Continuous-Motion End Effector Tool Exchange Without Precise Mounting
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Solution Overview
Problem
Existing tool changers for programmable motion devices are slow, leading to inefficiencies in automated systems, particularly in applications where rapid tool exchange is necessary, such as in logistics and manufacturing, where tools may be simpler and lighter, and precision mounting is not always required.
Innovation Solution
A method for rapid tool exchange on programmable motion devices that involves continuous linear motion, eliminating the need for fine and precise motions, allowing the end effector to remain in uniform motion while exchanging tools by using mechanisms like magnetic coupling, rollers, and exchange devices with serial or parallel arrangements of holders, enabling quick and efficient tool changes without the need for complex dismounting and mounting procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tool changers are used with precise mounting requirements, then manufacturing precision is improved, but tool changing speed deteriorates
Solution Approach 1:
The tool changing process is segmented into two distinct phases: a rapid approach phase where the end effector moves quickly to exchange tools, and a separate precision alignment phase that only occurs when needed. This segmentation allows the system to achieve high speeds during tool exchange while maintaining precision when required, resolving the contradiction between speed and precision.
Solution Approach 2:
The system dynamically adjusts its operation mode based on requirements. During normal tool exchange operations, the system operates in high-speed mode with continuous linear motion. When precision mounting is required, the system transitions to precision mode with fine motion control. This dynamic adaptability allows the system to optimize performance for each specific operation, resolving the speed-precision tradeoff.
2Reliability
If traditional tool changers with latch mechanisms are used, then tool security is improved, but tool changing time increases
Solution Approach 1:
The complex latch mechanism and multi-step securing process are extracted and eliminated from the rapid tool exchange process. Instead, the system uses simple mechanical interfaces with spring-loaded retainers that automatically engage during the continuous linear motion. This extraction of the time-consuming latch mechanism allows tool security to be maintained through simpler, faster means, resolving the contradiction between reliability and time.
Solution Approach 2:
The tool exchange mechanism is designed to be self-actuating during continuous linear motion. The spring-loaded retainers automatically engage and secure tools without requiring external actuation or complex control sequences. This self-service approach eliminates the time delays associated with manual or electronically-controlled latch mechanisms while maintaining tool security, resolving the contradiction between reliability and speed.
3Manufacturing precision
If precise and slow motions are used for tool mounting and dismounting, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The tool mounting and dismounting operations are segmented from the main production workflow. The end effector performs rapid tool exchanges during continuous linear motion without interrupting the production cycle. Precision operations are segregated to only occur when specifically required, rather than being applied to all tool changes. This segmentation allows high-speed operations to dominate the process, improving productivity while maintaining precision when needed.
Solution Approach 2:
The system maintains continuous linear motion during tool exchanges, eliminating idle periods and stop-and-start operations. The tool changing process occurs seamlessly during the continuous movement of the end effector, rather than requiring the system to stop for precision operations. This continuity of useful action maintains high productivity while precision requirements are met through the segmented approach, resolving the contradiction between manufacturing precision and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the time required for tool changes, enhancing the efficiency and speed of automated systems by allowing continuous motion during tool exchange, which is particularly beneficial in applications like order fulfillment and object sortation, where quick adaptation to different tools is essential.
Implementation Method 1
allowing the end effector to remain in uniform motion while exchanging tools by using mechanisms like magnetic coupling
Data Source
Figure 1A~1B
Figure 2A~2E
Figure 3A~3B
AI summary
A method is disclosed of changing a tool on a programmable motion device. The method includes the steps of moving an attachment portion of an end effector of the programmable motion device m a continuous motion; while the attachment portion of the end effector moves in the continuous motion, engaging one of: the attachment portion of the end effector with the tool, or the tool attached to the attachment portion of the end effector with an exchange system, and continuing to move the attachment portion of the end effector in the continuous motion to change a connection status of the attachment portion of the end effector while the attachment portion of the end effector moves in the continuous motion.