Programmable variable-pitch end effector

Abstract

An apparatus, system, and method for a programmable pitch end effector. Embodiments include a plurality of modules, where one module of the plurality of modules includes a base that is stationary in position on the x-axis, and where other modules of the plurality of modules include bases that are linearly movable on the x-axis; a plurality of clamps, each clamp uniquely associated with each of the plurality of modules remote from the base of each of the plurality of modules, the plurality of clamps being capable of clamping an article in a manufacturing or packaging line; a z-axis actuator capable of moving at least one of the plurality of grippers along a z-axis close to and away from the gripped article; a theta-axis actuator capable of moving at least one of the plurality of clips about a z-axis relative to a respective base of one of the plurality of modules corresponding to the one of the plurality of clips; and a linear motion actuator capable of providing linear motion of at least one of the plurality of modules along the x-axis.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 339,865, filed on May 9, 2022, and entitled “PROGRAMMABLE PITCH END EFFECTOR,” the entire contents of which are incorporated herein by reference as if fully set forth. background Technical Field

[0004] The present disclosure relates to robotics-based processing, and in particular to apparatus, systems, and methods related to programmable pitch changer end effectors.

[0005] Background

[0006] Robotic pick and place of parts typically involves repositioning the parts from one pitch / spacing / angle at pick to a different pitch / spacing / angle at subsequent part placement. Pickers also typically involve other part feed systems such as parallel guided conveyors or vibrating inline tracks.

[0007] Conventional pitch changes are typically based on a cam or plate cam of a spiral drum that can expand and retract multiple brackets or similar elements. However, such designs are limited in positioning flexibility, in part because the hard-tooled positioning cam design dictates a fixed start and fixed end position. Since such cam-based pitch changers require many steel components, these hard-tooled designs are also larger and heavier.

[0008] In addition to the above disadvantages, the end effectors of these hard tools must be changed for each new pitch / spacing / angle required for the pick. Furthermore, the hard tool end effectors only allow very limited changes between pick and place.

[0009] Therefore, there is a need for a lighter and more flexible programmable pitch / spacing / angle converter that facilitates conversion capabilities, flexibility, and variability between pick and place. Summary of the invention

[0010] Embodiments provide apparatus, systems, and methods for programmable pitch end effectors. Embodiments include: a plurality of modules, wherein one of the plurality of modules includes a base fixed in position on an x-axis, and wherein other of the plurality of modules includes a base capable of linear movement on the x-axis; a plurality of grippers, each uniquely associated with each of the plurality of modules away from a base of each of the plurality of modules, the plurality of grippers capable of gripping items in a manufacturing or packaging line; a z-axis actuator capable of moving at least one of the plurality of grippers along the z-axis toward and away from the gripped item; a θ-axis actuator capable of moving at least one of the plurality of grippers about the z-axis relative to a corresponding base of one of the plurality of modules corresponding to one of the plurality of grippers; and a linear motion actuator capable of providing linear motion of at least one of the plurality of modules along the x-axis.

[0011] Thus, embodiments provide a lighter and more flexible programmable pitch / spacing / angle converter that facilitates conversion capabilities, flexibility, and variability between pick and place. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Exemplary devices, systems, and methods will be described below with reference to the accompanying drawings, which are given by way of non-limiting examples only, and in which:

[0013] Figure 1 Aspects of a programmable pitch end effector are shown;

[0014] Figure 2A and 2B Aspects of a programmable pitch end effector are shown;

[0015] Figure 3 Aspects of a programmable pitch end effector are shown;

[0016] Figure 4 Aspects of a programmable pitch end effector are shown;

[0017] Figure 5 Aspects of a programmable pitch end effector are shown;

[0018] Figure 6 Aspects of a programmable pitch end effector are shown;

[0019] Fig. 7A and 7B Aspects of a programmable pitch end effector are shown;

[0020] Fig. 8A and 8B Aspects of a programmable pitch end effector are shown;

[0021] Fig. 9 Aspects of a programmable pitch end effector are shown;

[0022] Fig.10 Aspects of a programmable pitch end effector are shown; and

[0023] Fig.11 Aspects of a programmable pitch end effector are shown. DETAILED DESCRIPTION

[0024] The accompanying drawings and descriptions provided herein may have been simplified to illustrate the aspects related to the device, system and method described herein, and for the sake of clarity, other aspects that can be found in typical similar devices, systems and methods have been eliminated. Therefore, those skilled in the art will recognize that other elements and / or operations may be desirable and / or necessary for realizing the device, system and method described herein. But because such elements and operations are known in the art, and because they do not promote a better understanding of the present disclosure, for the sake of brevity, the discussion of such elements and operations may not be provided herein. However, the present disclosure is considered to still include all such elements, variations and modifications to the described aspects known to those of ordinary skill in the art.

