Capacity-configurable grid tray for robot part handling

Abstract

A configurable tray for robotic workpiece handling includes a frame including a plurality of frame segments arranged in a rectangle, each frame segment including a plurality of positioning features uniformly spaced along an inner edge of the frame segment; and a plurality of dividing strips configured to be selectively positioned within the frame to define one or more pockets for receiving a workpiece in a configurable mesh pattern, a first number of the plurality of dividing strips is selectively positioned between positioning features of a first pair of opposing frame segments and a second number of the plurality of dividing strips is selectively positioned between positioning features of a second pair of opposing frame segments. The second number of dividing strips of the plurality of dividing strips overlaps the first number of dividing strips of the plurality of dividing strips, the first pair of opposing frame segments being perpendicular to the second pair of opposing frame segments.

Description

Technical Field

[0001] The present disclosure relates generally to pallets for robotic part handling, and more particularly to grid pallets that can be configured to provide various grid patterns for positioning workpieces. Background Art

[0002] It is known to use a robotic arm to automatically "pick and place" a workpiece from a workpiece pallet into a fixture (eg, a vise or chuck) in a machine tool (eg, a CNC machine tool). Figure 1 A typical robotic machine tool management system 10 is shown, which generally includes a robot 12, which is controlled by a controller and has a gripper 16 for holding a workpiece. The robotic machine tool management system generally requires that the workpieces are present in a regular array in a part tray 18 for the robot 12 to programmatically and systematically pick them up. The sequence generally begins with the robot 12 picking up a workpiece from a part tray 18. Figure 2 The fixed array grid tray 18 shown picks up the workpiece 27 and opens the CNC automatic door 20. If there is a finished part 374 in the fixture 22, the second gripper usually removes the part first and then loads the new workpiece 27 into the fixture 22. After the workpiece is loaded, the robot 12 exits the CNC machine 24, the automatic door 20 closes, and the CNC machine 24 starts processing. The robot 12 then puts the finished part 374 back to the original position of the part in the grid tray 18, or alternatively places it in a separate finished part box. Afterwards, the robot 12 picks up the next workpiece 27 to be processed, and waits for the CNC machine 24 to complete processing of the current part, and repeats the process until all parts are processed.

[0003] The purpose of arranging the workpieces 27 in a regular array in the grid tray 18 is to simplify the programming of the robot 12 and to space the parts apart to provide space for the gripper fingers 26 to access the workpieces 27 without interfering with adjacent workpieces. The regular array provides an easy way for the operator to load the grid tray 18 and accurately place the workpieces for the robot 12, which is critical to ensuring that the robot 12 accurately loads the workpieces 27 into the fixture 22 (e.g., a pneumatic vise) for processing. The operator loads the grid tray 18 by placing the workpieces 27 in the pockets 28 and pushing the workpieces to the corners of the pockets 28, which ensures that the workpieces are accurately placed in each pocket 28. The process is simple and does not require precise positioning and alignment by the operator to fill the grid tray 18.

[0004] The main limitation of the fixed array grid pallet concept is that the grid pallet is limited to one pocket size and is optimized for only a single size workpiece. Most conventional grid pallets cannot be configured to accept workpieces of different sizes. In order to optimize capacity for workpieces of different sizes, each workpiece size requires the design, manufacture, installation and calibration of a different fixed array grid pallet designed with a pocket size that closely matches the part size. Similarly, if a subsequent manufacturing job has a workpiece that is larger than the pocket size of the current grid pallet, a new grid pallet with a larger pocket will need to be manufactured.

[0005] One existing grid tray 30 design that allows optimization of workpiece capacity over fixed surface area provides Figure 3 The array of nail holes or threaded holes 31 shown. This design allows the operator to place the workpieces 27 in a regular array that can be changed to hold workpieces of different sizes. The nails 32 ( Figure 4 However, these designs are expensive to manufacture and require at least three pins 32 to lock the position and orientation of the workpiece for a rectangular workpiece (eg, Figure 4 As shown, only two nails 32 are required for a circular workpiece 34.) Manually arranging the nails 32 in the pallet 30 for each workpiece size / shape is very cumbersome, making workpiece changes labor intensive and tedious.

[0006] While it is possible to use the grid lines as guides to carefully position the workpiece 27 on a part tray surface that has been laser engraved or otherwise marked with a regular array of grid lines, this approach would require much more time and precision than conventional grid tray designs for an operator to work with to load the workpiece 27. Furthermore, any error in the positioning of the workpiece 27 could result in a collision with the robotic gripper 16.

[0007] Variable capacity can also be achieved by eliminating the fixed array approach entirely. In contrast, in robotic bin picking, e.g. Figure 5As shown, a vision system is used in which a camera 36 or camera group is mounted on the wrist of the robot 12 or on a frame 38 external to the robot 12 to detect the position of the workpiece 27 in the bin 40 or on a conveyor or workbench. By taking multiple images of the workpiece, the vision system is taught the workpiece geometry. In addition, the robot 12 is taught where to clamp the workpiece 27 and how to approach and then retract after picking up the workpiece. When the workpiece 27 is provided to the robot system, the camera 36 is used to detect the position and orientation of the workpiece. The robot path is automatically generated and executed so that the robot 12 directly picks up the workpiece 27. These systems are typically very expensive, complex, and time-consuming to set up and program. Moreover, their reliability is much lower than providing a regular array of workpieces to the robot 12. In addition, their part cycle time may be slow because they usually require a re-clamping station in which the robot 12 releases the workpiece 27 in the fixture and re-clamps the workpiece 27 again in a more precisely fixed position before attempting to load the workpiece 27 into the fixture 22 of the CNC machine 24. As a result, these systems are more commonly used for sorting and other similar tasks as opposed to CNC machine tending. Summary of the invention

