Robot system with reconfigurable organ arrangement

Abstract

Robot system (10) comprising: a multi-axis robot (12) with an arm and a wrist (16); a gripper assembly (30) having a main boom (18), a tool changing assembly (21) arranged at a distal end of the main boom (18), parallel frame rails (23, 23A, 23B) arranged orthogonally with respect to the main boom (18) and rotatable with respect to an axis of the main boom (18), a plurality of tool support branches (25) arranged orthogonally with respect to the parallel frame rails (23, 23A, 23B), and a plurality of tool modules (35) each connected to one of the tool support branches (25), the tool modules (35) being rotatable and displaceable with respect to an axis of a respective one of the branches (25); a configuration tool (20) comprising a control block (26) disposed at a distal end of the configuration tool (20) and selectively engageable via the tool change assembly (21), and a working tool disposed at another distal end of the configuration tool (20); a controller (50) programmed to command the robot (12) to automatically configure the end-end assembly (30) by adjusting the tool modules (35) and / or the parallel rails (23, 23A, 23B) and / or the tool support branches (25) using the configuration tool (20) in response to a recognized work task, and to thereafter command engagement of the wrist (16) with the tool changing device (21, 21B, 21A, 22I) and execution of the recognized work task using the configured end-end assembly (30); and a configuration frame (75, 175), wherein the tool changing assembly (21) comprises a first tool changing device (21B) configured to engage the robot (12) and a second tool changing device (21A) configured to simultaneously engage the configuration frame (75, 175); and wherein the configuration frame (75, 175) includes a motor (66) having a rotor axis, and wherein the controller (50) is programmed to command the robot (12) to automatically engage the tool changing assembly (21) of the end effector assembly (30) with the second tool changing device (21A) of the configuration frame (75, 175) to thereby achieve a load position (I) of the configuration frame (75, 175), to automatically rotate the end effector assembly (30) 180 degrees with respect to the rotor axis into a configuration position of the configuration frame (75, 175), to command engagement of the wrist (16) with the configuration tool (20), and to configure the end effector assembly (30) using the configuration tool (20) to perform the recognized work task.

Description

[0001] This application claims priority to U.S. Provisional Application No. 62 / 142,748 and U.S. Provisional Application No. 62 / 142,751, both filed April 3, 2015, both of which are incorporated herein by reference in their entirety.

[0002] The present disclosure relates to a robot system with a reconfigurable end-effect device assembly.

[0003] Multi-axis industrial robots contain articulated arms connected by a shoulder joint. Each segment is driven by one or more articulated motors. Typical industrial robots are controlled with respect to six different control axes. Together, these control axes enable rotation of the robot relative to a fixed or mobile base, extension / retraction of a first arm, and raising / lowering of a second arm, as well as rotation of the shoulder joint and rotation / translation of a wrist located at a distal end of the second arm. Depending on the design, additional arms can be used in a serial arrangement, and an end effector connected to the wrist can be manipulated to perform a desired work task.

[0004] The term "end-end machine" refers to the specialized end links or segments that, depending on the robot's design, can safely grasp, transport, align, and release a workpiece or tool. Certain end-machine assemblies are constructed using a grid-like array of elongated beams and rails to which a set of tool modules is attached, such as suction cups or grippers of the type used to move metal plates or glass panes in a manufacturing facility. The individual tool modules can be manually adjusted by an operator into a predetermined configuration before performing a specified work task. While matrix-like end-machine assemblies of this type are useful in production / material handling environments, current designs may be suboptimal in terms of adjustability and overall space utilization.

[0005] The document US 2003 / 0 177 656 A1 discloses a gripper assembly that can be removed from a robot arm for configuration purposes, attached to a holder and reconfigured by the robot arm using a configuration tool.

[0006] The document US 2012 / 0 280 527 A1 discloses a reconfigurable end-gripper for attachment to a robot arm, which end-gripper is attached to a device frame by means of compressed air-operated clamps for reconfiguration and can then be reconfigured using a robot arm.

[0007] The document US 2015 / 0 020 365 A1 discloses a gripping device with automatically actuated locking mechanisms, which is clamped to a holding frame for reconfiguration, wherein the locking mechanisms are released before reconfiguration and locked again afterwards.

[0008] Document DE 10 2014 107 533 A1 discloses a reconfigurable robot end-gripper assembly comprising tandem branch connection assemblies, each with two branch connections, each having a releasable retaining cam. Only when the retaining cam is released can each of the tandem branch connection assemblies rotate and translate relative to a longitudinal axis of a link.

[0009] Document DE 10 2012 207 193 A1 discloses a line system for conducting activation power to a tool module of a reconfigurable end-gripper used with a robot arm. The line system comprises a rigid line section adapted to a first section of the reconfigurable end-gripper, a displaceable line section displaceably connected to a second section of the end-gripper, and a rotatable section.

[0010] Document DE 10 2009 057 013 A1 discloses an end-gripper that can be attached to a robot arm, comprising an articulated frame comprising a fixed disc coupled to a rotatable disc via a hinge and adjustable and locked at an angular position relative to the fixed disc. A tool module is mounted on the articulated frame, and a flexible conductor is coupled to the tool module. A flexible cladding unit comprises a flexible cable carrier that guides the flexible conductor to the tool module.

[0011] The object of the invention is to facilitate and automate the reconfiguration of gripping elements by a robot. This object is achieved by the robot systems according to claims 1 and 8. Advantageous further developments of the invention are described in the subclaims.

[0012] Disclosed herein is a robotic system including a multi-axis robot, an end-effector assembly, a configuration tool, and a controller. The robot, end-effector assembly, and configuration tool collectively address some of the aforementioned problems associated with existing end-effector designs. The end-effector assembly disclosed herein can be quickly reconfigured by the robot in response to control signals issued by the controller and subsequently used for material handling or other purposes when processing different components, such as contoured body panels or flat glass panes.Instead of conventional self-locking couplings or grippers, each tool module is automatically unclamped, moved, and re-clamped using screw clamp mechanisms configured as a set of linear and / or linear / rotary joint locks, which are selectively adjustable using the configuration tool. The robot system also includes a configuration frame with a motor having a rotor axis to automatically rotate the end effector assembly 180 degrees relative to the rotor axis into a configuration position of the configuration frame. The present design can provide certain cost and weight advantages relative to existing systems.