[0025] Embodiments are provided throughout the text so that the present disclosure is fully thorough and the scope of the disclosed embodiments is fully conveyed to those skilled in the art. Many specific details, such as embodiments of specific parts, devices and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. However, it is apparent to those skilled in the art that certain specific disclosed details do not need to be adopted, and the embodiments may be implemented in different forms. Therefore, the embodiments should not be construed as limiting the scope of the present disclosure. As described above, in some embodiments, known processes, known equipment structures and known technologies may not be described in detail.

[0026] The terms used herein are only for the purpose of describing specific embodiments, rather than being intended to be limiting. For example, as used herein, the singular forms "one", "an" and "the" may also be intended to include plural forms unless the context clearly indicates otherwise. The terms "include", "comprise", "contain", and "have" are inclusive, thus specifying the presence of the features, integers, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts and / or combinations thereof. Unless specifically determined to be a preferred or required execution order, the steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or shown. It should also be understood that additional or alternative steps may be used to replace the disclosed aspects or to be combined with the disclosed aspects.

[0027] When an element or layer is referred to as being "on," "over," "connected to," or "coupled to" another element or layer, unless expressly stated otherwise, it may be directly on, over, connected to, or coupled to another element or layer, or there may be intermediate elements or layers. Conversely, when an element or layer is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). In addition, as used herein, the term "and / or" includes any and all combinations of one or more associated listed items.

[0028] In addition, although the term first, second, third etc. can be used to describe various elements, components, regions, layers and / or parts here, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms are only used to distinguish an element, component, region, layer or part from another element, component, region, layer or part. Unless the context clearly indicates, otherwise the terms such as "first", "second" and other digital descriptions do not imply order or sequence when used in this article. Therefore, without departing from the teaching of the embodiment, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part.

[0029] The present disclosure relates to a programmable pitch machine, which may take the form of an end effector, for example. The programmable pitch machine addresses the need for a flexible and programmable pitch machine with a small, lightweight form factor, instant positioning transitions, and high flexibility between pick and place. The disclosed embodiments include multiple encoded servo drive modules to position components.

[0030] As a non-limiting example, an embodiment may include four mobile modules and one fixed module on the end effector head. The fixed module position may be robot driven, i.e., related to the position of the robot associated with the end effector, and the four mobile modules may be servo positioned relative to the fixed module. Of course, based on this disclosure, those skilled in the art will understand that other numbers of fixed or mobile modules may be provided within the scope of the embodiment.

[0031] Module position "recipes", that is, combinations and variations of the positions of the mobile modules, can be programmed individually for position and speed. Thus, product changeovers can be handled within the operating range of the end effector module with simple program recipe changes.

[0032] In other embodiments, components can be grouped, such as in pairs, and placed in individual or combined bags on a placement tray (e.g., which can be moved along a conveyor belt), rather than conforming to simple repeating intervals. For example, components can also be grouped, assembled, or electrically connected, such as in pairs or rows, when held on or by an end effector. That is, the flexibility of the individually programmable modules enables auxiliary operations on the fly that are not generally possible with fixed pitch machines.

[0033] The moving and fixed modules can incorporate z-axis adjustments that allow individual ones of the modules to selectively extend and retract toward and away from a pick or place tray. This enables pick and place without entering the pick or place location, and enables selective ignoring of defective, rejected, or mis-positioned parts. For example, the disclosed end effector can also selectively ignore those parts when they fail pre-inspection, such as by not extending for part picking. Similarly, the modules can include part presence sensors to detect the presence or absence of parts, which can prevent part and tray damage. All of the above additionally reduce scrap.