[0008] According to one embodiment, the present disclosure provides a configurable pallet for robotic workpiece handling, the pallet comprising: a frame comprising a plurality of frame segments arranged in a rectangular shape, each of the plurality of frame segments comprising a plurality of locating features evenly spaced apart along an inner edge of the frame segment; and a plurality of divider bars, each divider bar comprising a first end and a second end and configured to be selectively positioned within the frame, such that the first end is positioned at a locating feature of one of the frame segments and the second end is positioned at a locating feature of another of the frame segments, the other of the frame segments being aligned with the one of the frame segments Relative; wherein the plurality of dividers are configured to be positioned to define one or more configurable grid pattern of recesses for receiving workpieces by selectively positioning a first number of the plurality of dividers between positioning features of a first pair of opposing frame segments in the plurality of frame segments and selectively positioning a second number of the plurality of dividers between positioning features of a second pair of opposing frame segments in the plurality of frame segments, the second number of the plurality of dividers overlapping the first number of the plurality of dividers, the first pair of opposing frame segments being perpendicular to the second pair of opposing frame segments. In one aspect of this embodiment, each of the plurality of positioning features comprises a notch disposed between adjacent protrusions formed along the inner edge of the frame segments of the frame. Another aspect of this embodiment further comprises a base to which the frame is attached. In a variation of this aspect, the base comprises a pair of end plates and a plurality of inner plates. In another variation, the pair of end plates and the plurality of inner plates are configured to interlock to form the base. In another aspect of this embodiment, the plurality of frame segments comprise a pair of side segments and a pair of end segments. In a variation of this aspect, each of the pair of side segments includes a first end forming a first notch and a second end forming a second notch, and each of the pair of end segments includes a first end forming a first tab and a second end forming a second tab, the first notch being configured to mate with the first tab and the second notch being configured to mate with the second tab, thereby connecting the pair of side segments to the pair of end segments to form the frame. Another aspect of this embodiment also includes a pair of locking plates, each of which is attached to one of the plurality of frame segments and includes an inner portion that overlaps the ends of the second number of the plurality of divider bars to clamp the plurality of divider bars in place. A variation of this aspect also includes a base that is attached to the frame and includes a pair of end plates and a plurality of inner plates, wherein the plurality of frame segments, the plurality of divider bars, the pair of end plates, the plurality of inner plates, and the pair of locking plates have substantially the same length and substantially the same width.Yet another aspect of this embodiment further includes a plurality of height adjustment brackets and a plurality of clips, wherein each height adjustment bracket is positioned adjacent to a corner of the frame and includes a plurality of horizontal slots, and each of the plurality of clips is configured to extend through a pair of the plurality of horizontal slots and clip onto a frame segment to support the frame at a selectable height above a support surface. In a variation of this aspect, each of the plurality of height adjustment brackets includes a mounting plate and a vertical plate, the mounting plate being configured to be attached to the support surface, the vertical plate including the plurality of horizontal slots.

[0009] In another embodiment, the present disclosure provides a robotic machine tool management system, which includes: a robot having at least one gripper for grasping a workpiece; a controller configured to execute job manager software to control the movement of the robot; and a configurable pallet configured to hold the workpiece in one or more grid pattern recesses; wherein the configurable pallet includes: a frame, the frame including a plurality of frame segments, the plurality of frame segments including a plurality of positioning features evenly spaced along the inner edges of the frame segments; and a plurality of divider bars, the plurality of divider bars being configured to define the one or more grid pattern recesses by being selectively positioned within the frame in the following manner, namely, by selectively positioning a first number of the plurality of divider bars between the positioning features of a first pair of opposing frame segments in the plurality of frame segments and selectively positioning a second number of the plurality of divider bars between the positioning features of a second pair of opposing frame segments in the plurality of frame segments, the second number of the plurality of divider bars overlapping the first number of the plurality of divider bars, the first pair of opposing frame segments being perpendicular to the second pair of opposing frame segments. In one aspect of this embodiment, each of the plurality of locating features comprises a notch disposed between adjacent protrusions formed along an inner edge of the frame segment. In another aspect, the configurable tray further comprises a base to which the frame is attached. In a variation of this aspect, the base comprises a pair of end panels and a plurality of inner panels, the pair of end panels and the plurality of inner panels being configured to interlock to form the base. In yet another aspect, the plurality of frame segments comprise a pair of side segments and a pair of end segments, the pair of end segments being configured to cooperate with the pair of side segments to form the frame. In yet another aspect of this embodiment, the configurable tray further comprises a pair of locking plates, each of the locking plates being attached to one of the plurality of frame segments and comprising an inner portion that overlaps an end of the second number of the plurality of divider bars to clamp the plurality of divider bars in place. In a variation of this aspect, the configurable pallet further comprises a base attached to the frame and comprising a pair of end panels and a plurality of inner panels, wherein the plurality of frame segments, the plurality of divider bars, the pair of end panels, the plurality of inner panels, and the pair of locking panels have substantially the same length and substantially the same width. In another aspect of this embodiment, the configurable pallet further comprises a plurality of height adjustment brackets and a plurality of clips, wherein each height adjustment bracket is positioned adjacent to a corner of the frame and comprises a plurality of horizontal slots, and each of the plurality of clips is configured to extend through a pair of the plurality of horizontal slots and clip onto a frame segment to support the frame at a selectable height above a support surface.In yet another aspect, the job manager software causes the controller to display one or more grid tray configuration screens to enable an operator to define the number of rows and columns corresponding to each of the one or more grid patterns. In a variation of this aspect, the one or more configuration screens further enable the operator to define a length and width for each of the one or more grid patterns. In another variation, the one or more configuration screens further enable the operator to define pockets of each of the one or more grid patterns that are inaccessible to the robot.