[0013] In one possible embodiment, the end-end assembly includes two parallel frame rails with a plurality of orthogonally arranged tool support branches, all of which can be automatically repositioned by the robot and are arranged on an elongated main boom. A bidirectional coupling assembly includes lever arms configured to pivot the frame rails relative to an axis of the main boom. The bidirectional coupling assembly can be pneumatically locked or unlocked in some embodiments, and tubing can be routed around the bidirectional rotary coupling assembly to the individual tool modules to provide the required pneumatic force or vacuum, depending on the application.

[0014] The configuration tool disclosed herein may include a working tool such as a torque wrench or nutrunner, as well as a tool bit and a plurality of locating pins adapted for engagement with a mating feature of a joint locking mechanism during a configuration phase of control. During such a control phase, the end effector assembly may be deposited by the robot onto a configuration rack, whether suspended from above or mounted on a floor or machine column, to provide a known reference frame for configuration. The main boom includes a double-ended tool changer that allows simultaneous engagement of the main boom with the robot and the configuration rack.

[0015] Disclosed herein is a robot system comprising a multi-axis robot with an arm and a wrist. The system includes an end effector assembly having a main boom, a tool change assembly disposed at a distal end of the main boom, parallel frame rails disposed orthogonally with respect to the main boom and rotatable with respect to an axis of the main boom, a plurality of tool support branches disposed orthogonally with respect to the parallel frame rails, and a plurality of tool modules. The tool modules are each connected to one of the tool support branches and are rotatable and translatable with respect to an axis of a respective one of the branches.The system also includes a configuration tool having a control block disposed at a distal end of the configuration tool and selectively engageable via the wrist, and a working tool disposed at another distal end of the configuration tool.

[0016] As part of the system, a controller is programmed to command the robot to automatically configure the end effector assembly by adjusting the tool modules and / or the parallel rails and / or the tool support branches using the configuration tool in response to a detected work task and to subsequently command wrist engagement with the tool changing device and to execute the detected work task using the configured end effector assembly.

[0017] A configuration rack is included as part of the system. Such a configuration rack provides a known reference frame or calibrated coordinates for configuring the end-effector assembly. The tool change assembly includes a first tool change device configured to engage the robot and a second tool change device configured to simultaneously engage the configuration rack. The configuration rack includes a motor with a rotor axis for automatically rotating the end-effector assembly 180 degrees with respect to the rotor axis into a configuration position of the configuration rack.

[0018] The foregoing and other features and advantages of the present disclosure will be apparent from the following detailed description of some of the best modes, if known, and other embodiments for carrying out the disclosure as defined in the appended claims when read in conjunction with the accompanying drawings. Fig. 1 is a schematic diagram in perspective view of an exemplary robot system as described herein. Fig. 2A and Fig. 2B are schematic representations in perspective view of two possible exemplary configurations of a matrix-shaped gripping organ arrangement which can be used with the Fig. 1 shown robot system can be used. Fig. 3 is a schematic representation in perspective view of the gripping device arrangement shown in Fig. 1 - 2B. Fig. 4 is a schematic representation in perspective view with partial omissions of the gripping organ arrangement shown in Fig. 1 - 3 is shown. Fig. 5 is a schematic diagram in perspective view of an exemplary configuration tool used as part of the Fig. 1 shown robot system can be used. Fig. Figure 6 is a schematic diagram in perspective view of a portion of the configuration tool of Fig. 5 during an intervention in a configuration phase of the control system. Fig. Figure 7 is a schematic illustration in perspective view with partial omissions of an adjustable linear / rotary locking mechanism for the exemplary tool module shown in Fig. 6 is shown. Fig. 8 is a flowchart showing an exemplary method for controlling the robot system shown in Fig. 1 is shown. Fig. Figure 9 is a schematic plan view of the end effector assembly and a single-axis configuration frame in both a configuration position and a load position. Fig. 10A - C are perspective views of the gripper assembly of Fig. 8 when rotated or flipped between a load position and a configuration position. Fig. 11A - E are side view schematics of an alternative configuration rack with a two-axis sequence. Fig. 12 is a flowchart describing an exemplary method for using the configuration rack shown in Fig. 9 - 10C is shown.

[0019] With reference to the drawings, wherein like reference numerals designate like components throughout the several figures, a robot system 10 is shown in Fig. 1 schematically. The robot system 10 includes a multi-axis industrial robot 12, a configuration tool 20, which is Fig. 5 and Fig. 6, and a reconfigurable end effector assembly 30, described below with reference to Fig. 2A - 4 and 7. The control of the overall operation of the robot system 10 can be achieved by means of a controller (C) 50 by means of executing a method 100, for which an exemplary embodiment is described in Fig. 8. The robot system 10 may include a configuration frame 75, 175 as shown in Fig. 9 - 11E, wherein a method 200 for using the configuration frame 75, 175 in Fig. 12 is shown.

[0020] The Robot 12 by Fig. 1 may be designed as a conventional six-axis industrial robot as shown and may therefore include a fixed or a mobile base 13 and a plurality of robot joints J, at least some of which are arranged in Fig. 1. The various joints J connect segments or serial links of the robot 12, which include a lower arm 14, an upper arm 15, and a wrist 16, and together provide the desired range of motion and the desired number of control degrees of freedom required to perform assigned work tasks.

