector system may be mounted to a powered robotic arm.

[0075] A processor may be associated with the powered robotic arm.

[0076] In practicing the method, the first tool, the second tool, and the force control member may be fixed relative to one another, and the moving mechanism may be part of a powered manipulator.

[0077] In implementing the method, the moving mechanism may be a plate within the powered robot arm, and wherein aligning the second tool may include rotating the plate until the second tool is in position.

[0078] In implementing the method, receiving the input may include receiving an instruction from a controller. The instruction may include an end effector system position, and the end effector system position may be a first position or a second position.

[0079] In implementing the method, the powered robot arm may further include a microprocessor to execute a robot control system.

[0080] When implementing the method, the end actuator system may also include a third tool configured to contact and prepare the surface of an object, a fourth tool configured to contact and prepare the surface of an object, and the third tool may be configured to operate when the end actuator system is in a third position, and the fourth tool may be configured to operate when the end actuator system is in a fourth position.

[0081] In implementing the method, the system may further include a second force control member coupled to a third motor, the third motor being configured to operate a third tool. The second force control member may be coupled to a fourth motor, the fourth motor being configured to operate a fourth tool. The first tool may be coupled to the first motor via a first coupler, the first coupler being removably coupled to a spindle of the first motor at a first end. The first coupler may be removably coupled to the first tool at a second end.

[0082] In implementing the method, the first tool may be a sander, a polisher, a grinder, a wiper. The second tool may be the same as the first tool. The second tool may be different from the first tool.

[0083] When implementing this method, the system may also include: one or more sensors, which are configured to detect the working status of the end actuator tool when the functional component contacts and prepares the surface of the object; and a control circuit, which is used to receive signals from the sensors and process the signals to generate status information of the end actuator tool.

[0084] In implementing the method, the sensor may include at least one of a linear distance sensor for obtaining position data, a pressure sensor for obtaining pressure data, and a sensor for obtaining surface mapping data.

[0085] In implementing the method, the system may further include a mounting interface to functionally connect the end effector system to the powered robot arm.

[0086] The method may also include using a nozzle associated with the second tool to dispense a fluid onto the surface of the object. The fluid may be water, a surfactant, or a polish.

[0087] References throughout this specification to "one embodiment," "certain embodiments," "one or more embodiments," or "an embodiment," whether or not the term "exemplary" is included before the term "embodiment," mean that the particular features, structures, materials, or characteristics described in conjunction with the embodiment are included in at least one embodiment of certain exemplary embodiments of the present disclosure. Thus, expressions such as "in one or more embodiments," "in certain embodiments," "in one embodiment," or "in an embodiment" appearing in various places throughout this specification do not necessarily refer to the same embodiment in certain exemplary embodiments of the present disclosure. Furthermore, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

Claims

1. A dual mounted end effector system, the end effector system being mounted on a powered manipulator to prepare a surface of an object, the end effector system comprising: a first tool configured to contact and prepare the surface of the object; a second tool configured to contact and prepare the surface of the object; wherein the first tool and the second tool are arranged such that the first tool and the second tool are rotated 180° apart from each other; a single force control member for controlling the force of both the first tool and the second tool; and The force control member is configured to be aligned with the first tool at a position to contact and prepare the surface of the object in a first state, and to be aligned with the second tool at a position to contact and prepare the surface of the object in a second state, the first tool and the second tool being coupled to the same surface of the force control member, and the force control member realizing mutual conversion between the first state and the second state by rotating the first tool and the second tool by 180°, Wherein the first tool has a first motor, the first motor is configured to operate the first tool when the system is in a first position, and wherein the second tool has a second motor, the second motor is configured to operate the second tool when the system is in a second position. 2 . The system of claim 1 , wherein the first motor and the second motor are mounted to the force control member.

3. The system of claim 2, wherein the first motor and the second motor are mounted end to end such that the first tool and the second tool are approximately 180° apart.

4. The system of any one of claims 1 to 3, wherein the first tool is selected from the group consisting of a sander, a polisher, a grinder, a sprayer, a fluid applicator, or a fluid removal tool.

5. The system of any one of claims 1 to 3, wherein the first tool and the second tool are identical.

6. The system of any one of claims 1 to 3, wherein the first tool and the second tool are different.

7. A system according to any one of claims 1 to 3, and further comprising: a third tool configured to contact and prepare the surface of the object; a fourth tool configured to contact and prepare the surface of the object; and Wherein the third tool is configured to operate when the end effector system is in a third position, and wherein the fourth tool is configured to operate when the end effector system is in a fourth position.

8. The system of claim 7, wherein the system further comprises a second force control member coupled to a third motor configured to operate the third tool, and wherein the second force control member is coupled to a fourth motor configured to operate the fourth tool.

9. The system of any one of claims 2 to 3, wherein the first tool is coupled to the first motor via a first coupler, the first coupler being removably coupled to a spindle of the first motor on a first end.

10. The system of claim 9, wherein the first coupler is removably coupled to the first tool on a second end.

11. The system of any one of claims 1 to 3, wherein the second tool is selected from the group consisting of a sander, a polisher, a grinder, or a wiper.

12. The system according to any one of claims 1 to 3, and further comprising: one or more sensors, each tool including a functional component, the sensor being configured to detect an operating state of a tool of the end effector system when the functional component contacts and prepares the surface of the object; and A control circuit is configured to receive signals from the sensor and process the signals to generate status information of a tool of the end effector system.