[0034] The module may also include a theta-axis adjuster, for example, to rotate the component about a vertical axis. This addresses component pick and place that requires width and rotation adjustments to acquire or release aligned components.

[0035] The end effector movement modules can be arranged on linear bearing rails for low friction, durability and positioning repeatability. The main servo drive belt for the movement module can position the module laterally, the module Z axis can raise and lower the work tool, and the theta axis can rotate the tool about the Z axis. Modules can also be arranged in multiple rows for parallel work.

[0036] As a non-limiting example, each module may be driven by a dedicated drive belt to achieve low inertia, light weight positioning and repeatability. Alternative embodiments may use drive chains, such as miniature stainless steel chains, for example in hot or corrosive environments where rubber belts may fail.

[0037] Each servo drive module may have dedicated electrical and pneumatic harness services, such as using a micro "guide chain". Other embodiments may use ribbon cables or combined electrical and pneumatic ribbon cables. Grip open / close, vacuum on / off, theta on / off, part presence on / off, grip position sensing, and / or encoder position signals are typical signals that may be routed by these means.

[0038] In addition, a compact onboard servo driver board can control the individual module positions and I / O for pneumatics. All of the above can minimize the harness size of the end effector as a whole. In addition, an integrated pneumatic valve block can be integrally mounted to the end effector for fast response and further minimizing the harness size of the end effector.

[0039] More specifically, embodiments may include a multi-module, e.g., 5-module end effector with programmable, variable pitch. It may be desirable to have more modules or fewer modules given space constraints and the stroke length required for each module. Furthermore, the number of modules may depend on the stroke length between pick or place locations, and some modules may be active / inactive depending on such positioning.

[0040] Figure 1 A moving robot head 10 is shown, which may typically be a ceiling mount that "reaches down" to a conveyor 12 that runs along at least the x-axis (and in many cases along both the x-axis and the y-axis). Thus, a pick-up pallet 16 may run along one of the x-axis or the y-axis, while a place-down pallet may run along the other axis. A programmable pitch end effector 20 is attached to the robot head 10.

[0041] Figure 2A and 2B It is shown that the mobile modules 102a, b, c, d can move on one or more common base rails. The non-mobile module 104 at the end rail 106 can provide zero spacing, that is, it can be maintained in a certain position so that the programmable y-axis movement of other modules 102a, b, c, d along (one or more) common rails can start from this maintained zero point. Of course, in other embodiments, the non-mobile module 104 can be centered, rather than adjacent to the end rails, where odd or even numbered mobile modules 102a, b, c... spread out and converge to the center module.

[0042] Each mobile module 102a, b, c, d can have a dedicated drive belt and drive motor, such as an encoded servo motor, to allow programmability, and the belt (and therefore stroke) length of each module can be varied based on its minimum and maximum positions, as described in further detail below. These belts, motion stops, and belt drives (from corresponding motors) can be staggered along the end effector base plate, as also described in further detail below.

[0043] From this discussion, those skilled in the art will appreciate that the individual modules may be driven by alternative means such as pneumatics. In this case, the pick and place positions may be more limited to the spacing therebetween, since each module may be limited to a minimum and maximum run (and thus to the two available spacings for the pick and place trays); or, in such an alternative embodiment, intermediate motion stops may be provided, whereby additional pitch positions may be available for each module on the y-axis.

[0044] Depending on the size, shape and type of items being picked and placed, typically each module will terminate in a gripper 110. The gripper 110 may be a fork-shaped, mechanically, electrically or pneumatically actuated clamp-shaped or a buckle-shaped, hook-shaped, etc., and the type of gripper 110 employed may depend on the items being picked and placed.

[0045] Each module may additionally include dedicated actuators, z-axis drives (which may be dedicated to each module or which may function across several or all modules) to raise and lower the module, and / or part sensors to sense the presence or shape or position or grip of parts for pick and place. Each module may additionally have a theta-axis drive (which may be dedicated to each module or which may function across several or all modules).

[0046] Thus, given the capabilities provided above, the present module can individually and selectively pick from and place to a pallet. Variable spacing allows this to be accomplished without interfering with adjacent components of pallets of variable size associated with articles, including situations where the pick and place pallets differ in spacing and / or orientation.

