Electromagnetic Tool Changer for Fast Robot Tool Release
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Solution Overview
Problem
Conventional tool changers for robots require large structures and subsidiary equipment, leading to high expenses and noise, and they do not efficiently bind or separate tools, nor can they vibrate tools to remove residues effectively.
Innovation Solution
A tool changer system utilizing a magnetic force with a housing, inner core, coil, connecting cores or magnets, and a controller to selectively fasten and separate tools by regulating the current applied to the coil or magnets, allowing for rapid and precise tool changes and vibration at a frequency consistent with the tool's resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pneumatic system is used for tool changing, then the tool changer can bind and separate tools, but the structure becomes large and complex, requiring subsidiary equipment and incurring high expenses and noise
Solution Approach 1:
The patent replaces the pneumatic system with an electromagnetic system. Specifically, it uses an electromagnet (coil and core) to generate magnetic force for binding the tool, and controls separation by reversing the current direction to create repulsive force. This substitution eliminates the need for pneumatic components such as cylinders, valves, and air supply systems, thereby reducing structural complexity and noise while maintaining reliable tool binding and separation capabilities
Solution Approach 2:
The patent changes the physical state and control parameters by using electromagnetic fields instead of pneumatic pressure. By controlling the current magnitude and direction applied to the electromagnet, the system can dynamically adjust the binding force strength and transition between binding and separation states. This parameter-based control simplifies the system structure compared to mechanical pneumatic actuation
2Productivity
If a pneumatic system is used for tool changing, then the tool changer can perform tool changes, but noise is generated and expenses increase
Solution Approach 1:
The patent replaces the noisy pneumatic system with a silent electromagnetic system. The electromagnet generates magnetic force through electrical current without any moving parts or gas compression, eliminating the noise associated with pneumatic valves and air flow. This substitution maintains full tool change capability while removing the harmful noise factor and reducing operational expenses
3Productivity
If conventional tool changers are used, then tools can be changed, but the binding and separation process is not efficient and rapid
Solution Approach 1:
The patent replaces the slow pneumatic binding and separation mechanism with rapid electromagnetic actuation. The electromagnet can establish magnetic binding force almost instantaneously when current is applied, and can equally rapidly reverse to create repulsive force for separation. This electromagnetic actuation eliminates the delay inherent in pneumatic system response, achieving both rapid tool change speed and high binding/separation efficiency
Solution Approach 2:
The patent employs periodic or pulsing current application to the electromagnet to control the binding and separation cycle. By applying current in controlled pulses or periodic waves, the system achieves rapid repeated binding and separation actions, enhancing both the speed of tool changes and the efficiency of each binding/separation event
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
The system enables rapid, efficient tool changes and vibration to remove residues, reducing noise and structural complexity while improving work performance efficiency and responsiveness.
Implementation Method 1
a coil wound around the inner core, wherein a current is applied to the coil
Implementation Method 2
a pair of magnets connected to both ends of the inner core, protruding from the housing to the tool, and inserted into a connecting groove of the tool
Implementation Method 3
a controller configured to open or close the switch according to a set frequency... The set frequency may be consistent with a resonance frequency of the tool
Data Source
AI summary
A tool changer is included in a manipulator of a robot and selectively fastens to a tool by a magnetic force. The tool changer may include a housing; an inner core embedded in the housing; a coil wound around the inner core, wherein a current is applied to the coil; a pair of connecting cores connected to both ends of the inner core, protruding from the housing to the tool, and inserted into a connecting groove of the tool; a switch configured to regulate the current applied to the coil; and a controller configured to open or close the switch according to a set frequency.