Laser engraving system and methods of use

Abstract

A laser engraving system for laser engraving at least one item is disclosed. In at least one embodiment, the system provides a multi-axis robotic arm, an end effector engaged with the robotic arm and configured for secure engagement with the at least one item, an item conveyor configured for moving the at least one item to and from the robotic arm, and a laser module configured for laser engraving an outer surface of the at least one item. During use of the system, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

Description

LASER ENGRAVING SYSTEM AND METHODS OF USERELATED APPLICATIONS

[0001] This application claims priority and is entitled to the filing date of U.S. provisional application serial number 63 / 546,188, filed on October 28, 2023. The contents of the aforementioned application are incorporated herein by reference.BACKGROUND

[0002] The subject of this patent application relates generally to laser engraving, and more particularly to an improved laser engraving system and associated methods of use.

[0003] Applicant hereby incorporates herein by reference any and all patents and published patent applications cited or referred to in this application.

[0004] By way of background, laser engraving promotional and personalized items (i.e., any products / objects / items that are capable of being laser engraved, hereinafter collectively referred to as “items” for simplicity purposes) is a rapidly growing market today. However, due to the nature of laser optics, the item being customized must be held under the laser marker at a specific distance and location for the laser marker to be able to focus and create a good quality mark on the item. In order to achieve this, item customizers usually create custom fixtures or methods of holding items under the laser marker using a few screws to install them on the engraving area. These fixtures are often built for only one or a few types and brands of items, limiting the flexibility and overall speed of the marking process, and increasing customization costs. Moreover, the majority of processes are still dependent on a human operator which is not consistently repeatable and prone to error and wasted items. In addition, during the manual fixturing process, the laser marker, an expensive piece of equipment, sits idle. Due to these reasons, in most cases, single-piece customization (i.e., the customization of a single unit of an item) becomes too expensive to make economic sense.

[0005] Robot end effectors are often used in industrial automation systems for picking up and handling items. These robot end effectors typically consist of various types of multi-finger grippers and suction item grippers. The main issue with such grippers is that they don’t hold the items in a firm enough manner for use with processes where the item is to be manipulated. These effectors are usually built to carry the items, not hold them while processes are being performed on them; especially when the item’s mass is greater than a couple hundred grams and center of mass of the items are far away from the grabbing point. Moreover, there are otherissues with them, such as the ability to carry limited shapes of items and inaccuracy of the registration point which usually requires machine vision guidance and more complex automation to deal with.

[0006] Robotics arms, due to their flexibility and robustness, are becoming the preferred automation method in many industrial and medical material handling applications. In order to reliably pick up and register any type of item via a robotic arm, the end effector attached to the robotic arm must be able to get a good grip of an area of the item. For the sake of explanation, we will use insulated drinkware bottles as the sample of items we want to pick up using the robotic arm. Most drinkware items have a flat base for the ability to sit straight up on flat surfaces such as a table. The top of the drinkware however usually has various designs for better looks and attachments of different lids. As a result, handling drinkware items from the top end, especially when the top end is asymmetric, would most likely require a custom end effector design that is a perfect fit for the design of the item’s top end. Hence, it’s very challenging to create an end effector that can adapt to a variety of drinkware items from various manufacturers. On the other hand, the base of most drinkware is flat and some form of revolved symmetrical shape such as cylinder or cone. Therefore, the difference between the bases of the varieties of drinkware items are typically just a difference in diameter. This should be much easier to handle with an end effector. The issue that still remains is how to steadily hold the items until the robot arm picks them up, especially when the part needs to be held on a moving surface such as a conveyor carousel for example.

[0007] Aspects of the present invention fulfill these needs and provide further related advantages as described in the following summary.

[0008] It should be noted that the above background description includes information that may be useful in understanding aspects of the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.SUMMARY

[0009] Aspects of the present invention teach certain benefits in construction and use which give rise to the exemplary advantages described below.

[0010] The present invention solves the problems described above by providing an improved laser engraving system and associated methods of use for laser engraving an outer surface of at least one item. In at least one embodiment, the system provides a multi-axis robotic arm, anend effector engaged with a terminal end of the robotic arm and configured for secure engagement with the at least one item, an item conveyor configured for moving the at least one item to and from the robotic arm, and a laser module configured for laser engraving the outer surface of the at least one item. During use of the system, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

[0011] Other features and advantages of aspects of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of aspects of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings illustrate aspects of the present invention. In such drawings:

[0013] Figure 1 is a bottom plan view of an exemplary end effector of an exemplary laser engraving system in an open position, in accordance with at least one embodiment;

[0014] Figure 2 is a bottom plan view of the end effector in a closed position, in accordance with at least one embodiment;

[0015] Figures 3A and 3B are exploded views of the end effector, in accordance with at least one embodiment;

[0016] Figure 4 is a perspective view of the end effector in an engaged state with an exemplary item, in accordance with at least one embodiment;

[0017] Figures 5-9 are perspective views of select components of the system, illustrating an exemplary method of laser engraving an exemplary item, in accordance with at least one embodiment;

[0018] Figure 10 is a top plan view of an exemplary carousel of the system, in accordance with at least one embodiment;

[0019] Figure 11 is a bottom plan view of an exemplary item receiver, in accordance with at least one embodiment;

[0020] Figure 12 is a side elevational view of the item receiver, in accordance with at least one embodiment;

[0021] Figure 13 is a further top plan view of the carousel along with the item receivers, in accordance with at least one embodiment;

[0022] Figure 14 is a perspective view of the system with a housing door in an open position, in accordance with at least one embodiment;

[0023] Figure 15 is a further perspective view of the system with the housing door in a closed position, in accordance with at least one embodiment; and

[0024] Figure 16 is a further perspective view of the system with the housing door in the open position, in accordance with at least one embodiment.

[0025] The above described drawing figures illustrate aspects of the invention in at least one of its exemplary embodiments, which are further defined in detail in the following description. Features, elements, and aspects of the invention that are referenced by the same numerals in different figures represent the same, equivalent, or similar features, elements, or aspects, in accordance with one or more embodiments.DETAILED DESCRIPTION

[0026] As illustrated in the accompanying drawings, the present invention is an improved laser engraving system 20 and associated methods of use for custom engraving an outer surface 22 of an at least one item 24. In that regard, it should be noted that while certain types of items 24 (such as insulated bottles, for example) are shown and described herein for illustrative purposes, the system 20 should not be read as being so limited. Instead, in further embodiments, the system 20 may be configured for custom engraving any other type of item, now known or later developed. Accordingly, in further embodiments, the at least one item 24 may take on any sizes, shapes, dimensions and / or configurations, now known or later developed, with the components of the system 20, in turn, configured for accommodating such items 24. In at least one embodiment, as discussed in greater detail below, the system 20 provides a multi-axis robotic arm 26 with an improved end effector 28 capable of securely grasping a variety of different items 24, an improved item conveyor 30 capable of supporting avariety of different items 24 thereon, and a laser module 32 capable of laser engraving the outer surface 22 of a variety of different items 24. At the outset, it should be noted that the respective sizes, shapes, dimensions and relative positions of the various components of the system 20 as depicted in the drawings (and as described herein) are merely exemplary and are being shown for illustrative purposes. Accordingly, in further embodiments, each of the components of the system 20 may take on any other sizes, shapes, dimensions and / or relative positions, now known or later developed, so long as the system 20 is capable of substantially carrying out the functionality described herein.