[0010] In yet another embodiment, the present disclosure provides a method for configuring a pallet for robotic workpiece handling, the method comprising: selectively positioning a plurality of first divider bars within a corresponding plurality of evenly spaced first locating features formed on a first pair of opposing frame segments of a frame; selectively positioning a plurality of second divider bars within a corresponding plurality of evenly spaced second locating features formed on a second pair of opposing frame segments of the frame, the second pair of opposing frame segments being perpendicular to the first pair of opposing frame segments, and the plurality of second divider bars overlapping the plurality of first divider bars; and attaching a pair of locking bars to the second pair of opposing frame segments such that the locking bars overlap the ends of the plurality of second divider bars to clamp the plurality of second divider bars in place. One aspect of this embodiment also includes: assembling a base comprising a pair of end plates and a plurality of inner plates, the pair of end plates and the plurality of inner plates being configured to interlock to form the base; and attaching the frame to the base. In a variation of this aspect, attaching the frame to the base includes positioning the frame above the base and securing the frame to a plurality of height adjustment brackets connected to the base using a plurality of clips.

[0011] While multiple embodiments are disclosed, other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description which shows and describes illustrative embodiments of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The above and other features of the present disclosure and the manner of obtaining them will become more apparent, and the present disclosure itself will be better understood, by referring to the following description of embodiments of the present disclosure in conjunction with the accompanying drawings, in which:

[0013] Figure 1 It is a three-dimensional diagram of the robotic machine tool management system;

[0014] Figure 2 It is a three-dimensional image of a conventional grid tray;

[0015] Figure 3 It is another stereogram of a regular grid tray;

[0016] Figure 4 yes Figure 3 Another perspective view of a conventional grid tray;

[0017] Figure 5 is a stereogram of a conventional vision system for robotic bin picking;

[0018] Figure 6 is a top plan view of a configurable grid tray according to one embodiment of the present disclosure;

[0019] Figure 7 is a perspective view of a configurable grid tray according to another embodiment of the present disclosure;

[0020] Figure 8 yes Figure 7 an enlarged perspective view of a portion of a configurable grid tray;

[0021] Fig. 9 yes Figure 7 An exploded perspective view of the configurable grid tray;

[0022] Fig.10 yes Figure 7 A perspective view of an inner panel of a base of a configurable grid tray;

[0023] Fig.11 and Fig.12 is a perspective view of a configurable grid tray according to another embodiment of the present disclosure;

[0024] Fig.13 is a perspective view of a configurable grid tray according to the present disclosure, the configurable grid tray being positioned in a drawer of a robotic workstation;

[0025] Fig.14 is a perspective view of a configurable grid tray according to the present disclosure, the configurable grid tray being positioned on a workbench of a robotic workstation;

[0026] Fig.15 is a perspective view of a configurable grid tray according to the present disclosure positioned on an angled support surface of a robotic workstation;

[0027] Fig.16 is a screen shot configured to allow an operator to define a configurable grid tray in accordance with the present disclosure;

[0028] Fig.17 is another screen shot configured to allow an operator to define two grid patterns on a configurable grid tray in accordance with the present disclosure;

[0029] Fig.18 is a perspective view of a configurable grid tray according to the present disclosure, the configurable grid tray being on a workbench of a robotic workstation;

[0030] Fig.19 and Fig. 20 is a perspective view of a configurable grid tray in accordance with the present disclosure, the configurable grid tray being in a drawer of a robotic workstation;

[0031] Fig.21 is a perspective view of a configurable grid tray according to the present disclosure;

[0032] Fig. 22 and Fig.23 is a screen shot configured to allow an operator to define a configurable grid tray in accordance with the present disclosure; and

[0033] Fig.24 is a perspective view of a configurable grid tray according to the present disclosure, the configurable grid tray being on a worktable of a robotic workstation and configured to provide a plurality of different grid patterned pockets for positioning a workpiece.

[0034] Although the present disclosure may have various modifications and alternative forms, specific embodiments are shown by way of example in the accompanying drawings and are described in detail below. However, the present disclosure is not limited to the specific embodiments described. On the contrary, the present disclosure is intended to cover all modifications, equivalents and alternatives falling within the scope of the appended claims. DETAILED DESCRIPTION

[0035] See now Figure 6, shows the basic design of a configurable grid tray according to the teachings of the present disclosure. The grid tray 100 generally includes a frame 112 mounted on a base 114, the frame 112 being configured to accommodate a plurality of divider strips 116. In the example shown, the frame 112 includes four side segments 118-124 arranged to form a rectangle. Each side segment 118-124 includes an outer edge 126 and an inner edge 128, the inner edge 128 having a plurality of strip locating features 130. In this example, the strip locating features 130 include a plurality of equally spaced protrusions 132 that define recesses 134 between adjacent protrusions 132. However, it should be understood that the strip locating features 130 can have a variety of configurations. For example, the notch 134 can be curved or formed as a depression, the protrusion 132 can extend upward (i.e., extend out of the page) rather than having a surface that is planar with the upper surface of the side segments 118-124, the notch 134 can be omitted and the protrusion 132 can be a pin configured to pass through a corresponding opening in the end of the divider bar 116. Alternatively, the notch 134 and the protrusion 132 can be omitted and replaced by equally spaced magnets or magnetized portions of the side segments 118-124. The present disclosure contemplates other configurations. In any such variations, the bar locating feature 130 is configured to precisely locate the divider bar 116 at any of a plurality of equally spaced locations along the length of the side segments 118-124.

[0036] The frame 112 can be formed as an integral part of the base 114. Alternatively, the frame 112 can be attached to the base 114 using fasteners, welding, adhesives, clamps, or any other type of attachment mechanism. The base 114 can be a rectangular solid piece of material, the dimensions of which correspond to the outer edges 126 of the side segments 118-124 of the frame 112. Alternatively, the base 114 can have an opening formed through the base or formed using interlocking segments as described below. In some embodiments, for example, when the frame 112 is attached to another support surface (such as a workbench), the base 114 can be completely omitted.