[0021] As explained below with reference to the remaining figures, examples of such work tasks include grasping, lifting, positioning, and placing metal sheets or glass panes, along with a variety of other possible tasks such as painting and welding. Joint position sensors S can be mounted at each joint J. Jpositioned and configured to measure joint positions and report the measured joint positions to the controller 50 (arrow θ J ). In addition, one or more force sensors (not shown) may also be positioned at the joints J, e.g., at the wrist 16, and used to provide force or torque feedback to the controller 50, which may avoid excessive force on the workpiece or end effector assembly 30 when performing the method 100.

[0022] With reference to the end effector assembly 30 in particular, this structure may include a main boom 18 and a grid-like end effector array 19. The end effector array 19, in the illustrated embodiments, includes parallel frame rails 23 that are oriented with respect to a longitudinal axis A 18of the main boom 18 are arranged orthogonally. Tool support branches 25 can be cantilevered with respect to the frame rails 23 as shown and thus extend radially outward from the frame rails 23. The various tool support branches 25 are slidably mounted / slidable along a respective one of the frame rails 23. Individual tool modules 35, shown in the various figures as exemplary vacuum suction cups or grippers, depend from the tool support branches 25. Each frame rail 23, in turn, is connected to the main boom 18 via a conventional bidirectional coupling assembly 60 of the type known in the art, an exemplary embodiment of the bidirectional coupling assembly 60 being shown in Fig. 4 is best shown.

[0023] The main boom 18 includes a double-sided tool changing arrangement 21 with separate first and second tool changing devices 21A and 21B, wherein the first and second tool changing devices 21B and 21A are Fig. 2A and Fig. 2B. As is well known in the art, the term "tool changer" refers to manual or automatic assemblies that enable rapid interchange of robot end-tools. Such assemblies typically include integrated power and communication ports, connectors, and the like, as required for the function of the end tools 36. Unlike conventional tool changers, however, the tool changer assembly 21 is specifically designed to provide simultaneous engagement of the main boom 18 with both the robot 12 and a configuration rack 75, the latter in Fig. 1. A more detailed exemplary embodiment of the configuration frame 75 is shown in Fig. 8 - 9C and discussed below with reference to these figures. An alternative two-axis configuration frame 175 is shown in Fig. 10A - E shown.

[0024] In the present disclosure, the configuration frame 75 may be Fig. 1 may be attached to a floor 85 or suspended from a vertical surface, such as a machine column or a wall. The configuration frame 75 has a predetermined position in a Cartesian reference frame (e.g., XYZ) and thus provides a calibrated reference point for zeroing the robot 12 upon reconfiguration of the end effector assembly 30. For example, if a first configuration, which is shown in Fig. 2A, to another configuration shown in Fig. 2B, the robot 12 connects the first tool changer 21B to the configuration rack 75 and releases the second tool changer 21A. When the robot 12 reconfigures the end effector assembly 30, the free-space locations of each of the joint locking mechanisms described below are known to the controller 50 due to their known location in the reference frame provided by the configuration rack 75. In the event that the configuration of the end effector 30 becomes unknown during an operation, e.g., due to a crash event or a power failure, the end effector assembly 30, while suspended from the configuration rack 75, can be manually reset to a calibrated setting in which the positions of the various tool modules 36 are known, with the configuration then starting from the zeroed setting.

[0025] As described below with specific reference to Fig. 2A-4, the tool support branches 25 with the tool modules 35 attached thereto are automatically repositionable by the robot 12 using the configuration tool 20 in accordance with the method 100 and by instructions executed by the controller 50, and can thus be arranged as desired to enable the tool modules 35, or more specifically, the individual end tools 36 of the tool modules 35, to be attached to or otherwise interact with a given workpiece. In one non-limiting body panel example, the respective end tools 36 shown in the various figures are configured, for example, as pneumatic suction cups or grippers of the type commonly used to grip and move automotive or other body panels without damaging cosmetic visual surfaces.However, other end tools 36 may be readily contemplated within the intended scope of the present invention, such as pincers, clamps, spray nozzles, etc., and therefore the specific construction of the end tools 36 may vary.

[0026] Overall control of the robot system 10 is provided by the controller 50. The controller 50 may be configured as a host machine, e.g., a digital computer, specifically programmed to perform steps of the method 100. For this purpose, the controller 50 includes sufficient hardware to perform the required method steps, i.e., sufficient memory (M), a processor (P), and other associated hardware such as a high-speed clock, analog / digital and / or digital / analog circuits, a timer, input / output circuits and associated devices, signal conditioning and / or signal buffer circuits. The memory (M) includes sufficient tangible non-transitory storage, such as magnetic or optical read-only memory, flash memory, etc., as well as random access memory, electrically erasable programmable read-only memory, and the like.

[0027] As part of the method 100, the controller 50 receives the measured joint positions (arrow θ J ) from the position sensors (S J ) and records them, and it also monitors forces applied by or to the end-effector assembly 30 during the course of configuring the end-effector assembly 30 and while working on a given workpiece. The controller 50 generates or receives input signals (arrow 11) that inform the controller 50 of the required work tasks to be performed and identify the corresponding workpieces, and it outputs control signals (arrow 111) to the robot 12 to command the actions required by the robot 12.

[0028] In Fig. Two non-limiting exemplary workpieces 80 and 90 are schematically illustrated in Figures 2A and 2B, respectively. The workpieces 80 and 90 may have different sizes, shapes, and / or surface contours relative to each other and to other workpieces (not shown), or they may be constructed from different materials. Consequently, the construction of the workpiece 80 in Fig. 2A is shown to be considerably larger and more uniform than that of workpiece 90 of Fig. 2B, which is why different configurations of the same tool modules 35 are required. In a given production operation, any number of possible workpieces can be encountered and consequently the end-tool assembly 30 of the robot 12 is Fig. 1 reconfigurable to work with any of them individually as needed.