[0047] exist Figure 3 In the illustrated diagram of FIG. 1 , there are 5 modules, 4 of which 102a, b, c, d move in the Y and Z axes. The fifth module 104 moves only in the z axis. In the illustrated embodiment, each of the 4 moving modules has its own drive belt 202a, b, c, d and dedicated stepper motor. The motor can preferably make the drive belts 202a, b, c, d step in unison with each other, extending and retracting together to avoid conflicting movements.

[0048] Also shown is an integrated pneumatic block 210. In some embodiments, pneumatics can independently and programmably or in unison actuate the grippers 110 at the end of each module 102a, b, c, d, 104. Similarly, these grippers 110 can be electrically, electromechanically, pneumatically, or otherwise actuated.

[0049] Thus, embodiments provide programmability without the need to swap out end effectors. Such programmability can be provided for different pallet widths, orientations, and spacings, as well as for different robot and conveyor configurations, all with a single end effector.

[0050] like Figure 4 As shown, each module's drive belt 202a, b, c, d (and motor) may have a corresponding homing, distance or similar sensor 302a, b, c, d. The sensor allows the module base to be sensed as it is moved by the drive belt 202a, b, c, d.

[0051] Figure 5 The disclosed end effector 502 is again shown. The embodiments may preferably have a small and light form factor. As a non-limiting example, in the illustrated embodiment, the length of the end effector 502 may be in the range of 250-500 mm, such as about 350 mm; the width may be in the range of 100-300 mm, such as about 215 mm; the height may be in the range of about 100-300 mm, such as 225 mm; the total weight of the end effector 502 may be in the range of 2-10 kg, such as about 5 kg. Those skilled in the art will appreciate that these ranges are given by way of example only.

[0052] like Figure 6 As shown, each module may have its own dedicated cable management system 602, and may additionally have its own pneumatic device 604 (which may be derived from the end effector), such as for the vacuum cup gripper 110 ( Figure 6 Also shown are servo motors 610a,b,c,d (and associated encoders) for each of the four belt drives for the four motion modules 102a,b,c,d.

[0053] Fig. 7A and 7B The operation of the syringe 702 is shown. More specifically, the module 102b is shown manipulating the syringe 702 in its fixture 110. Further shown is the actuation extension 710 of the module 102b downward along the z-axis, and the actuation rotation 712 of the module on its theta axis. For example, these position changes can be achieved pneumatically. For example, the module can include a guide cylinder with a double-acting cylinder, for example with a stroke of 10 mm.

[0054] Fig. 8A and Figure 8B Shown above Fig. 7A and Figure 7B102B. Evident in this top view is the module head 802 that is not rotated (along the θ axis), and the head 802 rotated along the θ axis. The rotation may be position-encoded so that it can be performed at multiple stop points, such as between the travel stops 810 on the module head 802 as shown. As a non-limiting example, the rotation may be achieved by actuating to any of multiple positions of the single-acting spring extension cylinder 820 as shown.

[0055] Fig. 9 A 5 module end effector 902 is shown picking up a syringe 702 from a pick tray 910. The pitch end effector 902 extends each module 102a, c, d, 104 down the pick tray 910 in the Z axis to retrieve each syringe 702. It is noteworthy that in the illustration, the misplaced / misshapen parts are detected upstream and marked. Accordingly, the pick module 102b aligned over the part 702b in the pick tray has been automatically kept retracted to avoid picking up the defective / misplaced syringe.

[0056] exist Fig.10 Detection of a misplaced / defective component 702b in the previous figures is shown in a cross-sectional view of . Note that again, it is apparent that the module 102b corresponding to the defective component 702b does not extend downward in the z-axis toward the pick tray 910 so as not to pick up the defective component 702b.

[0057] Needless to say, active sensing / feedback can be used to avoid picking up defective parts, or to avoid placing parts in filled slots in the placement tray. For example, when the module is extended to place a syringe, pressure sensing can enable sensing of already loaded bags so that the already loaded slots can be skipped while the remaining bags can be loaded.

[0058] Fig.11 The picked syringes 702 are shown placed into a placement tray 950 (in this case, as a non-limiting example, the placement tray includes a blister pack). Notably, the placement tray 950 differs from the illustrated pick-up tray 910 in both the pitch between syringes 702 and the angles of the syringes 702.