[0037] The divider bars 116 are described as elongated strips of material having straight parallel side edges 136, a straight upper surface 138, a straight lower surface (not shown) parallel to the upper surface 138, and a pair of ends 140. In one embodiment, the height of the side edges 136 is less than the width of the upper surface 138 and the lower surface. In the depicted embodiment, each divider bar 116 is identical to the other divider bars. As will be apparent from the foregoing, the ends 140 of the divider bars 116 are configured to cooperate with or otherwise be precisely positioned by the bar positioning features 130 of the side segments 118-124 of the frame 112. In the example shown, the divider bars 116 are first positioned horizontally on the frame 112, and then additional divider bars 116 are positioned vertically on the frame 112 so that they overlap the horizontally positioned divider bars 116. In this manner, the divider bars 116 can be positioned to form one or more regular grid patterns, such as the grid pattern 142 and the grid pattern 144 in the example shown. Of course, the divider bars 116 can be positioned to form a single grid pattern across all or a portion of the base 114 within the frame 112. In an alternative embodiment, the divider bars 116 can be replaced with narrow rods that are placed on top of racks that are common in rack-and-pinion sets or even timing belts, which provide regular indentations to position the rods.

[0038] By positioning the divider bars 116 in the manner described above, a plurality of pockets 146 may be formed in a regular grid pattern that facilitates efficient operation and programming of the robot 12. For example, the grid pattern 142 includes nine equally spaced rectangular pockets 146A in a 3×3 grid. The grid pattern 144 also includes nine equally spaced rectangular pockets 146B in a 3×3 grid, although the pockets 146B are smaller than the pockets 146A and are formed to position smaller workpieces.

[0039] Regardless of the size of the pockets or workpieces, in this example, each workpiece 148 can be accurately and easily positioned on the grid tray 100 by registering the workpieces in the corners of the pockets 146. For example, in the grid pattern 142, three workpieces 148 are shown registered against the upper left corner of the pockets 146A so that the workpieces 148 are aligned and equidistantly spaced from each other, as provided by the conventional non-configurable grid tray described above.

[0040] Now refer to Figures 7 to 9, another embodiment of a grid tray is shown. Similar to the grid tray 100, the grid tray 200 generally includes a frame 212, a base 214, and a plurality of divider bars 216. The divider bars 216 are the same as the divider bars 116 described above with reference to the grid tray 100. However, in the grid tray 200, the frame 212 and the base 214 are formed using multiple parts, as further described below. In addition, the grid tray 200 also includes a pair of locking plates 250, which will be further described below.

[0041] The frame 212 includes two side segments 218, 220 and two end segments 222, 224. Each side segment 218, 220 includes an outer edge 226 and an inner edge 228 having a plurality of strip locating features 230 that are the same as or similar to the strip locating features 130 described above with reference to the grid tray 100. Each side segment 218, 220 also includes a notch 252 formed along the inner edge 228 near each end of the segment. Each end segment 222, 224 includes an outer edge 254 and an inner edge 256 having a plurality of strip locating features 230 as described above with reference to the grid tray 100. Each end segment 222, 224 also includes a tab 258 extending from each end of the segment that is sized to mate with the notch 252 of the side segments 218, 220, as described above with reference to the grid tray 100. Figure 8 20. In this manner, the side segments 218, 220 and the end segments 222, 224 can be assembled together to form the frame 212. It should be understood that the end segments 222, 224 can include the notches 252 and the side segments 218, 220 can include the tabs 258, or any other mating structures can be used to align and connect the side segments 218, 220 and the end segments 222, 224. Each of the side segments 218, 220 and the end segments 222, 224 includes a plurality of holes 260 that are configured to receive fasteners (not shown) to secure the grid tray 200 to a support surface.

[0042] As in Fig. 9, the base 214 includes a pair of end plates 262, 264 and a plurality of inner plates 266. The end plates 262, 264 are identical and only one is described herein. The end plate 264 includes a body 268 having an inner edge 270, an outer edge 272, a first end edge 274, and a second end edge 276. A tab 278 is formed along the inner edge 270 adjacent to the first end edge 274. A notch 280 is formed along the inner edge 270 adjacent to the second end edge 276. An outer hole 282 is formed through the end plate 264 adjacent to the first end edge 274 and is configured to receive a fastener (not shown) to connect the side segment 220 to the end plate 264. Similarly, an outer hole 284 is formed through the end plate 264 adjacent to the second end edge 276 and is configured to receive a fastener (not shown) to connect the side segment 218 to the end plate 264. A plurality of holes 286 are formed through the end plate 264 along the outer edge 272 and are configured to receive fasteners to connect the end section 222 to the end plate 264. A plurality of holes 288 are formed through the end plate 264 between the inner edge 270 and the outer edge 272 and are configured to receive fasteners to connect the locking plate 250 to the end plate 264. Finally, a plurality of holes 289 are formed through the end plate 264 adjacent to the edge 270 and are configured to receive fasteners to connect the end plate 264 to the robotic workstation 336. Fig. 9 As best shown in the figures, the tongue 278 of the end panel 264 is sized and positioned to be received by a mating recess formed along the edge of the inner panel 266, and the recess 280 of the end panel 264 is sized and positioned to accommodate a mating tongue formed along the edge of the inner panel 266, as further described below.