[0029] This means that the controller has 50 of Fig. 1 the specific workpiece to be machined via the input signals (arrow 11 of Fig. 1), such as by manual selection by an operator, by detection of an RFID tag, or by any other suitable identification process. The controller 50 then automatically selects a corresponding configuration from its memory (M). After the end effector assembly 30 has been hung on the configuration frame 75 and rotated into a configuration position, the robot 12 attaches the configuration tool 20 from Fig. 5 at a suitable workstation (not shown) on its wrist 16 or other suitable end link and configures the end effector assembly 30. Although omitted from the figures for simplicity of illustration, such a workstation may be embodied as a fixture that allows the configuration tool 20 to be held in a calibrated position, i.e., a position readily accessible to the wrist 16. This all takes place while the end effector assembly 30 remains captured on the configuration rack 75.

[0030] After the end effector 30 has been fully configured for the task at hand using the configuration tool 20, the robot 12 automatically places the configuration tool 20 at its workstation, releases the configuration tool 20 from the wrist 16, picks up the now configured end effector assembly 30 by engaging the tool change assembly 21, removes the end effector assembly 30 from the configuration frame 75, and begins operations on the workpiece 80 or 90. Although only two exemplary workpieces 80 and 90 are shown in Fig. 2A and Fig. 2B for ease of illustration, however, those skilled in the art will appreciate that the possible range of such workpieces can be as large or as small as required for the particular job being performed. In other words, the ability of robot 12 to reconfigure end-effector assembly 30 allows its use across a wide range of possible workpieces.

[0031] With reference to Fig. 3, the end effector assembly 30 includes a pair of frame rails 23A, 23B which, as mentioned above, are arranged with respect to the axis A 18of the main boom 18 are arranged orthogonally, with the various tool modules 35 connected to the radially extending tool support branches 25. In an exemplary embodiment in which the end tools 36 are pneumatic grippers, pneumatic pipes 76 can be laid along the main boom 18 and directed to the various end tools 36.

[0032] When the parallel frame rails 23A and 23B are Fig. 2 shown configuration tool 20, which is described below with reference to Fig. 5 described in detail, they can be adjusted with reference to a corresponding frame rail axis A 23A or A 23B rotate as indicated by respective arrows R1 and R2. Similarly, the tool modules 35 can rotate with respect to a linear / rotary locking axis A 38for a corresponding linear / rotary locking mechanism 38, as indicated by arrow R3. The linear / rotary locking axis A 38 is with respect to the branch axis A 25 orthogonal to the specific tool support branch 25 on which the linear / rotary locking mechanism 38 is arranged. A displacement of the tool modules 35 along a given branch axis A 25 is indicated by arrows T1 and T4. Additionally, each tool support branch 25 can be translated along one of the frame rails 23A or 23B, as indicated by respective arrows T2 and T3. In this manner, any number of different configurations of the tool modules 35 can be set by the robot 12 in response to the commands (arrow 111) from the controller 50, as needed.

[0033] Fig. 4 is a perspective view of a portion of the end effector assembly 30 shown in Fig. 3. The frame rails 23A and 23B have respective parallel rail axes A 23A and A 23B The main boom 18 is connected to the frame rails 23A, 23B via the bidirectional coupling assembly 60. Each tool support branch 25 is connected to one of the frame rails 23A, 23B via a linear locking mechanism 40. Each tool module 35 is connected to a corresponding tool support branch 25 via a linear / rotary locking mechanism 38, which also defines / serves as an air passage, as described below with reference to Fig. 7 is described in further detail.

[0034] An adjustment of a corresponding lever 47 of the bidirectional coupling arrangement 60, such as a rotation of a fork-shaped lever arm, as shown via an adjustment pin 127 of the configuration tool 20, which is shown in Fig. 5, performs a repositioning of one of the unlocked or loosened frame rails 23A or 23B. This means that the frame rails 23A or 23B are moved in a circular arc around a corresponding frame rail axis A using the robot 12 to move the adjustment pin 127. 23A or A 23B can be rotated as shown by the arrows R1 and R2 in Fig. 3. In one embodiment, pneumatic pressure is required for the bidirectional clutch assembly 60 to pneumatically unlock the bidirectional clutch assembly 60 from the parallel frame rails 23A, 23B by supplying air pressure to chambers (not shown) on one side of the bidirectional clutch assembly 60. Conversely, the bidirectional clutch assembly 60 can be pneumatically locked by supplying air pressure to the chambers (not shown) on the opposite side of the bidirectional clutch assembly 60. The linear / rotary locking mechanism 38, when sufficiently loosened, allows the tool module 35 depending therefrom to rotate along one of the axes A 25 is moved as indicated by arrow T1 or T4, and also around an axis A 38 is rotated as indicated by arrow R3.

[0035] Analogously, an adjustment of the linear locking mechanism 40 allows the tool support branches 25 to be moved along the frame rail axis A 23A or A 23B be moved as indicated by arrows T2 and T3. By programming the controller 50 with all required positions and orientations of the frame rails 23 and the tool support branches 25 for a given workpiece, the robot 12 can Fig. 1 can in turn be instructed to configure the end effector assembly 30 for use with a large number of different workpieces, this being carried out as required via automatic adjustment of the bidirectional coupling assembly 60, the linear / rotary locking mechanism 38 and / or the linear locking mechanism 40.

[0036] Fig. Figure 5 illustrates an exemplary embodiment of the configuration tool 20 previously described with reference to Fig. 1, the configuration tool 20 is shown attached to the wrist 16 of the robot 12. The configuration tool 20 includes an axially extending tool assembly 22 and a control block 26 disposed at opposite distal ends E1 and E2 of the configuration tool 20 and interconnected by axially extending support rails 24. The tool assembly 22 may include parallel discs 122, each shaped like a rectangle or polygon, each mounted on a first end disc 31 and extending toward a second end disc 131. The two end discs 31 and 131 may have a rectangular shape, with the first end disc 31 having a larger area than the second end disc 131 to enable use in configuring the end effector assembly 30.The adjustment pin 127 may be mounted on one of the parallel discs 122 and configured to engage with the pins shown in FIG. Fig. 4 shown levers 47 to engage.

