A simple exchange mechanism configured to detach or attach the master arm to the end effector

Abstract

To execute multiple tasks without the need to install different robots.SOLUTION: A simple interchange mechanism is provided allowing a robot arm to reliably, quickly and consistently change over from one end effector to another. The interchange mechanism incorporates mechanical and electromagnetic elements in three different areas that work synchronously, resulting in a flexible and scalable architecture that is simple yet stable, and adaptable to different configurations of the robot.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] A simple exchange mechanism for changing the end effector or manipulator at the distal end of the robotic master arm allows for quick and reliable changeover with flexibility and scalability. It also includes a computer interface for sending and receiving commands from the master robot based on the task being performed. This mechanism eliminates the complex alignment process when finding the latch position between the end effector and the master arm during the loading or unloading process, resulting in a robust and stable mechanism regardless of the size and weight of the end effector. [Background technology]

[0002] Modern manufacturing is typically fully automated, requiring tasks such as the assembly and machining of industrial products with small sizes and complex structures and dimensions. The manufacture of products such as semiconductor assemblies, automotive part assemblies, contact lenses, optical lenses, and small mechanical parts are some examples of components that are typically assembled and quality-tested before being packaged for final shipment to customers. Such components are often small, precision components with a wide variety of shapes, and require high-speed serial manufacturing, primarily using a single master robotic device. Therefore, setup changes, including changing the end effectors and tools of the robotic device, are required in manufacturing sites depending on the workpiece and associated process. For this reason, there is a growing demand for automated setup changes, which involve programming robotic devices to perform configuration changes.

[0003] In manufacturing, configuration setup is performed in the form of changing the end effector, arm, or tool of a robotic device according to the type of workpiece, along with changing the process flow, depending on the type of component to be assembled or manufactured. Manually changing the configuration of a conventional robotic device by an operator requires significant manual effort and work time, and so-called automatic configuration change is required, which may include changing the end effector as well as changing the programming of the robotic device whenever possible.

[0004] In view of the above, robotic devices are required to have a compact and simple configuration, specifications, and performance that allows for grasping, assembling, and processing of various types of workpieces, while at the same time increasing the overall availability of the robotic device by automatically changing tools to suit the tasks being performed on the workpieces.

[0005] Therefore, there is a need for a robotic device to have an easy exchange mechanism to accommodate different configurations of end effectors that allow for rapid, efficient, and consistent handling and manipulation of a wide variety of workpieces to enhance the functional characteristics of the robotic device.

[0006] Automatic exchange of operating units, such as end effectors, in robotic devices requires reducing the size and weight of the end effectors, if possible, shortening the time required to exchange these end effectors and their components, and increasing the accuracy of placement during exchange. The exchange system includes an end effector held by an exchange tool or gripper, and a master arm. Furthermore, in the case of robots such as robot hands or end effectors, the finger portions that manipulate the workpiece may be exchangeable in some cases. Switching from one configuration to another involves an electrical interface that uses software commands and electrical signals to operate the robot hand or end effector. The electrical interface includes mechanisms suitable for the master robot to detect what configuration the end effector or manipulator is in and whether it is mechanically locked in place to ensure proper loading and verification of the exchange end effector. Details of the electrical interface and command interface protocol are beyond the scope of this invention and are not disclosed. While past prior art has extensively disclosed robotic end effector switching, these prior art techniques are time consuming and involve manual intervention for proper setup, alignment, and configuration. They are also complex, inflexible, non-scalable, and require frequent intervention for proper operation. Summary of the Invention

[0007] Aspects of the present invention provide a simple exchange mechanism that is designed to reliably and consistently engage / attach or disengage / detach an end effector integrated into a robotic hand to a master robotic arm accurately and consistently in the shortest possible time. The exchange mechanism design includes three areas: While reference is made throughout this document to an end effector, it is important to note that the end effector always has an integrated robotic hand, and its functionality may vary depending on the task at hand.

[0008] The first exchange area includes the end effector engagement portion, the second area is the master arm, and the third area is a tool or gripper for engaging and disengaging the master arm from the end effector.

[0009] The end effector exchange area mainly comprises several torsion spring loaded levers that can rotate to a predetermined angle about their respective circular axes, and a magnetic steel plate whose surface interfaces with at least two recesses that accommodate the electromagnets attached to the master arm and the master arm pickup hook.