[0043] Reference now Fig.10, each inner panel 266 includes a first side edge 290, an opposite second side edge 292, a first end edge 294, a second end edge 296, a body portion 298, a first end portion 300, and a second end portion 302. The first end portion 300 terminates at the first end edge 294 and includes an opening 304 that is configured to receive a fastener (not shown) to secure the inner panel 266 to one of the side segments 218, 220. The second end portion 302 similarly terminates at the second end edge 296 and includes an opening 306 that is configured to receive a fastener (not shown) to secure the inner panel 266 to the other of the side segments 218, 220. Between the body portion 298 and the first end portion 300, the first side edge 290 forms a tab 308, and between the body portion 298 and the second end portion 302, the first side edge 290 defines a notch 310. Similarly, between the body portion 298 and the first end portion 300, the second side edge 292 defines a notch 312, and between the body portion 298 and the second end portion 302, the second side edge 292 defines a tab 314. This configuration of the inner panels 266 allows for interlocking of the inner panels 266 to form the base 214 between the end panels 262, 264. As will be apparent from the foregoing, any suitable interlocking structure may be used to connect the inner panels 266 to one another or at least position the inner panels 266 relative to one another.

[0044] Refer to Figures 7 to 9 , a locking plate 250 is provided to secure the divider bars 216 in their desired positions. The locking plate 250 is formed as a generally flat elongated strip having a plurality of through holes formed therethrough. After the frame 212 and the base 214 are assembled and connected together, the divider bars 216 are placed into the strip positioning features 230 in the manner described above to form one or more grid patterns for placing the workpieces 148. Finally, fasteners (not shown) are passed through the openings 316 to attach the locking plates 250 to the end plates 222, 224 of the base 214. The inner portion 318 of each locking plate 250 overlaps the ends of the plurality of upper divider bars 216 and clamps the plurality of upper divider bars 216 (and the plurality of lower divider bars 216 below the plurality of upper divider bars 216) in place. Thus, the grid tray 200 can be moved and / or reoriented without concern that the divider bars 216 may become dislocated.

[0045] One advantage of the multi-piece design of the grid pallet 200 is the substantial uniformity of the sizes of the separate components. Each of the side segments 218, 220 and end segments 222, 224 of the frame 214, each of the end panels 262, 264 and the plurality of inner panels 266 of the base 214, the divider bar 216 and the locking plate 250 are elongated, substantially flat components having substantially the same length. In this way, all of the components can be efficiently packaged together in a relatively small, dense container to minimize shipping costs.

[0046] Fig.11 and Fig.12 Yet another embodiment of a grid tray 200 is shown. In this embodiment, the grid tray 200 also includes a plurality of height adjustment brackets 320 (only one is shown) mounted to the base 214 adjacent each corner of the frame 212. In the example shown, each height adjustment bracket 320 includes a mounting plate 322 configured to be attached to the base 214 and a vertical plate 324 extending perpendicularly from the mounting plate 322. The vertical plate 324 includes a plurality of horizontal slots 326 sized and spaced such that a clip 328 may be placed through any two adjacent slots 326 to clip onto and support the frame 212 at a selected height. By including such a height adjustment mechanism, the grid tray 200 can be used to support taller workpieces 148 and provide better stability than a lower profile grid tray. Additionally, as shown in FIG. Fig.12 As shown, the grid tray 200 with the height adjustment bracket 320 can be used to support the cylindrical workpiece 148 placed sideways. By using the height adjustment bracket 320 to raise the frame 212 and the separator bar 216 to the appropriate height above the base 214, the grid tray 200 can be arranged so that a portion of the cylindrical workpiece 148 extends under the separator bar 216 to accurately position the workpiece 148, while the main portion of the workpiece 148 extends above the separator bar 216 to be grasped by the robot 12.

[0047] The embodiments of the grid trays 100 , 200 disclosed herein may be used in a variety of applications, such as in drawer systems and workbench systems, or in any other workpiece providing surface. Fig.13 The grid tray 200 is shown disposed in a drawer 330 of a robotic workstation 332. As shown, the workpiece 148 is registered against the inner right corner of the recess 146 formed by the divider bar 216. Fig.14 The grid tray 200 is shown disposed on top of the work table 334 of the robotic workstation 336. Fig.15 In another application shown, the grid tray 200 is disposed on an inclined support surface 338 of a robotic workstation 340 such that gravity ensures that the workpiece 148 remains secured in a desired position within the pocket 146 .

[0048] In certain embodiments, the robot 12 is controlled by a job manager software control system (hereinafter referred to as "job manager software") executed by a controller, which may be a CNC machine 24 ( Figure 1 ) controller 25, a separate computing device or a controller of the teaching pendant 14. Hereinafter, the job manager software is described as being executed by the controller 25. It should be understood that the term "controller" 25 used in this article includes hardware and software and / or firmware, the firmware including processing instructions executed on one or more programmable processors, application specific integrated circuits, field programmable gate arrays, digital signal processors, hard-wired logic or a combination thereof, which can be referred to as a "controller". Therefore, according to the embodiment, the various controllers can be implemented in any appropriate manner and will be retained according to the embodiments disclosed herein. The non-transitory machine-readable memory 27 is accessed by the controller 25 and includes instructions for execution by the controller 25. The memory can also be considered to be contained in any tangible form of a computer-readable carrier, such as a solid-state memory, which contains a suitable collection of computer instructions and data structures that will cause the controller 25 to perform the techniques described herein. The non-transitory computer-readable medium or memory may include a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (e.g., EPROM, EEPROM or flash memory) or any other tangible medium capable of storing information.

[0049] The operator can use the gripper fingers 26 of the robot 12 to measure and store the calibration of the grid tray 200 configuration, for example, by measuring three corner points of the grid tray 200 and adjusting the measurement points based on the width and length of the fingers 26 used as a calibration device as described below. The joint encoder positions are used to calculate the three corner points relative to the robot base coordinate system, thereby calculating the robot arm end position.

