Magnetic Breakaway End Effector for Autonomous Tool Exchange
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Solution Overview
Problem
Current automation systems for robotic picking in warehouses and retail facilities are inflexible, require significant infrastructure modifications, and suffer from issues like missed picks, long downtimes, safety hazards, and difficulty in changing tools due to complex mechanical devices that rely on positive air pressure.
Innovation Solution
A magnetic break-away and tool changer mechanism for autonomous mobile manipulation robots that reduces complexity, mass, and cost by using a novel adapter and end effector design with magnetic and electrical connectors, allowing quick and autonomous tool exchange and collision avoidance without the need for positive air pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex mechanical devices relying on positive air pressure are used for tool changing and collision detection, then collision detection capability is provided, but device complexity increases and operational reliability decreases due to calibration issues and long downtimes
Solution Approach 1:
The patent replaces complex mechanical devices relying on positive air pressure with a simplified magnetic field-based system. The magnetic field serves as an intermediary to detect collisions and trigger break-away mechanisms, eliminating the need for pneumatic systems and complex mechanical sensors, thereby reducing device complexity and improving operational reliability.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the end effector and the collision detection system. This magnetic field enables non-contact sensing and communication, allowing the system to detect collisions and control break-away without direct mechanical contact or complex pneumatic mechanisms, thus simplifying the overall system.
2Productivity
If complex mechanical devices are used for tool changing, then tool changing capability is provided, but loss of time increases due to long downtimes and difficulty in changing tools
Solution Approach 1:
The patent replaces mechanical tool changing mechanisms with a magnetic field-based system that enables rapid attachment and detachment of end effectors. The magnetic field allows for quick alignment and connection without complex mechanical alignment procedures, significantly reducing tool changing time and increasing productivity.
Solution Approach 2:
The patent incorporates preliminary alignment features such as magnetic attraction and mechanical guides that automatically position the end effector correctly during attachment. This preliminary action eliminates the need for manual alignment and complex positioning procedures, reducing tool changing time and preventing calibration issues.
3Ease of operation
If complex mechanical devices relying on positive air pressure are used, then collision detection is provided, but ease of operation worsens due to calibration issues and requirement for human intervention
Solution Approach 1:
The patent replaces mechanical collision detection systems with a magnetic field-based system that automatically detects collisions and triggers break-away without requiring human intervention or calibration. The magnetic field provides continuous sensing capability, enabling fully automated operation and improving ease of use.
Solution Approach 2:
The patent enables the system to automatically detect collisions and execute break-away actions through the magnetic field sensing mechanism. The system serves itself by automatically responding to collision events without requiring external calibration or human intervention, thereby improving ease of operation and automation capability.
4Object-affected harmful factors
If magnetic break-away mechanism is used, then safety improves by allowing harmlessly break-away upon collision, but device complexity increases due to magnetic and electrical connector integration
Solution Approach 1:
The patent merges the magnetic connector and electrical connector into a single integrated assembly. The magnetic field provides both the attachment force and the alignment function, while the electrical contacts are positioned to engage automatically during magnetic attachment. This merging reduces the number of separate components and simplifies the overall integration process.
Solution Approach 2:
The magnetic field serves as an intermediary that facilitates both mechanical attachment and electrical connection simultaneously. The magnetic attraction guides the end effector into proper alignment while the electrical contacts engage, eliminating the need for separate alignment and connection procedures, thus reducing integration complexity.
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 solution enhances picking efficiency, reduces downtime, improves safety by allowing the end effector to break away harmlessly upon collision, and enables easy tool changes, making it more adaptable to varying inventory and operations without human intervention.
Implementation Method 1
an adapter magnetic connector and an adapter electrical connector on the bottom surface of the adapter configured for connection with an end effector magnetic connector and an end effector electrical connector, respectively, to provide the releasable break-away connection between the adapter and the end effector
Data Source
AI summary
High precision end effectors for robots and adapters that provide attachment of the end effectors to a variety of robotic arms are disclosed. The combination provides for harmless break-away of the end effector on collision, and autonomous tool changer capability for mobile robots.