Coupling System Sensor Monitoring Tool Change Failures

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Solution Overview

Problem

Coupling systems in tool change systems for robots are prone to errors due to incorrect connection, contamination, and damage, especially in frequent use scenarios, where the coupling region represents a weak point and is exposed, leading to potential operational failures.

Innovation Solution

A coupling system with a first coupling part, a second coupling part, and at least one sensor connected to an evaluation unit that can detect measuring signals, allowing for the monitoring of the coupling state and mechanical loading, enabling fault-free coupling and initiating corrective actions such as tool exchange or movement adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If coupling systems are used frequently for tool changes, then productivity is improved, but the coupling region becomes more prone to damage and operational failures

Engineering Contradiction:

Improvetool change frequencyVSAvoidcoupling functionality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The sensor detects coupling status and mechanical loading before damage occurs, allowing preventive maintenance or corrective actions to be taken in advance. The evaluation unit monitors coupling conditions and can trigger warnings or shutdowns before the coupling region suffers actual damage from frequent operations.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If the coupling region is made more exposed to enable frequent tool changes, then ease of operation is improved, but the coupling parts become more vulnerable to contamination and damage

Engineering Contradiction:

Improvetool accessibilityVSAvoidcontamination and damage risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The sensor provides continuous feedback on the coupling status and mechanical loading conditions. The evaluation unit processes this information and can trigger alerts or corrective actions when contamination or damage is detected, allowing the system to respond to harmful factors while maintaining the exposed, accessible coupling design.

Inventive Principle:

Principle #23Feedback

3Reliability

If sensors and evaluation units are added to monitor coupling status, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvecoupling state monitoringVSAvoidsystem structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sensor and evaluation unit enable the coupling system to self-monitor its own status and detect issues autonomously. The system serves itself by automatically detecting coupling problems, mechanical loading conditions, and potential failures without requiring external inspection, thereby improving reliability through self-diagnosis.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS8042408B2Coupling system with a sensor and an evaluation unit

Publication Date: 2011.10.25 STAUBLI TEC SYST

AI summary

The invention relates to a coupling system, a coupling arrangement, a method for mechanically coupling a coupling system and a method for measuring the mechanical loading of a coupling system. The coupling system according to the invention includes a first coupling part, at least one second coupling part, which can be coupled with the first coupling part by way of at least one coupling, and at least one sensor, wherein the first coupling part has an evaluation unit (5), which can be connected to the at least one sensor for sensing measuring signals, and the measuring signals that are sensed by the evaluation unit (5) can be called up by way of the evaluation unit, wherein the coupling in the coupling area can be checked by means of the at least one sensor.