[0050] Fig.16 An interactive screen shot 342 generated by the job manager software is depicted to allow the grid tray 200 to be configured in a drawer system. It should be understood that the screen shot 342 and other screen shots described herein can be used with a drawer system, a workbench system, or any other system for providing workpieces 148. As shown, the operator can set the number of drawers by clicking on icon 344 and filling in field 346. The operator can use icons 348, 350 to navigate from one drawer configuration to another. By clicking on icon 352 and filling in fields 354 and 356, the operator can enter the number of rows and columns that the grid tray 200 has been configured to include. An illustration 358 of the physical grid tray 200 configuration is provided.

[0051] The operator may also update or define the actual length and width of the wells 146 of the grid tray 200 by filling in fields 362 and 364 and clicking on icon 360. Boxes 366 and 368 allow the operator to enter the grid size in millimeters or inches, respectively. Finally, the operator may save the drawer configuration by clicking on icon 370 and proceed to define the next drawer. Icon 372 allows the operator to load a previously defined drawer configuration stored on a memory accessible by the controller 25.

[0052] Fig.17 Another screen shot 400 generated by the job manager software is shown, which facilitates configuring two grid patterns on the same grid tray 200 in the same drawer. As shown, the first grid pattern portion 402 of the screen shot 400 has been completed to define a three-row, four-column grid pattern 358A having recesses 146 that are 80 mm long and 80 mm wide. The second grid pattern portion 404 of the screen shot 400 has been completed to define a one-row, four-column grid pattern 358B having recesses 146 that are 240 mm long and 80 mm wide.

[0053] Reference now Fig.18 , in such Fig.14 The grid tray 200 is depicted in the workbench system shown. Fig.18 , the grid tray 200 is disposed on top of the work table 334 of the robotic workstation 336 and is shown holding the workpiece 148 and the completed part 374 in the pocket 146 . Fig.18 Also shown is an exemplary robot 376 having six joints (J1-J6) that move the robot 376 relative to a robot base coordinate system 378 under the control of the controller 25 and move a pair of grippers 16, each gripper 16 having a pair of fingers 26 movable relative to a gripper coordinate system 380. The robot workstation 336 is located adjacent to a CNC machine 24 having a fixture 22 configured to hold a workpiece 148.

[0054] refer to Figures 19 to 21 The three-corner point calibration discussed above is further described. Fig.19 and Fig. 20 The grid tray 200 is shown in the drawer 330. Fig. 20 , the three corners of the grid pattern 382 configured in the grid tray 200 are labeled 1, 2 and 3. Fig.21 The gripper finger 26 is shown in contact with a corner 3 of the grid pattern 382. Calibration is performed by guiding the gripper 16 to Fig. 20For each corner, the finger 26 is aligned with the bottom of the recess 146 so that the gripper 16 is perpendicular to the plane of the grid tray 200, and is pressed to align with the edge of the recess so that the gripper 16 is aligned with the bottom of the recess 146. Fig. 20 B is aligned with the XY coordinate system, which is consistent with the grid tray 200. Fig.18 Each position is stored and calculated in the robot coordinate system 378 in . However, the stored position is the center of the gripper position, not the actual corner of the grid tray 200. To calculate the actual corner position, the width and length of the gripper finger 26 are measured and divided by 2 to give the finger calibration offsets X and Y. The directions of the X and Y vectors are then calculated from the three points using the following equations:

[0055]

[0056]

[0057] Knowing the X and Y directions, the actual corners of the grid tray 200 can be calculated by adding and subtracting the width and length of the finger 26 for each of the three points in the corresponding X and Y directions. This gives the three corner points of the grid tray 200 relative to the robot base coordinate system. Given Fig.16 Given the width and length of the recesses in the grid tray 200 shown in , as well as the number of recesses, the controller 25 can calculate the corner location of each recess. Knowing the dimensions of the workpieces 148 placed in the recesses 146 so that they are pushed into the bottom corner of each recess, the controller 25 can calculate where to position the gripper 16 to pick up any part in the grid tray 200. It should be understood that any calibration tool with fixed dimensions (which will fit within the recess 146) may be used as long as it is rigidly held or rigidly secured to the gripper 16 or robot end arm in place of the gripper finger 26 (if desired). One example is a cylindrical calibration tool. Another example is gripping the actual workpiece material with the gripper finger 26. The calibration described herein is performed for each grid pattern configured in the grid tray 200 (see Fig.24 , which depicts a plurality of grid patterns including grid pattern 384, grid pattern 386, grid pattern 388, and grid pattern 390). By calibrating each grid pattern, the controller 25 can calculate the pick and place position of the robot 12 for each pocket based on the pocket size and position as described above and the size of the workpiece 148.

[0058] Given the X and Y positions of each grid pattern of the grid tray 200 and the number of wells 146 in the rows and columns of each grid pattern, the controller 25 can display the available wells 146 and the operator can select to place the workpiece 148 in the available wells 146. This ability to size the wells to different sizes throughout the grid tray 200 allows the operator to optimize the available surface area for workpieces 148 of different sizes for unmanned robotic operation of different batches of workpieces 148.

[0059] According to one feature of the present disclosure, the controller 25 allows an operator to define segments or pockets 146 that should not be approached, to avoid interference between the robot 12 and the workpiece 148, or to avoid commanding the robot 12 to approach locations that cannot be reached by the gripper 16 due to reachable distance limits or other limitations in the robot's kinematics and gripper configuration. Fig.19 An exemplary situation is depicted in which a row 391 of wells 146 cannot be reached by the gripper 16 due to the possibility of collision with the drawers 330A, 330B.