13. The system of claim 12, wherein the sensor comprises at least one of a linear position sensor for obtaining position data, a pressure sensor for obtaining pressure data, and a sensor for obtaining surface mapping data.

14. The system of any one of claims 1 to 3, further comprising a mounting interface to functionally connect the end effector system to the powered manipulator.

15. The system of any one of claims 1 to 3, further comprising a nozzle configured to dispense a fluid onto the surface of the object.

16. The system of claim 15, wherein the fluid is selected from the group consisting of: water, a surfactant, or a polishing agent.

17. The system of claim 12, wherein the control circuit includes a communication component to transmit signals between the control circuit and a control system of the powered manipulator.

18. An automated surface preparation system, the automated surface preparation system comprising: The end effector system according to any one of claims 1 to 3; Powered robotic arm; and The system is mounted on the power robot arm.

19. The system of claim 18, wherein the powered manipulator further comprises a microprocessor to execute a robotic control system.

20. The system of any one of claims 1 to 3, wherein the powered robotic arm is an automotive repair robot, and wherein the first tool is configured to contact and abrade the surface.

21. The system of claim 20, wherein abrading the surface comprises the first tool removing a layer of material from the surface, and wherein the layer of material is a layer of paint, primer, electrocoat, or varnish on the surface.

22. A method of preparing a surface of an object using a surface preparation system, the method comprising: detecting an end effector system in a first position, wherein the end effector system comprises a first tool, a second tool and a single force control member, the force control member being used to control the force of both the first tool and the second tool, wherein the first tool and the second tool are coupled to a common surface of the force control member, the first tool having a first motor, the first motor being configured to operate the first tool when the system is in the first position, and wherein the second tool having a second motor being configured to operate the second tool when the system is in the second position, and wherein in the first position, the first tool is aligned with a surface of an object by means of the force control member controlling the force applied by the first tool to the surface of the object, the force control member enabling mutual conversion between the first position and the second position by 180° rotation of the first tool and the second tool; receiving input requiring the second tool to prepare the surface of the object; actuating a movement mechanism of the end effector system, wherein actuation includes aligning the second tool with the surface of the object by means of the force control member controlling a force applied by the second tool to the surface of the object; verifying the position of the second tool; and Wherein the steps of detecting, receiving, actuating and verifying are performed by the end effector system in response to instructions generated by a processor associated with the end effector system.

23. The method of claim 22, wherein the first motor and the second motor are mounted to the force control member.

24. The method of claim 22, wherein the first tool and the second tool are installed 180° apart.

25. The method of any one of claims 22 to 24, wherein the end effector system is mounted to a powered robotic arm.

26. The method of claim 25, wherein the processor is associated with the powered manipulator.

27. The method of claim 26, wherein the first tool, the second tool, and the force control member are fixed relative to each other, and wherein the movement mechanism is part of the powered manipulator.

28. The method of claim 27, wherein the moving mechanism is a plate within the powered robot arm, and wherein aligning the second tool comprises rotating the plate until the second tool is in position.

29. The method of any one of claims 22 to 24, wherein receiving input comprises receiving instructions from a controller, wherein the instructions comprise an end effector system position, and wherein the end effector system position is the first position or the second position.

30. The method of claim 25, wherein the powered robotic arm further comprises a microprocessor to execute a robotic control system.

31. The method of any one of claims 22 to 24, wherein the end effector system further comprises: a third tool configured to contact and prepare the surface of the object; a fourth tool configured to contact and prepare the surface of the object; and Wherein the third tool is configured to operate when the end effector system is in a third position, and wherein the fourth tool is configured to operate when the end effector system is in a fourth position.

32. A method according to claim 31, wherein the system further includes a second force control member connected to a third motor, the third motor being configured to operate the third tool, and wherein the second force control member is connected to a fourth motor, the fourth motor being configured to operate the fourth tool.

33. The method of claim 32, wherein the first tool is coupled to the first motor via a first coupler, the first coupler being removably coupled to a spindle of the first motor at a first end.

34. The method of claim 33, wherein the first coupler is removably coupled to the first tool on a second end.

35. The method of any one of claims 22 to 24, wherein the first tool is selected from the group consisting of: a sander, a polisher, a grinder, a wiper.

36. The method of claim 35, wherein the second tool is identical to the first tool.

37. The method of claim 35, wherein the second tool is a different tool than the first tool.

38. A method according to any one of claims 22 to 24, and further comprising: one or more sensors, each tool including a functional component, the one or more sensors being configured to detect an operating state of a tool of the end effector system when the functional component contacts and prepares the surface of the object; and A control circuit is configured to receive signals from the sensor and process the signals to generate status information of a tool of the end effector system.

39. The method of claim 38, wherein the sensor comprises at least one of a linear distance sensor for obtaining position data, a pressure sensor for obtaining pressure data, and a sensor for obtaining surface mapping data.

40. The method of claim 25, further comprising installing an interface to functionally connect the end effector system to the powered manipulator.

41. A method according to any one of claims 22 to 24, and further comprising dispensing a fluid onto the surface of the object using a nozzle associated with the second tool.

42. The method of claim 41, wherein the fluid is selected from the group consisting of: water, a surfactant, or a polishing agent.

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