[0037] A nut driver 33, for example a torque wrench, which rotates around an axis A 20 of the configuration tool 20, extends from the second end plate 131 and is used to adjust the linear / rotary locking mechanism 38 and / or the linear locking mechanism 40 mentioned above and in Fig. 3 and Fig. 4. At the distal end E2, the control block 26 may include electrical connectors 27 and an additional tool changing device 29, i.e., a mechanical coupling that enables the robot 12 to pick up the configuration tool 20, as well as guide pins 28 or other suitable coupling devices that enable the robot 12 to engage the configuration tool 20 with the wrist 16. The electrical connectors 27 carry necessary electrical power and control signals to operate the nut driver 33 via a drive motor 59 of the nut driver 33. After the configuration tool 20 has been coupled to the wrist 16, it locks into place, and electrical and / or pneumatic power is supplied to the nut driver 33 as needed to rotate a driver bit 133, e.g., a hex bit.A small motor control module 150 may be located on the configuration tool 20 to provide, in conjunction with the controller 50, local control of the operation of the configuration tool 20, such as overtorque settings and the like.

[0038] With reference to Fig. 6 illustrates the operation of the tool assembly 22 with respect to an adjustment of a tool module 35. As shown, the end tool 36 is bolted to a distal end of an angled pivot arm 42 and may also be spring-loaded via a spring and swing arm assembly 49 as shown to allow optimal adaptation to the different heights and contours of the workpieces, e.g., from 80 or 90 of Fig. 2A and Fig. 2B. To adjust the linear / rotary locking mechanism 38, which is attached to or integral with the pivot arm 42, the robot 12 is directed from Fig. 1, first, positioning pins P1 and P2, which extend outwardly from the end plate 131, with matching positioning holes 41 in a further distal end E4 of the pivot arm 42. The positioning pins P1 and P2 can be round or spherical and can be received in the positioning holes 41, which are defined by an insert 53 or a material of the angled pivot arm 42, as shown in the view with partial omissions of Fig. 7 is best shown.

[0039] After the nut driver 33 of Fig. 6 is correctly aligned, it can engage with a fastening element 52 of the linear / rotary locking mechanism 38. By loosening the fastening element 52, the linear / rotary locking mechanism 38 can be freely displaced along the axis of the tool support branch 25, and / or the tool module 35 can rotate freely about one of the linear / rotary locking axes A 38 from Fig. 3 or equivalent around the nut driver axis A 20 rotate. The robot 12 can then tighten the linear / rotary locking mechanism 38 in place after moving to the next adjustment location on the end effector assembly 30.

[0040] Fig. Figure 7 is a partial cross-sectional view of a linear / rotary locking mechanism 38 of Fig. 6 and a portion of the angled pivot arm 42 connected to the linear / rotary locking mechanism 38. The linear / rotary locking mechanism 38 is, in one embodiment, not only configured to be locked / unlocked with respect to a given tool support branch 25, but also serves as a manifold or air passage for delivering pneumatic power to the end tool 36. Accordingly, an air inlet 56 is formed in a body 54 of the linear / rotary locking mechanism 38, the body 54 being a box that surrounds the tool support branch 25 on all sides and extends along an axial groove 37 of the tool support branch 25 in the exemplary embodiment shown in Fig. 6. An air outlet 58 is arranged in a direction parallel to the branch axis A 25 oriented. Pneumatic pipes 76, as shown in Fig. 3, of the type used to apply vacuum or to supply air to the bidirectional clutch assembly 60 or to the end tools 36, may be wound onto the frame rails 23 and the tool support branches 25 to provide the necessary slack when the end tools 36 are repositioned by the robot 12.

[0041] In this way, part of the pneumatic pipes 76 of Fig. 3 to the linear / rotary locking mechanism 38, whereby air or a vacuum is passed through the body 54 and the air outlet 58 and finally connected to the end tool 36. Tightening the fastener 52 finally clamps the linear / rotary locking mechanism 38 to the tool support branch 25 to allow movement of the body 54 along the branch axis A 25 and the swivel arm 42 around the linear / rotary locking axis A 38around, while loosening the fastener 52 releases the linear / rotary locking mechanism 38 to move it along the branch axis A 25 to move. In an exemplary embodiment, the linear / rotary locking mechanism 38 may include cone support bushings 63 and cone support plugs 65 built onto or around the body 54, with the cone support bushing 63 defined by the pivot arm 42 as shown. Within this structure, an air passage 67 connects the air inlet 56 to the air outlet 58. Within the intended inventive scope, any other suitable internal construction needed to provide the specified clamping functionality may alternatively be used.

[0042] With reference to Fig. 8, an exemplary embodiment of the method 100 begins with step S102. In this step, the controller 50 selects a work task to be performed by the robot 12. For example, the controller 50 may be informed via the input signals (arrow 11) that it is necessary for the robot 12 to perform the Fig. 2A. The controller 50 can then extract from its memory (M) the required end effector configuration to perform the requested work task. Once the controller 50 knows the task to be performed and the configuration is loaded into the memory (M), the method 100 proceeds to step S104.

[0043] At step S104, the controller 50 instructs the robot 12 to pick up the configuration tool 20, by transmitting the control signals (arrow 111) from Fig. 1. In response to the robot control signals (arrow 111), the robot 12 moves its wrist 16 into engagement with block 26 of Fig. 5 and adjusts the gripping device arrangement 30 at the Fig. 1. While this process is taking place, the method 100 proceeds to step S106.

[0044] Step S106 involves determining whether the end effector assembly 30 has been fully configured for the current work task. The method 100 proceeds to step S108 when all frame rails 23 and tool support branches 25 have been adjusted and when all tool modules 35 are positioned as required and securely locked in place.

[0045] Having previously determined in step S106 that configuration has been completed, the robot 12 places the configuration tool 20 at a suitable workstation in step S108. Although omitted from the figures for simplicity of illustration, such a workstation may be embodied as a holder that allows the configuration tool 20 to be held in a calibrated position, i.e., a position easily accessible to the wrist 16. The robot 12 then picks up the now-adjusted end effector 30 from the configuration station 75. Step S108 may include aligning the tool changing device 21A with a matching structure (not shown) of the wrist 16 and locking the tool changing device 21A into place, e.g., via quick-connect couplings or the like. The method 100 then proceeds to step S110.