[0027] As discussed in greater detail below, in at least one embodiment, the system 20 provides a number of benefits as compared to known prior art laser engraving systems, including but not limited to: allowing for single piece personalization of items 24 (i.e., custom laser engraving of a single unit of an item 24 rather than needing to laser engrave a plurality of units of the same item 24 in order to cover expenses); eliminating the need for custom fixturing for each item 24; eliminating the hassle involved with creating artwork and setting up system 20 parameters manually for each item 24; increasing the speed of engraving; allowing for engraving on software definable areas of the items 24 in three dimensions; allowing for handling of drinkware items 24 (and other items 24 having lids) without requiring removal of the lid prior to engraving the item 24; and automatically aligning the custom engraving with any preexisting item 24 branding (i.e., any logos or other branding as placed on the item 24 by the manufacturer), which increases accuracy of the alignment and eliminates manual alignment time needed by an operator / user.

[0028] In at least one embodiment, the robotic arm 26 is a 6-axis arm, which allows the robotic arm 26 to adapt to a variety of items 24 in real time by actuating around, and eliminates the need for custom fixturing for each item 24. In further embodiments, the robotic arm 26 may be any other multi-axis, articulating robotic arm 26, now known or later developed, capable of substantially carrying out the functionality described herein.

[0029] In at least one embodiment, the end effector 28 of the robotic arm 26 is sized and configured for securely grasping a variety of different items 24 having a substantially cylindrical or conical shape in cross-section. However, in further embodiments, the end effector 28 may be configured for securing grasping items 24 having a substantially non-cylindrical or non-conical shape in cross-section, such as square or hexagonal for example. In at least one embodiment, the end effector 28 is removably engaged with a terminal end 34 of the robotic arm 26. In at least one alternate embodiment, the end effector 28 is permanently secured or otherwise integral with the terminal end 34 of the robotic arm 26.

[0030] In at least one embodiment, as best illustrated in Figs. 1 -4, the end effector 28 provides a substantially planar effector body 36. In at least one embodiment, the effector body 36 is substantially disc-shaped; however, in further embodiments, the effector body 36 may take on any other sizes, shapes, dimensions and / or configurations, now known or later developed, so long as the end effector 28 is capable of substantially carrying out the functionality described herein. In at least one embodiment, the effector body 36 is constructed out of aluminum. However, in further embodiments, the effector body 36 may be constructed out of any other materials, now known or later developed, so long as the end effector 28 is capable of substantially carrying out the functionality described herein. In at least one embodiment, the effector body 36 provides an engagement surface 38 sized and configured for being positioned in abutting contact with the outer surface 22 of the item 24 when the item 24 is securely grasped by the end effector 28 (as illustrated in Fig. 4).

[0031] In at least one embodiment, as best illustrated in Figs. 1 and 2, the engagement surface 38 provides an at least one suction aperture 40 positioned substantially at a center 42 of the engagement surface 38, as defined by a longitudinal axis of the effector body 36. In that regard, it should be noted that all references to radial, axial, and circumferential directions and measurements in relation to the end effector 28 and the components thereof refer to the center 42 of the engagement surface 38, unless specified otherwise, and terms such as “inwardly” and “outwardly” generally indicate a lesser or greater radial distance from the center 42 of the engagement surface 38, wherein a radial may be in any direction perpendicular and radiating outward from the center 42 of the engagement surface 38. In at least one embodiment, the at least one suction aperture 40 is in fluid communication with an at least one pneumatic suction device (such as a venturi vacuum generator, for example) configured for creating a suction force via the at least one suction aperture 40 which, in turn, creates a temporary suction engagement between the at least one suction aperture 40 and the outer surface 22 of the item 24, as discussed further below. In at least one embodiment, the engagement surface 38 of the effector body 36 provides a vacuum seal layer 46 configured for compensating for any minor angle variations between the outer surface 22 of the item 24 and the engagement surface 38 of the effector body 36, thereby facilitating the suction engagement between the at least one suction aperture 40 and the outer surface 22 of the item 24. In at least one such embodiment, the vacuum seal layer 46 is constructed out of a silicone or rubber material having a Shore hardness rating of about 40A or less. However, in further embodiments, the vacuum seal layer 46 may be constructed out of other materials, now known or later developed, and / or may have a Shore hardness rating of greater than 40A. In such embodiments, the vacuum seal layer 46 provides corresponding apertures positioned in alignment with the at least one suction aperture 40. In at least one embodiment, the vacuum seal layer 46 is engaged with the engagement surface 38 using an adhesive; however, in further embodiments, the vacuum seal layer 46 maybe engaged with the engagement surface 38 using any other technique or mechanism, now known or later developed.

[0032] In at least one embodiment, as best illustrated in Figs. 3A and 3B, an opposing rear surface 48 of the effector body 36 provides an arm mount 50 configured for securing the end effector 28 to the robotic arm 26. Additionally, in at least one embodiment, the arm mount 50 provides a cavity which seals with the at least one suction aperture 40 using an O-ring. This part also has a threaded hole on its side which connects to a small chamber that joins the cavity described above. In at least one embodiment, a standard M5 fitting screws into this hole which allows for the connection of a 6mm suction air line. This suction airline is in fluid communication with the suction device in order to create suction. In at least one embodiment, the rear surface 48 also provides a cavity to mount a TOOL-ID board 52 and a magnetic encoder board 54.

[0033] In at least one embodiment, the TOOL-ID board 52 is a printed circuit board which consists of a microcontroller, a voltage regulator, a robot tool changer connector, an RS485 transceiver, a mezzanine board connector, and indicator LEDs. The purpose of the TOOL-ID board 52 is for identification of the type, serial number, and version of the end effector 28, which allows the controller of the system 20 to identify the end effector 28 and verify its legitimacy. It’s also used for detecting the angle of the gripper arms 58 (discussed below) for verification of correct gripping and diameter of the item 24 being handled. The TOOL-ID board 52 gets its power from the robot tool changer connector which is connected to the tool flange of the robotic arm 26. A voltage regulator is used to bring the standard supply voltage of the robotic arm 26 down to the voltage rails needed for the micro controller and other components of the TOOL-ID board 52 to use. The microcontroller uses UART interface to communicate with the robotic arm 26 controller or external controller using the RS485 transceiver on board. The microcontroller is also connected to the magnetic encoder described below. The firmware running on the micro controller contains code to: allow saving information such as tool identification code, serial number of end effector 28, and version of the end effector 28; collect information from the encoder and button on the encoder board; control status and power LEDs on the TOOL-ID board 52; and communicate and relay information to the robotic arm 26 and / or external controller using the RS485 communication bus.

[0034] In at least one embodiment, the magnetic encoder board 54 is a printed circuit board which consists of a magnetic encoder IC, a button, and a mezzanine connector. The mezzanine connector interconnects the magnetic encoder board 54 with the TOOL-ID board 52 for power and communication. The main purpose of the button is to allow the service technician and operator to trigger different modes and actions for the robotic arm 26 and end effector 28. Such actions can involve putting the robotic arm 26 into different supported modes, turning on / off thesuction lines, etc. The purpose of the magnetic encoder board 54 is to sense the angle of the gripper arms 58 for diameter and proper gripping detection.