[0010] The second exchange area is the distal end of the master arm, which includes an electromagnet mounted at the center of the arm and at least two extensions formed in a hook shape around the center of the electromagnet. These extensions are designed to properly align with the steel plate of the end effector for good stability. The two extension hooks function as latch points between the master arm and the end effector. The lever functions as a latch lock that allows the end effector to be securely attached to the master arm.

[0011] The third exchange area is an exchange mechanism that includes a simple cover plate that moves on a horizontal axis. This cover plate functions to move a lever outward on the end effector to expose the end effector recess before the master arm extension hook moves down into the recess. It also functions to hold the end effector in place using a pair of grippers during the process of latching and unlatching the end effector from the master arm. During the loading process, after the master arm moves down into the end effector recess, the exchange tool's top cover moves back or retracts, releasing the two levers. These levers are restored to their original positions by torsion springs. This completes the attachment process of the master arm to the end effector. The master arm now moves away from the exchange tool, freeing the rigidly attached end effector for further tasks to be performed. During the unloading process, the exchange tool's top cover moves forward, pushing the end effector lever outward and simultaneously unlatching the master arm from the end effector. The master arm then moves up to disengage the end effector, completing the disengagement process. The top cover of the exchange tool returns to its original position.

[0012] During the installation or removal process, the involved exchange tool operates with a set of spring-loaded jaw grippers. An in-line top cover moves back and forth to push against a spring-loaded lever on the end effector, subsequently performing the latching and unlatching process. The simplicity of the exchange tool with mechanisms at the end of the master arm and end effector forms the basis of the present invention.

[0013] Further features of the present disclosure will become apparent from the following description of exemplary embodiments which proceeds with reference to the accompanying drawings. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a perspective view of a robotic device with several end effectors arranged around it. [Figure 2] FIG. 2 is a perspective view of the exchange tool of the present invention. [Figure 3] FIG. 3 is a perspective view of the opposite side of FIG. 2. [Figure 4] FIG. 10 is a bottom view of the exchange tool of the present invention with a robot end effector ready to be docked. [Figure 5] FIG. 10 is a bottom view of the exchange tool of the present invention after the robot end effector has completed the docking process. [Figure 6] FIG. 10 is a bottom view of the change tool of the present invention with the robot end effector lever extended out to expose the recess accessed by the master arm moving down. [Figure 7] FIG. 10 is a perspective view of the master arm ready to move down and latch onto the end effector held in place by the exchange tool. [Figure 8] FIG. 10 is a cross-sectional view of the master arm and end effector held by the exchange tool after the master arm hook has reached the bottom point of the recess in the end effector. [Figure 9] FIG. 10 is a cross-sectional view of the master arm and end effector held by the exchange tool after the master arm hook has reached the bottom point of the recess in the end effector, with the top cover of the exchange tool retracted and the lever returning to its initial position, resulting in the lever latch engaging the master arm hook. [Figure 10] FIG. 10 is a perspective view of the robotic device showing the master arm latched to one of the end effectors. [Figure 11] FIG. 10 is a perspective view of the master arm moved away from the exchange tool with the end effector engaged or latched into place. [Figure 12] FIG. 1 is a perspective view of a robotic device with an end effector ready for the next task at hand. [Figure 13]10 is a cross-sectional view of the master arm and end effector held by the exchange tool after the master arm has moved up and out of the recess in the end effector, with the top cover of the exchange tool pushing the lever outward, thereby disengaging the latch with the master arm hook as part of the end effector unloading process. DETAILED DESCRIPTION OF THE INVENTION

[0015]

[0023] The following embodiments of the present invention will be described with reference to the accompanying drawings. The following embodiments are described merely as examples, and the detailed configuration may be appropriately changed by those skilled in the art without departing from the spirit of the present invention. Terms such as "manipulator" and "end effector" are used interchangeably in this specification.

[0016] Fig. 1 shows an example of a robot arm exchange system according to an embodiment of the present invention. Fig. 1 is an explanatory diagram showing the configuration of a robot arm exchange system 100. The robot arm exchange system 100 includes a robot device 5, a plurality of exchange tools 10, a plurality of end effectors 15 integrated into a plurality of robot hands E1, E2, and E3, and a pair of robot master arms 20.