[0046] Step S110 includes executing the assigned work task, such as picking up the workpiece 80 from Fig. 2A using suction and depositing the workpiece at a target location, such as a vehicle body or a work platform area. The method 100 proceeds to step S112 after work on the workpiece is completed.

[0047] Step S112 includes determining whether work on all similar workpieces for the current work item has been completed. For example, if a stack of a predetermined number of workpieces is to be picked up and placed on a conveyor belt, the controller 50 may determine in step S112 whether work on all of the predetermined number of workpieces has been completed. The method 100 proceeds to step S114 when the stack is complete.

[0048] At step S114, the controller 50 determines whether another work task is to be performed by the robot 12, e.g., a task involving lifting and placing the alternative workpiece 90 from Fig. 2B. If so, the method 100 proceeds to step S116. Otherwise, the method 100 proceeds to step S115.

[0049] Step S115, which is reached when the current work task is completed and there are no further work tasks that the robot 12 needs to complete, comprises placing the end effector assembly 30 on the configuration station 75 of Fig. 1, and commanding the robot 12 to execute a wait or off state, after which the robot 12 waits for further instructions. Thereafter, the method 100 resumes at step S102.

[0050] At step S116, the robot 12 next loads the end effector assembly 30 onto the configuration rack 75 of Fig. 1, attaches the configuration tool 20 to a holder (not shown) and proceeds to step S102. The method 100 is then executed as described above with reference to steps S102-S114.

[0051] With reference to Fig. 9, the end effector assembly 30 is shown in two positions: a load position (I) and a configuration position (II). At a given time, only one of the two positions is possible, as described below with reference to Fig. 10A - C is described in detail, and therefore the configuration position (II) is shown in dashed lines.

[0052] In one possible embodiment, the configuration frame 75 described above with reference to Fig. 1, be a single-axle bogie and may therefore include a bogie motor 66 having a rotation axis A 66The frame motor 66 may be any electric motor or other rotary actuator operable to rotate the end effector assembly 30 180 degrees about the axis A 66 from the load position (I) to the configuration position (II) and back again. In the load position (I), the end effector assembly 30 is positioned so that the axis A 18 of the main boom 18 is horizontal with respect to the ground 85, as in Fig. 10A and at 45 degrees to the axis A 66 The tool changing arrangement 21, which in the view of Fig. 9 is not visible, is engaged with a suitable tool changing device 221, which is mounted on the axis A 66 is arranged adjacent to the frame motor 66.

[0053] Successful docking of the tool change assembly 21 to the tool change device 221 may be automatically detected, such as via a switch sensor (not shown), as is known in the art, and communicated to the controller 50. The controller 50 may then command the robot 12 to remove the configuration tool 20 from Fig. 5 from a workstation or fixture (not shown). While the robot 12 retrieves the configuration tool 20, the frame motor 66 automatically rotates about the axis A 66 in the direction of arrow X1. This rotation causes the end effector assembly 30 to rotate 180 degrees with respect to the 45-degree diagonal axis A 66 is turned over so that the end effector assembly 30 is oriented vertically within the configuration frame 75, as shown in Fig. 10C, whereby the configuration position (II) of Fig. 9 is reached. A rotation in the reverse direction is indicated by an arrow X2. In the configuration position (II) the robot 12 is Fig. 1 is able to begin reconfiguring the end effector assembly 30 using the configuration tool 20.

[0054] As part of the present design, a torque / force sensor S F be positioned on the frame motor 66, for example clamped between the tool changing device 221 and the frame motor 66. Such a torque / force sensor S Fcan detect potential overload torques / forces (arrow F0) during the configuration phase and transmit the detected values ​​to the controller 50, with torques / forces above a threshold force being used by the controller 50 to stop the process or take other corrective action. One advantage of such a design feature is that a small pulling force between the configuration tool 20 and the linear locking mechanism 40 or the linear / rotary locking mechanism 38 can be translated to a more readable load on the torque / force sensor S F will be reinforced to protect the end effector assembly 30, the configuration frame 75 and the robot 12 from excessive stress or strain.

[0055] Fig. 10A - C together illustrate the progression of the end effector assembly 30 as it moves from the load position shown in Fig. 10A, through an intermediate position ( Fig. 10B) and finally into the configuration position ( Fig. 10C). In the exemplary embodiment of Fig. 9-10C, the configuration frame 75 may be vertically oriented with respect to a machine column 88 or other vertical surface.

[0056] In Fig. 10A, the gripping device arrangement 30 is oriented such that the axis A 18 of the main boom 18 is horizontal with respect to a plane of the ground 85, which is also determined by the load position I in Fig. 9 is displayed. In the load position of Fig. 10A, the end tools 36 point away from the robot 12, as indicated by arrows R, and thus represent a rearward orientation with respect to the robot 12. In Fig. 10B, the end effector assembly 30 was rotated by half its range of motion about the axis A 66around, with the rotation beginning to expose the tool modules 35 to the robot 12. Fig. 10C represents the configuration position, ie position II of Fig. 9. Once the configuration position of Fig. 10C is reached, the tools 36 are exposed to the robot 12, as indicated by arrows F, thereby illustrating a forward-facing orientation with respect to the robot 12. The robot 12 can then use the configuration tool 20 to adjust the end effector assembly 30 as needed depending on the work task to be performed. Consequently, the overall sequence allows the end effector assembly 30 to be locked and rotated between the load and configuration positions in a spatially efficient manner.