[0035] In at least one embodiment, the effector body 36 further provides a centering mechanism 56 configured for ensuring the item 24 is substantially axially aligned with the center 42 of the engagement surface 38 prior to the outer surface 22 of the item 24 being engaged with the engagement surface 38 via the at least one suction aperture 40. In at least one embodiment, the centering mechanism 56 provides a plurality of radially arranged rotatable gripper arms 58 pivotally mounted on or adjacent to the engagement surface 38, about a perimeter of the effector body 36, and radially arranged about the center 42 of the engagement surface 38. In at least one embodiment, the gripper arms 58 are oriented so as to lie and selectively pivot in a plane that is substantially parallel with the engagement surface 38, with the gripper arms 58 configured for moving between one of an open position (Fig. 1 ) - wherein the gripper arms 58 are rotated outwardly away from the center 42 of the engagement surface 38 - and a closed position (Figs. 2) - wherein the gripper arms 58 are rotated inwardly toward the center 42 of the engagement surface 38, such that the gripper arms 58 come into abutting contact with the outer surface 22 of the item 24 (Figs. 4). Accordingly, terminal ends of the gripper arms 58 cooperate to define an imaginary receiving boundary 60 having a receiving diameter D1 (Fig. 2) that is sized for approximating an outer diameter D2 (Fig. 4) of the item 24. Additionally, because the gripper arms 58 move between the open and closed positions, the gripper arms 58 are capable of being selectively rotated inwardly and outwardly relative to the center 42 of the engagement surface 38, thereby allowing the receiving diameter D1 to be selectively adjusted in order to accommodate a wide range of items 24 having varying outer diameters D2. In at least one embodiment, the gripper arms 58 are moved between the open and closed positions using pneumatic actuation. However, in further embodiments, the gripper arms 58 may be moved between the open and closed positions using any other techniques or mechanisms, now known or later developed, so long as the gripper arms 58 are capable of substantially carrying out the functionality described herein.

[0036] In at least one embodiment, the gripper arms 58 are pivotally engaged with the effector body 36 using pivot pins 62, which extend through the effector body 36 and engage with corresponding lever arms 64 at the rear surface 48 of the effector body 36. In at least one embodiment, a low-friction disc 66 - constructed out of a low-friction material, such as nylon for example - is positioned on the rear surface 48 of the effector body 36 and selectively rotatable relative to the rear surface 48 of the effector body 36. In such embodiments, the lever arms 64 are linked and driven using the low-friction disc 66. In at least one embodiment, the low-friction disc 66 provides a slot within which a lever arm bearing 68 is positioned for each lever arm 64. When the low-friction disc 66 is rotated, it results in rotating the lever arms 64. Since all leverarms 64 are mounted to the same low-friction disc 66, when the low-friction disc 66 is rotated, all gripper arms 58 will simultaneously move between the open and closed positions. In addition, in at least one embodiment, there is a mounting hole on both the low-friction disc 66 and the rear surface 48 of the effector body 36 which are used for installing an actuating mechanism 70 used to actuate the gripper arms 58 (such as a pneumatic actuator, in at least one embodiment).

[0037] In at least one embodiment, the gripper arms 58 are configured for moving between the open and closed positions in unison, such that the receiving boundary 60 is substantially coaxially aligned with the center 42 of the engagement surface 38 which, in turn, ensures that the item 24 is also substantially coaxially aligned with the center 42 of the engagement surface 38; thereby ensuring proper positioning of the outer surface 22 of the item 24 relative to the at least one suction aperture 40 when the item 24 is inserted within the receiving boundary 60 during use of the system 20. In at least one embodiment, the centering mechanism 56 provides five radially spaced apart gripper arms 58; however, in further embodiments, the centering mechanism 56 provides less than five gripper arms 58 or more than five gripper arms 58. In at least one embodiment, the gripper arms 58 have a shape that corresponds to a shape of the effector body 36 - such as an arcuate shape as illustrated in the drawings, for example. However, in further embodiments, the gripper arms 58 may have a shape that does not correspond to the shape of the effector body 36. Additionally, in further embodiments, the gripper arms 58 may take on any other sizes, shapes, dimensions, configurations, quantities and or relative positions, now known or later developed, so long as the gripper arms 58 are capable of substantially carrying out the functionality described herein.

[0038] In at least one embodiment, the terminal end of each gripper arm 58 provides a rotatable friction wheel 72 positioned and configured for being in frictional rolling contact with the outer surface 22 of the item 24 when the gripper arms 58 are in the closed position, so as to prevent the gripper arms 58 from scratching or otherwise damaging the outer surface 22 of the item 24. In at least one embodiment, the friction wheels 72 are spring-biased so as to reduce the frictional forces between the friction wheels 72 and the outer surface 22 of the item 24.

[0039] In at least one embodiment, as illustrated in Figs. 5-9, during use of the system 20, the end effector 28 is utilized in the following series of steps. First, the item 24 is oriented such that a relatively flat portion of the outer surface 22 of the item 24 (such as a bottom surface 74 of the item 24, for example) is facing the engagement surface 38 of the end effector 28 (Fig. 5). The robotic arm 26 then positions the engagement surface 38 of the end effector 28 into linear alignment with the item 24, such that the item 24 is substantially axially aligned with the center 42 of the engagement surface 38 (Fig. 6). With the gripper arms 58 in the open position, therobotic arm 26 moves the engagement surface 38 of the effector body 36 into abutting contact with the outer surface 22 of the item 24 - such that the outer surface 22 of the item 24 is positioned over the at least one suction aperture 40. The robotic arm 26 creates a small separation (typically a few millimeters) between the engagement surface 38 of the effector body 36 and the outer surface 22 of the item 24 - at which point the gripper arms 58 are moved into the closed position (Fig. 7), thereby centering the item 24 relative to the center 42 of the engagement surface 38. The robotic arm 26 moves the engagement surface 38 of the effector body 36 back into abutting contact with the outer surface 22 of the item 24, and the at least one suction device creates a suction engagement between the at least one suction aperture 40 and the outer surface 22 of the item 24. The gripper arms 58 are moved back into the open position, and the robotic arm 26 picks up the item 24 (Fig. 8) and transports the item 24 to the laser module 32 (Fig. 9) to be engraved, as discussed further below.

[0040] As mentioned above, in at least one embodiment, the system 20 further provides an improved item conveyor 30 capable of supporting a variety of different items 24 thereon and moving said items 24 to and from the robotic arm 26 during use of the system 20, as discussed further below. In at least one embodiment, the item conveyor 30 is configured as a conveyor carousel 76; however, in further embodiments, the item conveyor 30 may take on any other configurations, now known or later developed (such as a conveyor belt, for example), so long as the item conveyor 30 is capable of substantially carrying out the functionality described herein. In at least one embodiment, the conveyor carousel 76 provides a circular, substantially planar carousel base 78 configured for selectively rotating relative to the robotic arm 26, an at least one perpendicularly oriented carousel divider 80 engaged with the carousel base 78 and configured for dividing the carousel base 78 into two or more carousel sections 82, and an item receiver 84 positioned within the carousel base 78 in each of the carousel sections 82. In at least one embodiment, the at least one carousel divider 80 is further configured for providing protective shielding from the laser module 32 while an item 24 is being laser engraved, thereby protecting both the user as well as any additional items 24 positioned on the conveyor carousel 76, as discussed further below. In at least one embodiment, the at least one carousel divider 80 is constructed out of an acrylic or polycarbonate material capable of blocking any laser radiation from the laser module 32 during use of the system 20; however, in further embodiments, any other materials (or combinations of materials), now known or later developed, may be substituted, so long as the at least one carousel divider 80 is capable of substantially carrying out the functionality described herein. In at least one embodiment, the conveyor carousel 76 further provides a drive mechanism 86 configured for selectively rotating the carousel base 78 during use of the system 20, as also discussed further below.