[0017] 2 and 3 show two perspective views of the exchange tool 10. The tool includes a horizontally movable top cover 25 that can move in both directions 27. Under the horizontally movable top cover 25 is an end effector gripper 30 with an integrated spring 40, as shown in FIG. 3. The spring 40 serves to hold the gripper 30 in a closed position. The workpieces 25, 30, and 40 are suitably integrated into a base plate 28, which together form the exchange tool. The exchange tool 10 serves to hold end effectors integrated into robot hands (E1, E2, E3, etc. in FIG. 1). This allows the master arm 20 in FIG. 1 to be loaded or unloaded with different end effectors.

[0018] 4 and 5 are bottom views of the change tool 10 (top cover 25 not shown) to better understand the function of the gripper. In FIG. 4, during the process of unloading the end effector, the end effector 15 is pushed towards the gripper 30 (which is normally closed due to the effect of spring 40 compressed in direction 43), and the gripper 30 is forced open to accommodate the end effector. For reference and explanation during the end effector loading and unloading process, it is important to note the position A2 of the lever 35 in FIG. 4.

[0019] In the next step, referring to FIG. 5 as the end effector 15 moves to position A1, a sensing mechanism (not shown) immediately stops further movement of the master arm 20 in FIG. 1. At the same time, the gripper 30 is able to hold the end effector 15 in place by the force of the spring 40. The gripper 30 is attached to two fulcrums 38 and is held closed by the springs 40 due to the spring force indicated at 42. It is important to note the simplicity of the loading process of the end effector 15 using a tool 10 designed to use the gripper 30 and springs 40. This feature is key to the ease of use and scalability of the exchange tool 10.

[0020] The exchange tool 10 in Figure 6 shows the end effector 15 held firmly in place by the gripper 30. A magnetic steel plate 34 attached to the center of the end effector 15 provides a stable and sturdy mechanical fixation to the electromagnet attached to the master arm 20 in Figure 7, described below.

[0021] In the next step, the process of engaging or attaching the end effector 15 to the master arm 20 in FIG. 7 will be described. Referring to FIG. 6, the end effector 15 is designed to have a pair of recessed portions 22A to allow the master arm hooks 22B in FIG. 7 to engage with the end effector 15. Hereinafter, the recessed portions 22A in FIG. 6 and the master arm hooks 22B in FIG. 7 may be generally referred to as a latch mechanism. The latching and unlatching process between the master arm 20 integrated into the robot hand E1 in FIG. 7 and the end effector 15 begins when the top cover 25 of the exchange tool in FIG. 6 presses a pair of levers 35 on the end effector 15. As a result, the pair of recessed portions 22A become accessible to the master arm hooks 22B, which move downward to begin the engagement process. Referring to FIG. 8, the master arm 20 then moves downward toward the end effector 15 and stops when the master arm hooks 22B of the master arm 20 are inside the recessed portions 22A of the end effector 15. When the lever 35 is in the home position A3, a It is important to note that the latching process is not complete, as indicated by the empty area in . The electromagnet 33 is electrically and mechanically integrated into the center of the master arm 20, and when the electromagnet 33 is energized, a strong holding force is possible through a steel plate 34 attached to the center of the end effector 15. Referring to Figure 9, the top cover 25 of the exchange tool is retracted, allowing the lever 35 to return to the initial position A2, while at the same time 37 b9, the pair of master arm hooks 22B are latched to the pair of end effector levers 35 of the master arm 20. Note that the pair of levers 35 move to position A2 due to the force of the torsion spring 32. Upon energizing the electromagnet 33, the magnetic force can hold the end effector 15 in place via the steel plate 34, thereby completing the latching process of the end effector 15 to the master arm 20. Referring to FIG. 9, a key feature of the present invention is that the end effector 15 is foolproof latched to the master arm 20, even in the event of an electrical failure that results in the de-energization of the electromagnet 33. The pair of master arm hooks 22B are safely latched to the pair of end effector levers 35 due to the torsion spring force of 32 in FIG. 9, ensuring that the end effector 15 will not detach from the master arm 20. This safety feature provides a damage-free and safe environment during operation of the robot 5 in FIG. 1, regardless of the task being performed.