[0057] Multi-axis designs can be used as alternatives to the single-axis motor 66 design shown in Fig. 9 and 10A-C. For example, a two-step approach may be used. At the start of the process, a first actuator may tilt and lift the end effector assembly 30 through a 180-degree range of inversion along a tilt axis, e.g., 30 degrees with respect to the vertical. Thereafter, the end effector assembly 30 may be tilted rearwardly such that the end effector assembly 30 remains vertically mounted with the various tool modules 35 facing the robot 12. Following the configuration phase, the end effector assembly 30 may be tilted, inverted, and tilted again such that the tool modules 35 again face a machine column 88. These and other embodiments may be contemplated within the present inventive scope.

[0058] Fig. 11A-E collectively illustrate an alternative configuration frame 175 providing an alternative two-axis configuration sequence. In this embodiment, the configuration frame 175 includes a linear actuator 95, e.g., a cylinder and piston, a ball screw, or other suitable linear actuator having a longitudinal axis A. 95 . Fig. Figure 11A shows the end effector assembly 30 in a load configuration, being vertically positioned with respect to the machine column 88 after engagement of the tool change assembly 21 with the tool change device 221 (see Fig. 9) of the configuration frame 175.

[0059] Once the end effector assembly 30 has successfully docked, the actuator 95 tilts the end effector assembly 30 by a calibrated tilt angle (θτ), as shown in Fig. 10B, such as by retracting a piston arm in the direction of arrow 96, to cause a corresponding tilting of the main boom 18. The calibrated tilt angle (θτ) may be in the exemplary range of approximately 25-35 degrees, or in another embodiment, 30 degrees, with the actual range depending on available space. The end tools 36 remain directed away from the robot 12 (not shown), as indicated by arrows R. After the axis of the main boom 18 has been tilted to the calibrated tilt axis (θτ), as shown in Fig. 11C, the motor 66 rotates the end effector assembly 30 as described above with reference to Fig. 9 - 10C is explained.

[0060] Fig. Figure 11D illustrates the end effector assembly 30 after the end effector assembly 30 has been rotated 180 degrees so that the end tools 36 now face the robot 12, as indicated by the arrows F. At this point, as shown in Fig. 11E, the linear actuator 95 extends in the direction of arrow 98 to return the end effector assembly 30 to a vertical orientation as shown. Consequently, Fig. 11E represents the configuration position mentioned above, while Fig. 11A represents the load position. In contrast to the single-axis design, in which the main boom 18 is oriented horizontally in the load position, the two-axis design of Fig. 11A - E a vertical orientation of the main boom 18 in both the load position and the configuration position.

[0061] With reference to Fig. 12, an exemplary method 200 for operating the configuration rack 75 of Fig. 9 - 10C or the alternative configuration frame 175 from Fig. 11A-E at step S202, in which the end effector assembly 30 is positioned on the configuration rack 75, 175 in the load position. Step S202 may include engaging the tool changer 21 at the end of the main boom 18 with the tool changer 221 disposed on the configuration rack 75, wherein the general structure of a tool changer and the engagement techniques are known in the art. The method 200 then proceeds to step S204.

[0062] At step S204, the controller 50 determines Fig. 1, whether the end effector assembly 30 is securely locked onto the configuration frame 75 or 175, e.g., using a switch sensor or other suitable means. Steps S202 and S204 are repeated until the controller 50 has verified that the end effector assembly 30 is securely locked into the load position, e.g., position I of Fig. 9 or the position shown in Fig. 11A. The method 200 then proceeds to step S206.

[0063] Step S206 includes releasing the robot wrist 16 from the end effector assembly 30, commanding the robot 12 to pick up the configuration tool 20 from a suitable workstation (not shown), and flipping or tilting and flipping the now-captured end effector assembly 30 from the load position using either the single-axis or dual-axis approach described above.

[0064] Step S208 includes determining whether the configuration tool 20 has been attached to the robot wrist 16 and whether the end effector assembly 30 has reached the configuration position of Fig. 10C or Fig. 11E. If not, the method 200 repeats step S206 as disclosed above. The method 200 proceeds to step S210 if the configuration position has been reached.

[0065] At step S210, the controller 50 next commands the robot 12 to configure the end effector assembly 30 using the configuration tool 20 provided in Fig. 5. Thereafter, the method 200 proceeds simultaneously to steps S212 and S213.

[0066] Step S212 involves determining whether the controller configuration phase is complete. Steps S210 and S212 continue in a loop until the end effector assembly 30 has been correctly configured, after which the method proceeds to step S214.

[0067] Step S213 includes the torque / force sensor S Fis used to measure the torques / forces between the configuration tool 20 and / or another structure of the configuration frame 75, 175 and the tool changing device 221, and that the measured torques / forces are compared with a calibrated threshold torque or a calibrated threshold force. The use of the torque / force sensor S F in the configuration position allows the controller 50 to determine whether any of the reconfigurable components exhibit excessive resistance or are otherwise not moving freely. If so, the robot 12 may damage the end effector assembly 30, and consequently, control measures are taken by the controller 50 to prevent this from occurring. By using the torque / force sensor S Fplaced on the tool changing device 21 at the upper end of the gripper assembly 30, a small pressure force is also applied to a more readable load on the sensor S F amplified. The higher resolution will help provide fewer false readings. The method 200 proceeds to step S212 if the threshold torque or force is not exceeded, and alternatively to step S215 if the threshold torque or force is exceeded.

[0068] At step S214, the robot 12 releases Fig. 1 next removes the configuration tool 20 and places it at a suitable workstation (not shown). While this is taking place, the frame motor 66 rotates the now configured end effector assembly 30 back to the load position of Fig.10A, effectively reversing the operation described with reference to steps S202-S214. The method 200 proceeds to step S216.

[0069] Step S215 includes executing a control action in response to the threshold force detected in step S213. Possible example control actions include stopping the configuration movement of robot 12 or reversing the configuration movement to a default / failsafe position suitable for zeroing or maintenance.

[0070] At step S216, the robot 12 picks up the end effector assembly 30 and begins working on the workpiece using the now configured end effector assembly 30. When the work task is completed, the method 200 returns to step S202.