[0041] In at least one embodiment, each item receiver 84 is removably engaged with the corresponding one of the carousel sections 82. In at least one such embodiment, each of the carousel sections 82 provides a receiver aperture 88 sized and configured for removably receiving an item receiver 84 therewithin. In at least one embodiment, as best illustrated in Figs. 10 and 11 , each receiver aperture 88 provides an at least one aperture engagement mechanism 90 that is positioned and configured for removable engagement with a corresponding at least one receiver engagement mechanism 92 positioned on the corresponding item receiver 84. In at least one embodiment, the at least one aperture engagement mechanism 90 and receiver engagement mechanism 92 cooperate to assist in preventing the item receiver 84 from becoming unintentionally disengaged from the receiver aperture 88 during use of the system 20. Additionally, in at least one embodiment, as illustrated in Fig. 13, the at least one aperture engagement mechanism 90 and receiver engagement mechanism 92 further cooperate to maintain a proper rotational orientation of the item receiver 84 relative to the receiver aperture 88 and corresponding carousel section 82 during use of the system 20, as discussed further below. In at least one embodiment, the at least one aperture engagement mechanism 90 and receiver engagement mechanism 92 are magnets; however, in further embodiments, the at least one aperture engagement mechanism 90 and receiver engagement mechanism 92 may be any other structure or mechanism, now known or later developed, capable of creating a removable engagement between the item receiver 84 and receiver aperture 88 - including but in no way limited to threading, adhesives, buttons, snaps, hook-and-loop material, etc. Additionally, in further embodiments, the at least one aperture engagement mechanism 90 and receiver engagement mechanism 92 may take on any other sizes, shapes, dimensions, quantities, configurations and / or relative positions, now known or later developed, so long as the conveyor carousel 76 is capable of substantially carrying out the functionality described herein. In at least one embodiment, an outer surface of the item receiver 84 provides a keyed surface that is configured for indexing within a corresponding keyed shape of the receiver aperture 88, with the keyed shape of the receiver aperture 88 ensuring a proper rotational orientation of the item receiver 84 relative to the receiver aperture 88 and corresponding carousel section 82 when the item receiver 84 is inserted within the receiver aperture 88.

[0042] In at least one embodiment, as best illustrated in Figs. 11 and 12, each item receiver 84 provides a receiver body 94 configured for being inserted within a receiver aperture 88 of the carousel base 78. In at least one embodiment, the receiver body 94 provides an item adapter 96 sized and configured for removably receiving a portion of the item 24 therewithin. In at least one such embodiment, where the flat portion of the outer surface 22 of the item 24 to be engaged by the end effector 28 is a lower end 98 of the item 24 (Figs. 4-9), the item adapter 96 is shaped and configured for removably receiving an opposing upper end 100 of the item 24.Thus, the at least one item receiver 84 is positioned and configured for supporting the item 24 in an orientation that allows the end effector 28 to engage the flat portion of the outer surface 22 of the item 24, as discussed above. Furthermore, in embodiments where the item receiver 84 is configured for supporting the item 24 in an upside-down orientation as illustrated in Figs. 4-9, and the item 24 is a drinkware item 24 (or another item 24 having a lid), the item receiver 84 is capable of supporting the upper end 100 of the item 24 with the lid still engaged (i.e., there is no need to remove the lid of the item 24 prior to laser engraving the item 24) which, in turn, eliminates any additional time that would otherwise be required to remove the lid prior to laser engraving the item 24, then re-engaging the lid after laser engraving the item 24. In at least one embodiment, the item adapter 96 is permanently engaged or otherwise integral with the receiver body 94. In at least one alternate embodiment, the item adapter 96 is removably insertable within the receiver body 94. In at least one such alternate embodiment, each of the item adapter 96 and receiver body 94 may provide corresponding engagement mechanisms to assist in preventing the item adapter 96 from becoming unintentionally disengaged from the receiver body 94 during use of the system 20, similar to the at least one aperture engagement mechanism 90 and receiver engagement mechanism 92 discussed above.

[0043] In at least one embodiment, while each item adapter 96 of the item receivers 84 is custom configured based on the shape of the item 24 that the item adapter 96 is designed to receive and support (such that each item receiver 84 might ultimately have a different item adapter 96, in at least one embodiment), the receiver body 94 of each item receiver 84 has a uniform shape and outer diameter D2 so as to be removably engageable with any of the receiver apertures 88 of the carousel base 78. This allows for any item receiver 84 to be quickly and easily swapped in and out of the same carousel base 78, by virtue of the uniform shape and configuration of the receiver body 94, to accommodate the specific items 24 (or combinations of items 24) to be laser engraved at any given time.

[0044] As mentioned above, in at least one embodiment, the system 20 further provides a laser module 32 capable of laser engraving the outer surface 22 of a variety of different items 24. In at least one embodiment, the laser module 32 provides a laser 102 that is one of a Co2, UV, fiber, or green laser capable of laser engraving the outer surface 22 of the item 24; however, in further embodiments, other types of suitable lasers may be substituted. In at least one embodiment, the laser module 32 uses a proprietary field programmable gate array ( “FPGA”) based controller laser interface module (“LIM”) which helps serialize all the sensors and signals into a single data cable, monitors safety of the system 20 and sensors, controls and adapts to multiple types of laser sources, controls and adapts to multiple types of 2- or 3-axis scan heads, and provides custom designed mirror mounts which allows for easily calibrating the laser 102. Additionally, in at least one embodiment, the custom interface for the LIM reducessystem 20 wiring complexities and increases future laser head expandability without the need to change hardware design. In at least one embodiment, the laser module 32 further provides an at least one machine vision camera 104 positioned and configured for assisting the robotic arm 26 with aligning the outer surface 22 of the item 24 with the laser 102, as discussed further below.

[0045] In at least one such embodiment, as illustrated in Figs. 14-16, each of the laser module 32, robotic arm 26 and item conveyor 30 are positioned within a housing 106 so as to provide a protective shielding between the components of the system 20 and the operator / user of the system 20 - particularly with respect to the laser radiation produced by the laser module 32. In at least one embodiment, the housing 106 provides an at least one access door 108 configured for providing selective access to the item conveyor 30 while also providing protective shielding from the laser module 32. In at least one embodiment, the at least one access door 108 is constructed out of an acrylic or polycarbonate material capable of blocking any laser radiation from the laser module 32 during use of the system 20; however, in further embodiments, any other materials (or combinations of materials), now known or later developed, may be substituted, so long as the at least one access door 108 is capable of substantially carrying out the functionality described herein. In at least one embodiment, the at least one access door 108 is configured for being automatically opened and closed by the system 20 to allow the user to swap item receivers 84 and / or load / unload items 24 when the system 20 determines that it is safe to do so. Additionally, in at least one embodiment, the conveyor carousel 76 is configured for selectively rotating in pre-defined increments so as to allow access to one or more of the carousel sections 82 (and, in turn, the corresponding item receivers 84) via the access door 108, while the at least one carousel divider 80 creates a protective barrier between the access door 108 and the laser module 32. In at least one embodiment, the system 20 is configured for only rotating the conveyor carousel 76 when the access door 108 is closed. Accordingly, in such embodiments, the system 20 provides at least one protective barrier between the user and the laser module 32 at all times during use of the system 20. It should be noted that the housing 106 depicted in the drawings is merely exemplary and shown for illustrative purposes. In further embodiments, the housing 106 (along with the various components of the housing 106) may take on any other sizes, shapes, dimensions and / or configurations, now known or later developed - dependent at least in part on the types of items 24 to be laser engraved - so long as the system 20 is capable of substantially carrying out the functionality described herein.