[0022] FIG. 10 is a perspective view of the robot master arm 20 latched to the end effector 15 and ready to be unloaded from the exchange tool 10.

[0023] Figure 11 is a perspective view of the robot master arm 20 completing the unloading process and moving away from the exchange tool 10. To understand the unloading process, refer to Figure 4, where the gripper 30 of the exchange tool 10 is held in a closed position by the force of the spring 40. As the master arm 20 in Figure 11 moves away, the gripper 30 is forced open as shown in Figure 4.

[0024] The process of loading and unloading the end effector 15 to / from the exchange tool 10 is controlled by the force of the spring 40. This makes the mechanism simple, effective and scalable.

[0025] 12 is a perspective view of the robot with the master arm 20 latched to the end effector 15 integrated into the robot arm E1, ready to proceed to the next task programmed by the user. The unloading process is the same for E2, E3 (FIG. 10) or any other type of end effector depending on the type of task.

[0026] FIG. 13 is a cross-sectional view of the disengaged master arm 20 and end effector 15. Referring to FIG. 8, the unlatching or disengagement process begins with the top cover 25 of the exchange tool 10 pushing the lever 35 to move outward to position A3. As seen in FIG. 8, the lever 35 unlatches, clearing the way as shown at 37a. This ensures that the recess 22A is now clear for the master arm hook 22B of the master arm 20 to move up. In FIG. 13, the electromagnet 33 is first de-energized, after which the master arm 20 moves up and away from the end effector 15 as shown in FIG. 13. The robotic device 5 returns to its predetermined position as shown in FIG. 1. This completes the unlatching or disengagement between the master arm 20 and the end effector 15.

[0027] The use of actuators, motors, or other rocking or rotating mechanisms is outside the scope of the present invention and will not be described herein. Additionally, it should be recognized that terms such as (attach, latch, engage) and (disengage, unlatch, disengage) are often used interchangeably.

[0028] While the present invention has been described with reference to a specific embodiment, it should be understood that the invention is not limited to the disclosed exemplary embodiment. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions. Those skilled in the art will recognize and appreciate the numerous variations, modifications, and alternatives that may become apparent upon reading the above description.

Claims

1. A simple exchange mechanism configured to detach or attach a master arm to an end effector, comprising: a master arm having an electromagnet and at least two protruding hooks integrated at its center for engaging an end effector; an exchange tool including a horizontally moving top cover, under which there is a gripper for gripping the end effector, both of which are mounted on a plate for proper mechanical stability; and an end effector that is mechanically integrated into multiple robot hands adapted for different tasks, wherein a magnetic plate is precisely aligned with the electromagnet of the master arm to achieve a stable gripping force upon engagement, at least two levers are used to latch and unlatch with the protruding hooks of the master arm, at least two recesses are mechanically aligned to accommodate the protruding hooks of the master arm, and a torsion spring is configured to apply force to the at least two levers.

2. The simple exchange mechanism of claim 1 , wherein the master arm moves up and down during an attachment or detachment process to or from the end effector.

3. 10. The easy change mechanism of claim 1, wherein the gripper of the change tool is spring-loaded to hold the end effector in place even in the absence of electrical power.

4. The easy exchange mechanism of claim 2 , wherein the top cover of the exchange tool functions to open and close the at least two levers of the end effector during the installation and removal processes.

5. 2. The easy exchange mechanism of claim 1, wherein the protruding hooks of the master arm engage recesses in the end effector, and the at least two levers on the end effector function to latch or unlatch the master arm to the end effector.

6. 6. The simple exchange mechanism of claim 5, wherein an electromagnet in the master arm ensures strong and secure engagement with the end effector due to magnetic force when energized.

7. 6. The simple exchange mechanism of claim 5, wherein said protruding hook and said at least two levers of said master arm allow said end effector to remain engaged with said master arm in the event of a power failure.

8. 2. The simple exchange mechanism of claim 1, wherein the protruding hook and the at least two levers of the master arm, in combination with the electromagnet, accurately and consistently attach and detach the end effector to and from the master arm in the shortest possible time, resulting in fast changeover.

9. 10. The simple exchange mechanism of claim 1, wherein a plurality of exchange tools are mounted around the robot, each holding different end effectors that are integrated into different robot hands designed for specific tasks.

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