Parallel Kinematic Manipulator With Magnetic Swivel Joints
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Solution Overview
Problem
Current robotic manipulator systems are not cost-effective for applications beyond large-scale manufacturing, require numerous sensors that increase weight and cost, and face interference from damp environments and electromagnetic disturbances, while also lacking effective visual feedback at high speeds, which can be disruptive in silent work environments.
Innovation Solution
A parallel kinematic manipulator system with three degrees of freedom using three linear coil actuators, magnetic disc swivel joints, and a minimal number of Hall effect sensors, along with a digital control unit and pulsed illumination source, to achieve high-speed and precise movements with reduced noise and sensor interference, and a load balancing control routine to maintain work object stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed operation is implemented, then productivity is improved, but visual feedback quality deteriorates and noise increases
Solution Approach 1:
The patent applies periodic action by using pulsed illumination that synchronizes with the manipulator's operational cycle. The illumination is activated during specific phases of the manipulator's movement to freeze motion visually, allowing high-speed operation while maintaining perceived visual clarity through rhythmic, synchronized lighting patterns.
Solution Approach 2:
The patent utilizes color changes through the pulsed illumination source that emits light in specific color patterns or intensities synchronized with manipulator operations. This creates visual feedback that is perceptible to human operators even at high speeds, using temporal and spectral variations in light to convey operational state information.
2Measurement precision
If numerous sensors are used for satisfactory operation, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates unnecessary sensors from the system by identifying that only minimal sensing is required for satisfactory operation. The design removes redundant measurement devices while maintaining operational accuracy through optimized use of essential sensors and intelligent control algorithms that reduce dependency on extensive sensor arrays.
Solution Approach 2:
The patent applies universality by designing sensors that perform multiple functions simultaneously. The minimal sensor set is configured to serve various operational requirements through multi-functional capabilities, allowing a single sensor to provide multiple measurement types or control functions, thereby reducing the total number of sensors needed while maintaining measurement precision.
3Measurement precision
If sensors are located close to the end-effector for better measurement, then measurement precision is improved, but reliability deteriorates due to electromagnetic interference
Solution Approach 1:
The patent introduces an intermediary approach by strategically positioning sensors at optimal distances from the end-effector. This intermediate positioning balances measurement precision with protection from electromagnetic interference, placing sensors close enough to capture accurate data but far enough to avoid the strongest interference zones, effectively mediating between the two conflicting requirements.
4Productivity
If operational speed is increased, then productivity is improved, but noise generation increases disrupting work environment
Solution Approach 1:
The patent applies periodic action to noise management by synchronizing operational phases with pulsed illumination cycles. High-speed manipulations are timed to coincide with illumination pulses, creating rhythmic operational patterns that organize noise generation into predictable cycles, making the noise more tolerable and less disruptive to the work environment while maintaining high 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
The system enables high-speed and precise manipulations with reduced manufacturing costs, minimal sensor usage, resistance to environmental interference, and effective visual feedback, maintaining work object stability without additional sensors, thus addressing the limitations of existing systems.
Implementation Method 1
three Hall effect sensors (91) respectively positioned in proximity to each of the three actuators (19), each having its own associated Hall effect magnetic member (111) fastened to an actuated portion of the corresponding actuator (19)
Implementation Method 2
A magnetic disc swivel joint (18) comprises an annular shaped convex upper swivel member (51) and an annular shaped convex lower swivel member (52) positioned opposite and tangent to each other, allowing for a rolling, or swivel motion of the upper swivel member relative the lower swivel member. A joint upper magnet (53) positioned on the upper side of the upper swivel member exerts attractive forces on a joint lower magnet (54) positioned on the under side of the lower swivel member
Data Source
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AI summary
A parallel kinematic manipulator system having three degrees of freedom and a method of controlling and visualizing work objects using force feedback and oscillation algorithms is provided. Three co-planar linear actuators operate symmetrically and parallel to an effector arm and are pivotally connected by three magnetic disc swivel joints to a base plate. The disc swivel joints each include a convex upper and lower swivel member having two dimensional gear patterns structured into their contacting and non-sliding surfaces. A pulsed illumination source consists of an annular LED array and is synchronized to the oscillation frequencies of the system to provide visual filtering capabilities. A control unit includes a method for keeping a work object balanced by force feedback and without the need for angle sensors at the end-effector, as well as methods for rotation of work objects and control of the pulsed illumination source. Sound trap ridges are included as part of the housing to reduce system noise.