[0046] In at least one embodiment, during use of the system 20, the at least one item 24 is laser engraved using the following series of steps. First, in at least one embodiment, the user uses available machine interfaces (such as barcode scanner, HMI, apps, etc.) to call a system 20 job file which contains information regarding the item(s) 24 to be laser engraved such as aheight, a diameter, a 3D model of the shape, an engravable area, a design to be laser engraved, etc. The user then inserts the appropriate item receiver(s) 84 into the receiver aperture(s) 88 of the conveyor carousel 76. The user next positions a first item 24 in the at least one item receiver 84 that is currently accessible via the access door 108. Upon the system 20 detecting the presence of the item 24 within the item receiver 84 (or, alternatively, upon the user manually signaling to the system 20 that the item 24 has been positioned within the item receiver 84 - such as by pressing a button, for example), the system 20 rotates the conveyor carousel 76 so as to move the first item 24 into position relative to the robotic arm 26. In at least one embodiment, rotating the conveyor carousel 76 so as to move the first item 24 into position relative to the robotic arm 26 also simultaneously rotates a further one of the item receivers 84 so as to be accessible via the access door 108, thereby allowing the user to position a subsequent item 24 in said item receiver 84. In at least one embodiment, the system 20 determines whether the end effector 28 of the robotic arm 26 is compatible with the first item 24. In at least one such embodiment, upon determining that the end effector 28 is not compatible with the first item 24, the system 20 alerts the user so that a compatible end effector 28 can be installed. In at least one alternate embodiment, the system 20 is capable of automatically installing the compatible end effector 28 on the robotic arm 26.

[0047] In at least one embodiment, the end effector 28 picks up the item 24 as discussed above (Fig. 8) and transports the item 24 to the laser module 32 (Fig. 9) to be laser engraved. In at least one embodiment, depending on the provided job file, if needed, the robotic arm 26 performs necessary maneuvers to hold the item 24 under the machine vision camera 104. In at least one such embodiment, the robotic arm 26 further performs any necessary alignment procedures using the machine vision camera 104 input so as to properly align the outer surface 22 of the item 24 with the laser 102 - for example, if the outer surface 22 of the item 24 has a manufacturer logo or other pre-existing designs, the machine vision camera 104 assists the robotic arm 26 in positioning the item 24 so that the design to be laser engraved is ideally positioned relative to the pre-existing designs on the item 24. In at least one embodiment, the robotic arm 26 uses a 3D model of the item 24 and other provided information in the job file to perform necessary maneuvers to position a first engravable area of the outer surface 22 of the item 24 at a correct focal distance relative to the laser 102. The laser 102 then laser engraves the desired design onto the outer surface 22 of the item 24. If there are any additional engravable areas on the outer surface 22 of the item 24 to be laser engraved, the robotic arm 26 repositions the item 24 as needed and these laser engraving steps are repeated. Once the laser engraving has been completed, the robotic arm 26 places the item 24 back into the corresponding item receiver 84, and the conveyor carousel 76 is rotated. In at least one embodiment, while these laser engraving steps are being executed, the user is able to load the next item 24 into the next item receiver 84 on the conveyor carousel 76 (via the access door108) so as to queue the next item 24 for laser engraving. Once the conveyor carousel 76 rotates enough times until the first item 24 is once again accessible via the access door 108, the user is able to remove the first item 24, which is now laser engraved. These steps may be repeated until all items 24 have been laser engraved.

[0048] Accordingly, in at least one embodiment, as a result of this process: custom fixturing for every type of item 24 is no longer necessary; the laser module 32 is not held up by a change of fixture; the processes of loading one item 24 and laser engraving another item 24 are now able to occur in parallel, which minimizes laser 102 off time while increasing productivity since the laser 102 is no longer waiting for the operator and fixture changes; the process of laser 102 alignment with the item 24 is now less prone to human error since the machine vision camera 104 and robotic arm 26 are able to handle those steps automatically; the laser engraving process is more consistent and repeatable; and the system 20 is adaptable to more types of items 24 as long as there is an item receiver 84 configured for supporting them.

[0049] Aspects of the present specification may also be described as the following embodiments:

[0050] 1 . A laser engraving system configured for laser engraving an outer surface of an at least one item, the system comprising: a multi-axis robotic arm; an end effector engaged with a terminal end of the robotic arm and configured for secure engagement with the at least one item, the end effector comprising: a substantially planar effector body providing an engagement surface sized and configured for being positioned in abutting contact with the outer surface of the item; the engagement surface providing an at least one suction aperture positioned substantially at a center of the engagement surface, the at least one suction aperture in fluid communication with an at least one suction device configured for creating a suction force via the at least one suction aperture which, in turn, creates a temporary suction engagement between the at least one suction aperture and the outer surface of the item; a centering mechanism configured for ensuring the at least one item is substantially axially aligned with the center of the engagement surface prior to the outer surface of the item being engaged with the engagement surface via the at least one suction aperture, the centering mechanism comprising: a plurality of gripper arms pivotally mounted about a perimeter of the effector body and radially arranged about the center of the engagement surface, the gripper arms configured for moving between one of an open position - wherein the gripper arms are rotated outwardly away from the center of the engagement surface - and a closed position - wherein the gripper arms are rotated inwardly toward the center of the engagement surface and cooperate to define an imaginary receiving boundary substantially coaxially aligned with the center of the engagement surface and having a receiving diameter that approximates an outer diameter of the at least oneitem, such that the gripper arms come into abutting contact with the outer surface of the at least one item so as to maintain the at least one item in an orientation that is substantially perpendicular to the center of the engagement surface, with a central longitudinal axis of the at least one item being substantially coaxially aligned with the center of the engagement surface; an item conveyor configured for moving the at least one item to and from the robotic arm; and a laser module configured for laser engraving the outer surface of the at least one item; whereby, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

[0051] 2. The laser engraving system according to embodiment 1 , wherein the robotic arm is a 6-axis arm.

[0052] 3. The laser engraving system according to embodiments 1-2, wherein the end effector is removably engaged with the terminal end of the robotic arm.

[0053] 4. The laser engraving system according to embodiments 1 -3, wherein the effector body is substantially disc-shaped.

[0054] 5. The laser engraving system according to embodiments 1 -4, wherein the effector body is constructed out of aluminum.

[0055] 6. The laser engraving system according to embodiments 1 -5, wherein the engagement surface of the effector body provides a vacuum seal layer positioned between the engagement surface and the outer surface of the item, thereby facilitating the suction engagement between the at least one suction aperture and the outer surface of the item.

[0056] 7. The laser engraving system according to embodiments 1 -6, wherein the vacuum seal layer is constructed out of a silicone or rubber material having a Shore hardness rating of about 40A or less.

[0057] 8. The laser engraving system according to embodiments 1 -7, wherein the vacuum seal layer provides an at least one corresponding aperture positioned in alignment with the at least one suction aperture.

[0058] 9. The laser engraving system according to embodiments 1 -8, wherein an opposing rear surface of the effector body provides an arm mount configured for securing the end effector to the robotic arm.

[0059] 10. The laser engraving system according to embodiments 1-9, wherein the at least one suction device is mounted to an opposing rear surface of the effector body.

[0060] 11. The laser engraving system according to embodiments 1 -10, wherein the gripper arms are oriented so as to lie and selectively pivot in a plane that is substantially parallel with the engagement surface.

[0061] 12. The laser engraving system according to embodiments 1-11 , wherein the centering mechanism provides five radially spaced apart gripper arms.