[0060] In such Fig.19 In the case shown, the operator can access the Fig. 22 Screen 400 is shown generated by the job manager software to define pockets 146 that are empty or should not be accessed. Fig. 22 Screen 400 is shown in which drawer 330 has been configured to include two different sized workpieces 148 for different jobs (i.e., job 1 and job 2). As shown, job 1 includes ten workpieces in a grid pattern 402, in which two recesses 146A, 146B are defined as empty or inaccessible. Job 2 includes three larger workpieces in a grid pattern 404, in which one recess 146C is defined as empty or inaccessible. Similar to Fig.16 342 of screen 400, screen 400 allows the operator to move from one drawer definition to another (icon 406, icon 408), load a pre-existing job file by clicking on icon 410, save the current job file by clicking on icon 412, select all recesses 146 that receive workpieces 148 by clicking on icon 414 instead of selecting each recess individually, and clear or deselect all recesses 146 (i.e., set them to empty) by clicking on icon 416.

[0061] In an alternative embodiment, the operator may Fig.19 and Fig. 20 Measure the three corners of the grid tray 200 as described and enter the position 422 of the divider bar 216 into the job manager software, as shown in FIG. Fig.23The Job Manager software then displays the resulting grid tray 418. The operator can click Fig. 22 icon 409 to select any pockets 146 that must be blocked to complete the setup. The operator then selects which job is in each pocket 146 of the fully defined grid pallet. The operator can select a job program (CNC program for cutting the part) using browse icon 411 and a robot program using browse icon 413. If there are multiple jobs programmed for the grid pallet 200, screen 400 shows which jobs are in which pockets as the jobs are programmed. Each job is labeled sequentially, in this case Job 1 and Job 2. Loading and saving a job will simply load the data of a previously saved job and fill in the pockets that were saved if pockets are available.

[0062] Since the bar locating features 230 are evenly spaced on the grid tray 200, the job manager software can calculate the location of any workpiece 148 based on the size of the workpiece 148 and the location in the grid tray so that the robot 12 can pick and place it accordingly. In a variation of this embodiment, each bar locating feature 230 can be numbered on the grid tray by laser etching or otherwise to allow for easier identification for input into the job manager software. In addition, the overall size of the bar locating features 230 and the grid tray are user-defined parameters in the job manager software. Fig.24 An exemplary grid pallet 200 is shown configured for several different jobs using workpieces 148 of different sizes.

[0063] As used herein, the modifier "about" used in conjunction with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes at least the degree of error associated with the measurement of the particular quantity). When used in the context of a range, the modifier "about" should also be considered to disclose the range defined by the absolute values ​​of the two endpoints. For example, a range of "about 2 to about 4" also discloses a range of "2 to 4".

[0064] It should be understood that the connecting lines shown in the various figures included herein are intended to represent exemplary functional relationships and / or physical connections between the various elements. It should be noted that there may be many alternative or additional functional relationships or physical connections in an actual system. However, benefits, advantages, solutions to problems, and any elements that may cause any benefits, advantages, or solutions to occur or become more significant should not be interpreted as key, necessary, or essential features or elements. Therefore, the scope is limited only by the appended claims, wherein, unless explicitly stated, reference to an element in the singular does not mean "one and only one", but means "one or more". In addition, in the case of a phrase similar to "at least one of A, B, or C" used in the claims, it is intended that the phrase should be interpreted as meaning: A alone may be present in an embodiment; B alone may be present in an embodiment; C alone may be present in an embodiment; or any combination of elements A, B, or C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.

[0065] In the detailed description section of this document, references to "one embodiment," "an embodiment," "an exemplary embodiment," etc. indicate that the described embodiment may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. In addition, these phrases do not necessarily refer to the same embodiment. In addition, when a particular feature, structure, or characteristic is described in conjunction with an embodiment, it should be considered that it is within the knowledge of a person skilled in the art to benefit from the content of this disclosure to affect such feature, structure, or characteristic in conjunction with other embodiments (whether or not explicitly described). After reading this specification, a person skilled in the relevant art will understand how to implement the present disclosure in alternative embodiments.

[0066] In addition, no element, component, or method step in the present disclosure is intended to be dedicated to the public, regardless of whether the element, component, or method step is explicitly stated in the claims. Unless a claim element herein is explicitly stated using the phrase "means by...", the element should not be interpreted under the provisions of 35 U.S.C. §112(f). As used herein, the terms "comprises," "includes," or any other variation thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements, but may also include other elements that are not explicitly listed or inherent to those processes, methods, articles, or apparatuses.

[0067] Various modifications and additions may be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the above-described embodiments relate to specific features, the scope of the present disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Therefore, the scope of the present disclosure is intended to include all such substitutions, modifications, and variations that fall within the scope of the claims and all equivalents thereof.

Claims

1. A configurable pallet for robot workpiece handling, the configurable pallet comprising: a frame comprising a plurality of frame segments arranged in a rectangular shape, each frame segment of the plurality of frame segments comprising a plurality of locating features evenly spaced along an inner edge of the frame segment; as well as a plurality of divider bars, each divider bar including a first end and a second end and configured to be selectively positioned within the frame such that the first end is positioned at a locating feature of one of the frame segments and the second end is positioned at a locating feature of another of the frame segments that is opposite the one of the frame segments; Wherein, the plurality of separator bars are configured to be positioned to define one or more configurable grid pattern recesses for receiving workpieces by selectively positioning a first number of the plurality of separator bars between positioning features of a first pair of opposing frame segments in the plurality of frame segments and selectively positioning a second number of the plurality of separator bars between positioning features of a second pair of opposing frame segments in the plurality of frame segments, the second number of the plurality of separator bars overlapping the first number of the plurality of separator bars, the first pair of opposing frame segments being perpendicular to the second pair of opposing frame segments.

2. The configurable pallet according to claim 1, wherein: Each of the plurality of locating features includes a notch disposed between adjacent projections formed along an inner edge of a frame segment of the frame.

3. The configurable pallet of claim 1 further comprising a base, the frame being attached to the base.

4. The configurable pallet according to claim 3, wherein: The base includes a pair of end plates and a plurality of inner plates.