[0071] Thus, at the end of a material handling operation, the method 200 allows the robot 12 to unload the end effector assembly 30 onto the configuration rack 75 or 175, lock and rotate the end effector assembly 30 into a reconfigurable position, retrieve a configuration tool 20 from a tool rack or fixture, and begin configuring the end effector assembly 30. At the end of the configuration phase, the configuration rack 75 or 175 rotates the end effector assembly 30 back to the load position and releases it. The robot 12 can then retrieve the end effector assembly 30 from the configuration rack 75 or 175 and resume the material handling operation or another operation.

Claims

[1] Robot system (10) comprising: a multi-axis robot (12) with an arm and a wrist (16); a gripper assembly (30) having a main boom (18), a tool changing assembly (21) arranged at a distal end of the main boom (18), parallel frame rails (23, 23A, 23B) arranged orthogonally with respect to the main boom (18) and rotatable with respect to an axis of the main boom (18), a plurality of tool support branches (25) arranged orthogonally with respect to the parallel frame rails (23, 23A, 23B), and a plurality of tool modules (35) each connected to one of the tool support branches (25), the tool modules (35) being rotatable and displaceable with respect to an axis of a respective one of the branches (25); a configuration tool (20) comprising a control block (26) disposed at a distal end of the configuration tool (20) and selectively engageable via the tool change assembly (21), and a working tool disposed at another distal end of the configuration tool (20); a controller (50) programmed to command the robot (12) to automatically configure the end-end assembly (30) by adjusting the tool modules (35) and / or the parallel rails (23, 23A, 23B) and / or the tool support branches (25) using the configuration tool (20) in response to a recognized work task, and to thereafter command engagement of the wrist (16) with the tool changing device (21, 21B, 21A, 22I) and execution of the recognized work task using the configured end-end assembly (30); and a configuration frame (75, 175), wherein the tool changing assembly (21) comprises a first tool changing device (21B) configured to engage the robot (12) and a second tool changing device (21A) configured to simultaneously engage the configuration frame (75, 175); and wherein the configuration frame (75, 175) includes a motor (66) having a rotor axis, and wherein the controller (50) is programmed to command the robot (12) to automatically engage the tool changing assembly (21) of the end effector assembly (30) with the second tool changing device (21A) of the configuration frame (75, 175) to thereby achieve a load position (I) of the configuration frame (75, 175), to automatically rotate the end effector assembly (30) 180 degrees with respect to the rotor axis into a configuration position of the configuration frame (75, 175), to command engagement of the wrist (16) with the configuration tool (20), and to configure the end effector assembly (30) using the configuration tool (20) to perform the recognized work task. [2] Robot system (10) according to claim 1, wherein the tool modules (35) are pneumatic suction cups or grippers. [3] The robot system (10) of claim 2, wherein the end effector assembly (30) includes a plurality of linear / rotary locking mechanisms connecting the tool modules (35) to a respective one of the branches (25). [4] The robot system (10) of claim 3, wherein each of the plurality of linear / rotary locking mechanisms defines an air passage (67) configured to apply a negative pressure to the suction cups or grippers. [5] The robot system (10) of claim 1, further comprising a bidirectional coupling assembly (60) configured to lock or release the parallel frame rails (23, 23A, 23B) with respect to the main boom (18). [6] The robot system (10) of claim 1, wherein the controller (50) is further programmed to automatically detect whether the configuration of the end effector assembly (30) is complete and thereafter rotate the end effector assembly (30) 180 degrees with respect to the rotor axis back to the load position. [7] The robot system (10) of claim 1, wherein the configuration frame (75, 175) further includes a linear actuator (95) operable to tilt the end effector assembly (30) to a calibrated tilt angle (θτ) before rotating the end effector assembly (30) via the motor (66). [8] Robot system (10) comprising: a multi-axis robot (12) having an arm and a wrist (16); a gripper assembly (30) having a main boom (18), a tool changing assembly (21) disposed at a distal end of the main boom (18), parallel frame rails (23, 23A, 23B) disposed orthogonally with respect to the main boom (18) and rotatable with respect to an axis of the main boom (18), a plurality of tool support branches (25) disposed orthogonally with respect to the parallel frame rails (23, 23A, 23B), and a plurality of tool modules (35) connected to a respective one of the tool support branches (25), the tool modules (35) being rotatable and displaceable with respect to an axis of a respective one of the branches (25), the gripper assembly (30) including a plurality of linear / rotary locking mechanisms connecting the tool modules (35) to a respective one of the branches (25); a configuration tool (20) having a control block (26) disposed at a distal end of the configuration tool (20) and selectively engageable via the wrist (16), and a working tool disposed at another distal end of the configuration tool (20); a configuration frame (75, 175) providing a known reference frame for configuring the end-end assembly (30), wherein the tool changing assembly (21) includes a first tool changing device (21B) configured to engage the robot (12) and a second tool changing device (21A) configured to simultaneously engage the configuration frame (75, 175); and a controller (50) programmed to command the robot (12) to automatically configure the end effector assembly (30) by adjusting the tool modules (35) and / or the parallel rails (23, 23A, 23B) and / or the tool support branches (25) using the configuration tool (20) in response to a detected work task, and to thereafter command engagement of the wrist (16) with the tool changing device (21, 21B, 21A, 221) and execution of the detected work task using the configured end effector assembly (30); wherein the configuration frame (75, 175) includes a motor (66) having a rotor axis, and wherein the controller (50) is programmed to command the robot (12) to automatically engage the tool changing assembly (21) of the end effector assembly (30) with the second tool changing device (21A) of the configuration frame (75, 175) to thereby achieve a load position (I) of the configuration frame (75, 175), to automatically rotate the end effector assembly (30) 180 degrees with respect to the rotor axis into a configuration position of the configuration frame (75, 175), to command engagement of the wrist (16) with the configuration tool (20), and to configure the end effector assembly (30) using the configuration tool (20) to perform the recognized work task.

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