[0062] 13. The laser engraving system according to embodiments 1 -12, wherein the gripper arms have a shape that corresponds to a shape of the effector body.

[0063] 14. The laser engraving system according to embodiments 1 -13, wherein the gripper arms have a substantially arcuate shape.

[0064] 15. The laser engraving system according to embodiments 1-14, wherein a terminal end of each gripper arm provides a rotatable friction wheel positioned and configured for being in frictional rolling contact with the outer surface of the item when the gripper arms are in the closed position.

[0065] 16. The laser engraving system according to embodiments 1 -15, wherein the friction wheels are spring-biased so as to reduce the frictional forces between the friction wheels and the outer surface of the item when the gripper arms are in the closed position.

[0066] 17. The laser engraving system according to embodiments 1 -16, wherein the item conveyor is a conveyor carousel comprising: a circular, substantially planar carousel base configured for selectively rotating relative to the robotic arm; an at least one perpendicularly oriented carousel divider engaged with the carousel base for dividing the carousel base into two or more carousel sections; an item receiver positioned within the carousel base in each of the carousel sections; and a drive mechanism configured for selectively rotating the carousel base.

[0067] 18. The laser engraving system according to embodiments 1 -17, wherein the at least one carousel divider is constructed out of an acrylic or polycarbonate material capable of blocking any laser radiation from the laser module.

[0068] 19. The laser engraving system according to embodiments 1-18, wherein each item receiver is removably positioned within the corresponding one of the carousel sections.

[0069] 20. The laser engraving system according to embodiments 1 -19, wherein each of the carousel sections provides a receiver aperture sized and configured for removably receiving the corresponding item receiver therewithin.

[0070] 21. The laser engraving system according to embodiments 1-20, wherein each receiver aperture provides an at least one aperture engagement mechanism that is positioned and configured for removable engagement with a corresponding at least one receiver engagement mechanism positioned on the corresponding item receiver.

[0071] 22. The laser engraving system according to embodiments 1 -21 , wherein the at least one aperture engagement mechanism and receiver engagement mechanism cooperate to maintain a proper rotational orientation of the item receiver relative to the corresponding receiver aperture.

[0072] 23. The laser engraving system according to embodiments 1 -22, wherein the at least one aperture engagement mechanism and receiver engagement mechanism are magnets.

[0073] 24. The laser engraving system according to embodiments 1-23, wherein each item receiver comprises: a receiver body configured for being inserted within a corresponding receiver aperture of the carousel base; and an item adapter sized and configured for removably receiving a portion of the at least one item therewithin so as to maintain the at least one item in an orientation that is substantially perpendicular to the carousel base.

[0074] 25. The laser engraving system according to embodiments 1 -24, wherein the item adapter of at least one of the item receivers is configured for removably receiving an upper end of the at least one item, thereby supporting the at least one item in an orientation that allows the end effector of the robotic arm to securely engage an opposing lower end of the at least one item.

[0075] 26. The laser engraving system according to embodiments 1 -25, wherein the item adapter of at least one of the item receivers is removably insertable within the corresponding receiver body.

[0076] 27. The laser engraving system according to embodiments 1-26, wherein the receiver body of each item receiver has a uniform shape and outer diameter so as to be removably engageable with any of the receiver apertures of the carousel base.

[0077] 28. The laser engraving system according to embodiments 1 -27, wherein the laser module comprises: a laser capable of laser engraving the outer surface of the item; and an at least one machine vision camera positioned and configured for assisting the robotic arm with aligning the outer surface of the item with the laser.

[0078] 29. The laser engraving system according to embodiments 1 -28, wherein the laser is one of a Co2, UV, fiber, or green laser.

[0079] 30. The laser engraving system according to embodiments 1 -29, wherein each of the robotic arm, item conveyor and laser module are positioned within a protective housing.

[0080] 31 . The laser engraving system according to embodiments 1 -30, wherein the housing provides an at least one access door configured for providing selective access to the item conveyor while also providing protective shielding from the laser module.

[0081] 32. The laser engraving system according to embodiments 1 -31 , wherein the at least one access door is constructed out of an acrylic or polycarbonate material capable of blocking any laser radiation from the laser module.

[0082] 33. A laser engraving system configured for laser engraving an outer surface of an at least one item, the system comprising: a multi-axis robotic arm; an end effector engaged with a terminal end of the robotic arm and configured for secure engagement with the at least one item; an item conveyor configured for moving the at least one item to and from the robotic arm, the item conveyor comprising: a circular, substantially planar carousel base configured for selectively rotating relative to the robotic arm; an at least one perpendicularly oriented carousel divider engaged with the carousel base for dividing the carousel base into two or more carousel sections; and an item receiver removably positioned within the carousel base in each of the carousel sections, each item receiver comprising: a receiver body configured for being inserted within a corresponding receiver aperture of the carousel base; and an item adapter sized and configured for removably receiving a portion of the at least one item therewithin so as to maintain the at least one item in an orientation that is substantially perpendicular to the carousel base; and a laser module configured for laser engraving the outer surface of the at least one item; whereby, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

[0083] 34. A laser engraving system configured for laser engraving an outer surface of an at least one item, the system comprising: a multi-axis robotic arm; an end effector engaged with a terminal end of the robotic arm and configured for secure engagement with the at least one item, the end effector comprising: a substantially planar effector body providing an engagement surface sized and configured for being positioned in abutting contact with the outer surface of the item; the engagement surface providing an at least one suction aperture positioned substantially at a center of the engagement surface, the at least one suction aperture in fluidcommunication with an at least one suction device configured for creating a suction force via the at least one suction aperture which, in turn, creates a temporary suction engagement between the at least one suction aperture and the outer surface of the item; a centering mechanism configured for ensuring the at least one item is substantially axially aligned with the center of the engagement surface prior to the outer surface of the item being engaged with the engagement surface via the at least one suction aperture, the centering mechanism comprising: a plurality of gripper arms pivotally mounted about a perimeter of the effector body and radially arranged about the center of the engagement surface, the gripper arms configured for moving between one of an open position - wherein the gripper arms are rotated outwardly away from the center of the engagement surface - and a closed position - wherein the gripper arms are rotated inwardly toward the center of the engagement surface and cooperate to define an imaginary receiving boundary substantially coaxially aligned with the center of the engagement surface and having a receiving diameter that approximates an outer diameter of the at least one item, such that the gripper arms come into abutting contact with the outer surface of the at least one item so as to maintain the at least one item in an orientation that is substantially perpendicular to the center of the engagement surface, with a central longitudinal axis of the at least one item being substantially coaxially aligned with the center of the engagement surface; an item conveyor configured for moving the at least one item to and from the robotic arm, the item conveyor comprising: a circular, substantially planar carousel base configured for selectively rotating relative to the robotic arm; an at least one perpendicularly oriented carousel divider engaged with the carousel base for dividing the carousel base into two or more carousel sections; and an item receiver removably positioned within the carousel base in each of the carousel sections, each item receiver comprising: a receiver body configured for being inserted within a corresponding receiver aperture of the carousel base; and an item adapter sized and configured for removably receiving a portion of the at least one item therewithin so as to maintain the at least one item in an orientation that is substantially perpendicular to the carousel base; a laser module configured for laser engraving the outer surface of the at least one item, the laser module comprising: a laser capable of laser engraving the outer surface of the item; and an at least one machine vision camera positioned and configured for assisting the robotic arm with aligning the outer surface of the item with the laser; and a protective housing within which each of the robotic arm, item conveyor and laser module is positioned; whereby, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

[0084] In closing, regarding the exemplary embodiments of the present invention as shown and described herein, it will be appreciated that an improved laser engraving system andassociated methods of use are disclosed. Because the principles of the invention may be practiced in a number of configurations beyond those shown and described, it is to be understood that the invention is not in any way limited by the exemplary embodiments, but is generally directed to a laser engraving system and is able to take numerous forms to do so without departing from the spirit and scope of the invention. It will also be appreciated by those skilled in the art that the present invention is not limited to the particular geometries and materials of construction disclosed, but may instead entail other functionally comparable structures or materials, now known or later developed, without departing from the spirit and scope of the invention.