5. The configurable pallet according to claim 4, wherein: The pair of end plates and the plurality of inner plates are configured to interlock to form the base.

6. The configurable pallet of claim 1, wherein: The plurality of frame segments include a pair of side segments and a pair of end segments.

7. The configurable pallet according to claim 6, wherein: Each of the pair of side segments includes a first end forming a first recess and a second end forming a second recess, and each of the pair of end segments includes a first end forming a first tongue and a second end forming a second tongue, the first recess being configured to cooperate with the first tongue and the second recess being configured to cooperate with the second tongue, thereby connecting the pair of side segments to the pair of end segments to form the frame.

8. The configurable pallet of claim 1 , further comprising a pair of locking plates, each locking plate being attached to one of the plurality of frame segments and comprising an inner portion overlapping ends of the second number of the plurality of divider bars to clamp the plurality of divider bars in place.

9. The configurable pallet of claim 8, further comprising a base attached to the frame and comprising a pair of end panels and a plurality of inner panels, wherein: The plurality of frame segments, the plurality of divider bars, the pair of end panels, the plurality of inner panels, and the pair of locking panels have substantially the same length and substantially the same width.

10. The configurable tray of claim 1, further comprising a plurality of height adjustment brackets and a plurality of clips, wherein: Each height adjustment bracket is positioned adjacent a corner of the frame and includes a plurality of horizontal slots, and each of the plurality of clips is configured to extend through a pair of the plurality of horizontal slots and clip onto a frame segment to support the frame at a selectable height above a support surface.

11. The configurable pallet of claim 10, wherein: Each of the plurality of height adjustment brackets includes a mounting plate configured to be attached to the support surface and a vertical plate including the plurality of horizontal slots.

12. A robot machine tool management system, the robot machine tool management system comprising: a robot having at least one gripper for gripping a workpiece; a controller configured to execute job manager software to control movement of the robot; as well as a configurable tray configured to hold a workpiece in one or more grid-patterned pockets; Wherein, the configurable tray includes: a frame comprising a plurality of frame segments including a plurality of locating features evenly spaced along inner edges of the frame segments; and A plurality of divider bars configured to be selectively positioned within the frame to define the one or more grid pattern pockets by selectively positioning a first number of the plurality of divider bars between locating features of a first pair of opposing frame segments in the plurality of frame segments and selectively positioning a second number of the plurality of divider bars between locating features of a second pair of opposing frame segments in the plurality of frame segments, the second number of the plurality of divider bars overlapping the first number of the plurality of divider bars, the first pair of opposing frame segments being perpendicular to the second pair of opposing frame segments.

13. The robot machine tool management system according to claim 12, wherein: Each of the plurality of locating features includes a notch disposed between adjacent projections formed along an inner edge of the frame segment.

14. The robot machine tool management system according to claim 12, wherein: The configurable tray also includes a base to which the frame is attached.

15. The robot machine tool management system according to claim 14, wherein: The base includes a pair of end plates and a plurality of inner plates configured to interlock to form the base.

16. The robot machine tool management system according to claim 12, wherein: The plurality of frame segments include a pair of side segments and a pair of end segments, the pair of end segments being configured to cooperate with the pair of side segments to form the frame.

17. The robot machine tool management system according to claim 12, wherein: The configurable pallet also includes a pair of locking plates, each locking plate attached to one of the plurality of frame segments and including an inner portion overlapping ends of the second number of the plurality of divider bars to clamp the plurality of divider bars in place.

18. The robot machine tool management system according to claim 17, wherein: The configurable pallet also includes a base attached to the frame and including a pair of end panels and a plurality of inner panels, wherein the plurality of frame segments, the plurality of divider bars, the pair of end panels, the plurality of inner panels, and the pair of locking panels have substantially the same length and substantially the same width.

19. The robot machine tool management system according to claim 12, wherein: The configurable tray also includes a plurality of height adjustment brackets and a plurality of clips, wherein each height adjustment bracket is positioned adjacent a corner of the frame and includes a plurality of horizontal slots, and each of the plurality of clips is configured to extend through a pair of the plurality of horizontal slots and clip onto the frame segment to support the frame at a selectable height above a support surface.

20. The robot machine tool management system according to claim 12, wherein: The job manager software causes the controller to display one or more grid tray configuration screens to enable an operator to define the number of rows and columns corresponding to each of the one or more grid patterns.

21. The robot machine tool management system according to claim 20, wherein: The one or more configuration screens also enable the operator to define a length and a width of each of the one or more grid patterns.

22. The robot machine tool management system according to claim 20, wherein: The one or more configuration screens also enable the operator to define pockets of each of the one or more grid patterns that are inaccessible to the robot.

23. A method of configuring a pallet for robotic workpiece handling, the method comprising: selectively positioning a plurality of first divider bars within a corresponding plurality of evenly spaced first positioning features formed on a first pair of opposing frame segments of the frame; selectively positioning a plurality of second divider bars within a corresponding plurality of evenly spaced second positioning features formed on a second pair of opposing frame segments of the frame, the second pair of opposing frame segments being perpendicular to the first pair of opposing frame segments, and the plurality of second divider bars overlapping the plurality of first divider bars; and A pair of locking bars are attached to the second pair of opposing frame segments such that the locking bars overlap ends of the second plurality of divider bars to clamp the second plurality of divider bars in place.

24. The method according to claim 23, further comprising: assembling a base, the base comprising a pair of end panels and a plurality of inner panels, the pair of end panels and the plurality of inner panels being configured to interlock to form the base; and The frame is attached to the base.

25. The method according to claim 24, wherein: Attaching the frame to the base includes positioning the frame above the base and securing the frame to a plurality of height adjustment brackets connected to the base using a plurality of clips.

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