[0059] That is, the pitch end effector can change the pitch of its modules 102a, b, c, d, 104 from the pick-up function, such as Fig.11 In addition, the module heads 102a, b, c, d, 104 are adjusted in the θ-axis (before, after or during the extension of the z-axis function of each module) to correspond to the angular changes in the placement tray 950a, b, c positions, which are different from the position of the pick tray 910 shown above.

[0060] like Fig.12 As shown, a blister (placement) tray 950 is loaded with syringes 702 and may thereafter be hermetically sealed, for example, with a blister pack lid. Thus, the θ adjustment of the pitch changer saves costs by providing a method for efficiently matching the tray pockets of the pick tray 910 and the place tray 950. Such cost savings may derive from other aspects, by optimizing the trays to save material, and by optimizing the conveyor configuration by allowing rotation and pitch variation of the tray contents.

[0061] In addition, the description of the present disclosure is provided to enable those skilled in the art to make or use the disclosed embodiments. Various modifications to the present disclosure will be apparent to those skilled in the art, and the general principles defined herein may be applied to other variations without departing from the spirit or scope of the present disclosure. Therefore, the present disclosure is not intended to be limited to the embodiments and designs described herein, but should conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A programmable variable pitch end effector, comprising: a plurality of modules, wherein one module of the plurality of modules comprises a base fixed in position on the x-axis, and wherein another module of the plurality of modules comprises a base capable of linear movement on the x-axis; a plurality of grippers, each gripper uniquely associated with each of the plurality of modules remote from a base of each of the plurality of modules, the plurality of grippers capable of gripping articles in a manufacturing or packaging line; a z-axis actuator capable of moving at least one of the plurality of grippers along a z-axis toward and away from a gripped item; a θ-axis actuator capable of moving at least one of the plurality of fixtures about a z-axis relative to a corresponding base of one of the plurality of modules corresponding to one of the plurality of fixtures; as well as A linear motion actuator is capable of providing linear motion of at least one module of the plurality of modules along an x-axis.

2. The programmable pitch end effector according to claim 1, wherein: Each of the z-axis actuators uniquely corresponds to one of the plurality of modules.

3. The programmable variable pitch end effector according to claim 1, wherein: Each of the θ-axis actuators uniquely corresponds to one of the plurality of modules.

4. The programmable pitch end effector according to claim 1, wherein: The clamp comprises a vacuum clamp.

5. The programmable pitch end effector according to claim 1, wherein: The clamp includes one of a fork and a jaw.

6. The programmable pitch end effector according to claim 1, wherein: The clamp includes a buckle.

7. The programmable pitch end effector according to claim 1, wherein: Each of the linear motion actuators uniquely corresponds to the base capable of performing the linear motion.

8. The programmable pitch end effector according to claim 7, wherein: The linear motion actuator includes a drive belt.

9. The programmable variable pitch end effector according to claim 8, wherein: The drive belt is driven by a motor.

10. The programmable pitch end effector according to claim 9, wherein: The motor is a servo motor.

11. The programmable pitch end effector according to claim 10, wherein: The servomotor is encoded.

12. The programmable pitch end effector of claim 1, further comprising a sensor that monitors the linear motion.

13. The programmable pitch end effector of claim 1, further comprising a sensor that monitors actuation of the z-axis actuator.

14. The programmable pitch end effector according to claim 13, wherein: Actuation of the z-axis actuator is canceled based on the sensor.

15. The programmable pitch end effector according to claim 14, wherein: The actuation is cancelled due to the sensor detecting a defective part.

16. The programmable pitch end effector according to claim 1, wherein: The linear motion actuator includes a drive train.

17. The programmable pitch end effector according to claim 1, wherein: The plurality of modules includes 5 modules.

18. The programmable pitch end effector according to claim 1, wherein: The θ-axis actuator modifies a position of a corresponding one of the plurality of grippers about a z-axis between a pick function and a place function for a gripped item.

19. The programmable pitch end effector according to claim 1, wherein: The linear motion actuator modifies a position of a corresponding one of the plurality of grippers between a pick function and a place function for a gripped item.

20. The programmable pitch end effector according to claim 1, wherein: The θ-axis actuator includes at least two motion stops.

Images