[0085] Certain embodiments of the present invention are described herein, including the best mode known to the inventor(s) for carrying out the invention. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor(s) expect skilled artisans to employ such variations as appropriate, and the inventor(s) intend for the present invention to be practiced otherwise than specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described embodiments in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

[0086] Groupings of alternative embodiments, elements, or steps of the present invention are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other group members disclosed herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

[0087] Unless otherwise indicated, all numbers expressing a characteristic, item, quantity, parameter, property, term, and so forth used in the present specification and claims are to be understood as being modified in all instances by the terms “about” and “approximately.” As used herein, the terms “about” and “approximately” mean that the characteristic, item, quantity, parameter, property, or term so qualified encompasses a range of plus or minus ten percent above and below the value of the stated characteristic, item, quantity, parameter, property, or term. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims,each numerical indication should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and values setting forth the broad scope of the invention are approximations, the numerical ranges and values set forth in the specific examples are reported as precisely as possible. Any numerical range or value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Recitation of numerical ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate numerical value falling within the range. Unless otherwise indicated herein, each individual value of a numerical range is incorporated into the present specification as if it were individually recited herein. Similarly, as used herein, unless indicated to the contrary, the term “substantially” is a term of degree intended to indicate an approximation of the characteristic, item, quantity, parameter, property, or term so qualified, encompassing a range that can be understood and construed by those of ordinary skill in the art, or at least encompassing a range of plus or minus ten percent above and below the value of the stated characteristic, item, quantity, parameter, property, or term.

[0088] Use of the terms “may” or “can” in reference to an embodiment or aspect of an embodiment also carries with it the alternative meaning of “may not" or “cannot.” As such, if the present specification discloses that an embodiment or an aspect of an embodiment may be or can be included as part of the inventive subject matter, then the negative limitation or exclusionary proviso is also explicitly meant, meaning that an embodiment or an aspect of an embodiment may not be or cannot be included as part of the inventive subject matter. In a similar manner, use of the term “optionally” in reference to an embodiment or aspect of an embodiment means that such embodiment or aspect of the embodiment may be included as part of the inventive subject matter or may not be included as part of the inventive subject matter. Whether such a negative limitation or exclusionary proviso applies will be based on whether the negative limitation or exclusionary proviso is recited in the claimed subject matter.

[0089] The terms “a,” “an,” “the” and similar references used in the context of describing the present invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, ordinal indicators - such as “first,” “second,” “third,” etc. - for identified elements are used to distinguish between the elements, and do not indicate or imply a required or limited number of such elements, and do not indicate a particular position or order of such elements unless otherwise specifically stated. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the present invention and does not pose alimitation on the scope of the invention otherwise claimed. No language in the present specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0090] When used in the claims, whether as filed or added per amendment, the open-ended transitional term “comprising” (along with equivalent open-ended transitional phrases thereof such as “including,” “containing” and “having”) encompasses all the expressly recited elements, limitations, steps and / or features alone or in combination with un-recited subject matter; the named elements, limitations and / or features are essential, but other unnamed elements, limitations and / or features may be added and still form a construct within the scope of the claim. Specific embodiments disclosed herein may be further limited in the claims using the closed- ended transitional phrases “consisting of” or “consisting essentially of” in lieu of or as an amendment for “comprising.” When used in the claims, whether as filed or added per amendment, the closed-ended transitional phrase “consisting of” excludes any element, limitation, step, or feature not expressly recited in the claims. The closed-ended transitional phrase “consisting essentially of” limits the scope of a claim to the expressly recited elements, limitations, steps and / or features and any other elements, limitations, steps and / or features that do not materially affect the basic and novel characteristic(s) of the claimed subject matter. Thus, the meaning of the open-ended transitional phrase “comprising” is being defined as encompassing all the specifically recited elements, limitations, steps and / or features as well as any optional, additional unspecified ones. The meaning of the closed-ended transitional phrase “consisting of” is being defined as only including those elements, limitations, steps and / or features specifically recited in the claim, whereas the meaning of the closed-ended transitional phrase “consisting essentially of” is being defined as only including those elements, limitations, steps and / or features specifically recited in the claim and those elements, limitations, steps and / or features that do not materially affect the basic and novel characteristic(s) of the claimed subject matter. Therefore, the open-ended transitional phrase “comprising” (along with equivalent open-ended transitional phrases thereof) includes within its meaning, as a limiting case, claimed subject matter specified by the closed-ended transitional phrases “consisting of” or “consisting essentially of.” As such, embodiments described herein or so claimed with the phrase “comprising” are expressly or inherently unambiguously described, enabled and supported herein for the phrases “consisting essentially of” and “consisting of.”

[0091] Any claims intended to be treated under 35 U.S.C. §112(f) will begin with the words “means for,” but use of the term “for” in any other context is not intended to invoke treatment under 35 U.S.C. §112(f). Accordingly, Applicant reserves the right to pursue additional claims after filing this application, in either this application or in a continuing application.

[0092] It should be understood that any methods disclosed herein, along with the order in which the respective elements of any such method are performed, are purely exemplary. Depending on the implementation, they may be performed in any order or in parallel, unless indicated otherwise in the present disclosure.

[0093] All patents, patent publications, and other publications referenced and identified in the present specification are individually and expressly incorporated herein by reference in their entirety for the purpose of describing and disclosing, for example, the compositions and methodologies described in such publications that might be used in connection with the present invention. These publications are provided solely for their disclosure prior to the filing date of the present application. Nothing in this regard should be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention or for any other reason. All statements as to the date or representation as to the contents of these documents are based on the information available to the applicants and does not constitute any admission as to the correctness of the dates or contents of these documents.

[0094] While aspects of the invention have been described with reference to at least one exemplary embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims and it is made clear, here, that the inventor(s) believe that the claimed subject matter is the invention.

Claims

CLAIMSWhat is claimed is:1 . A laser engraving system configured for laser engraving an outer surface of an at least one item, the system comprising: a multi-axis robotic arm; an end effector engaged with a terminal end of the robotic arm and configured for secure engagement with the at least one item, the end effector comprising: a substantially planar effector body providing an engagement surface sized and configured for being positioned in abutting contact with the outer surface of the item; the engagement surface providing an at least one suction aperture positioned substantially at a center of the engagement surface, the at least one suction aperture in fluid communication with an at least one suction device configured for creating a suction force via the at least one suction aperture which, in turn, creates a temporary suction engagement between the at least one suction aperture and the outer surface of the item; a centering mechanism configured for ensuring the at least one item is substantially axially aligned with the center of the engagement surface prior to the outer surface of the item being engaged with the engagement surface via the at least one suction aperture, the centering mechanism comprising: a plurality of gripper arms pivotally mounted about a perimeter of the effector body and radially arranged about the center of the engagement surface, the gripper arms configured for moving between one of an open position - wherein the gripper arms are rotated outwardly away from the center of the engagement surface - and a closed position - wherein the gripper arms are rotated inwardly toward the center of the engagement surface and cooperate to define an imaginary receiving boundary substantially coaxially aligned with the center of the engagement surface and having a receiving diameter that approximates an outer diameter of the at least one item, such that the gripper arms come into abutting contact with the outer surface of the at least one item so as to maintain the at least one item in an orientation that is substantially perpendicular to the center of the engagement surface, with a central longitudinal axis of the at least one item being substantially coaxially aligned with the center of the engagement surface; an item conveyor configured for moving the at least one item to and from the robotic arm; and a laser module configured for laser engraving the outer surface of the at least one item;whereby, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

2. The laser engraving system of claim 1 , wherein the end effector is removably engaged with the terminal end of the robotic arm.

3. The laser engraving system of claim 1 , wherein the engagement surface of the effector body provides a vacuum seal layer positioned between the engagement surface and the outer surface of the item, thereby facilitating the suction engagement between the at least one suction aperture and the outer surface of the item.

4. The laser engraving system of claim 1 , wherein an opposing rear surface of the effector body provides an arm mount configured for securing the end effector to the robotic arm.

5. The laser engraving system of claim 1 , wherein the at least one suction device is mounted to an opposing rear surface of the effector body.

6. The laser engraving system of claim 1 , wherein the gripper arms are oriented so as to lie and selectively pivot in a plane that is substantially parallel with the engagement surface.

7. The laser engraving system of claim 1 , wherein a terminal end of each gripper arm provides a rotatable friction wheel positioned and configured for being in frictional rolling contact with the outer surface of the item when the gripper arms are in the closed position.

8. The laser engraving system of claim 7, wherein the friction wheels are spring-biased so as to reduce the frictional forces between the friction wheels and the outer surface of the item when the gripper arms are in the closed position.

9. The laser engraving system of claim 1 , wherein the item conveyor is a conveyor carousel comprising: a circular, substantially planar carousel base configured for selectively rotating relative to the robotic arm; an at least one perpendicularly oriented carousel divider engaged with the carousel base for dividing the carousel base into two or more carousel sections; an item receiver positioned within the carousel base in each of the carousel sections; and a drive mechanism configured for selectively rotating the carousel base.

10. The laser engraving system of claim 9, wherein each item receiver is removably positioned within the corresponding one of the carousel sections.

11. The laser engraving system of claim 10, wherein each of the carousel sections provides a receiver aperture sized and configured for removably receiving the corresponding item receiver therewithin.

12. The laser engraving system of claim 11 , wherein each receiver aperture provides an at least one aperture engagement mechanism that is positioned and configured for removable engagement with a corresponding at least one receiver engagement mechanism positioned on the corresponding item receiver.

13. The laser engraving system of claim 11 , wherein each item receiver comprises: a receiver body configured for being inserted within a corresponding receiver aperture of the carousel base; and an item adapter sized and configured for removably receiving a portion of the at least one item therewithin so as to maintain the at least one item in an orientation that is substantially perpendicular to the carousel base.

14. The laser engraving system of claim 13, wherein the item adapter of at least one of the item receivers is configured for removably receiving an upper end of the at least one item, thereby supporting the at least one item in an orientation that allows the end effector of the robotic arm to securely engage an opposing lower end of the at least one item.

15. The laser engraving system of claim 13, wherein the receiver body of each item receiver has a uniform shape and outer diameter so as to be removably engageable with any of the receiver apertures of the carousel base.

16. The laser engraving system of claim 1 , wherein the laser module comprises: a laser capable of laser engraving the outer surface of the item; and an at least one machine vision camera positioned and configured for assisting the robotic arm with aligning the outer surface of the item with the laser.

17. The laser engraving system of claim 1 , wherein each of the robotic arm, item conveyor and laser module are positioned within a protective housing.

18. The laser engraving system of claim 17, wherein the housing provides an at least one access door configured for providing selective access to the item conveyor while also providing protective shielding from the laser module.

19. A laser engraving system configured for laser engraving an outer surface of an at least one item, the system comprising: a multi-axis robotic arm; an end effector engaged with a terminal end of the robotic arm and configured for secure engagement with the at least one item; an item conveyor configured for moving the at least one item to and from the robotic arm, the item conveyor comprising: a circular, substantially planar carousel base configured for selectively rotating relative to the robotic arm; an at least one perpendicularly oriented carousel divider engaged with the carousel base for dividing the carousel base into two or more carousel sections; and an item receiver removably positioned within the carousel base in each of the carousel sections, each item receiver comprising: a receiver body configured for being inserted within a corresponding receiver aperture of the carousel base; and an item adapter sized and configured for removably receiving a portion of the at least one item therewithin so as to maintain the at least one item in an orientation that is substantially perpendicular to the carousel base; and a laser module configured for laser engraving the outer surface of the at least one item; whereby, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

20. A laser engraving system configured for laser engraving an outer surface of an at least one item, the system comprising: a multi-axis robotic arm; an end effector engaged with a terminal end of the robotic arm and configured for secure engagement with the at least one item, the end effector comprising: a substantially planar effector body providing an engagement surface sized and configured for being positioned in abutting contact with the outer surface of the item; the engagement surface providing an at least one suction aperture positioned substantially at a center of the engagement surface, the at least one suction aperture in fluid communication with an at least one suction device configured for creating a suction force via the at least one suction aperture which, in turn, creates a temporary suction engagement between the at least one suction aperture and the outer surface of the item;a centering mechanism configured for ensuring the at least one item is substantially axially aligned with the center of the engagement surface prior to the outer surface of the item being engaged with the engagement surface via the at least one suction aperture, the centering mechanism comprising: a plurality of gripper arms pivotally mounted about a perimeter of the effector body and radially arranged about the center of the engagement surface, the gripper arms configured for moving between one of an open position - wherein the gripper arms are rotated outwardly away from the center of the engagement surface - and a closed position - wherein the gripper arms are rotated inwardly toward the center of the engagement surface and cooperate to define an imaginary receiving boundary substantially coaxially aligned with the center of the engagement surface and having a receiving diameter that approximates an outer diameter of the at least one item, such that the gripper arms come into abutting contact with the outer surface of the at least one item so as to maintain the at least one item in an orientation that is substantially perpendicular to the center of the engagement surface, with a central longitudinal axis of the at least one item being substantially coaxially aligned with the center of the engagement surface; an item conveyor configured for moving the at least one item to and from the robotic arm, the item conveyor comprising: a circular, substantially planar carousel base configured for selectively rotating relative to the robotic arm; an at least one perpendicularly oriented carousel divider engaged with the carousel base for dividing the carousel base into two or more carousel sections; and an item receiver removably positioned within the carousel base in each of the carousel sections, each item receiver comprising: a receiver body configured for being inserted within a corresponding receiver aperture of the carousel base; and an item adapter sized and configured for removably receiving a portion of the at least one item therewithin so as to maintain the at least one item in an orientation that is substantially perpendicular to the carousel base; a laser module configured for laser engraving the outer surface of the at least one item, the laser module comprising: a laser capable of laser engraving the outer surface of the item; and an at least one machine vision camera positioned and configured for assisting the robotic arm with aligning the outer surface of the item with the laser; and a protective housing within which each of the robotic arm, item conveyor and laser module is positioned;whereby, with the at least one item positioned on the item conveyor, said item is moved to the robotic arm, allowing the end effector of the robotic arm to securely engage said item and move said item to the laser module where the outer surface of said item can be laser engraved, after which the robotic arm replaces said item back on the item conveyor.

Images