Magnetic Robot Tool Changer for Fast Quiet Tool Coupling

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Solution Overview

Problem

Conventional tool changers for robots are bulky, expensive, and noisy due to their reliance on pneumatic systems, making them inefficient for rapid and precise tool changes.

Innovation Solution

A compact tool changer system utilizing a bar-shaped magnet rotated by a motor within a non-magnetic housing, with a magnetic core comprising first and second poles and terminals, allowing for controlled magnetic flux and efficient tool coupling and decoupling through magnetic forces, eliminating the need for external systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a pneumatic system is used for tool changing, then the tool changer can provide sufficient force for tool coupling and decoupling, but the structure becomes bulky and requires subsidiary equipment

Engineering Contradiction:

Improvetool coupling forceVSAvoidsystem structure

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent replaces the pneumatic system with a magnetic field-based system. A magnet rotates within a core structure to generate magnetic flux that couples and decouples tools, eliminating the need for bulky pneumatic components and subsidiary equipment while maintaining sufficient coupling force

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state from pneumatic pressure to magnetic flux density. By controlling the rotation angle of the magnet relative to the core, the magnetic flux parameter is modulated to achieve tool coupling and decoupling, enabling compact design with rapid response

Inventive Principle:

Principle #35Parameter changes

2Force

If a pneumatic system is used for tool changing, then the tool changer can provide sufficient force, but noise is generated

Engineering Contradiction:

Improvetool coupling forceVSAvoidnoise

Core Design Contradiction:

ForceVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes the noisy pneumatic system with a silent magnetic field system. The magnetic flux generated by the rotating magnet provides the necessary coupling force without generating mechanical noise, eliminating the harmful noise factor while maintaining force effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Force

If a pneumatic system is used for tool changing, then the tool changer can provide sufficient force, but the response speed is reduced

Engineering Contradiction:

Improvetool coupling forceVSAvoidtool changing speed

Core Design Contradiction:

ForceVSSpeed

Solution Approach 1:

The patent replaces the slow pneumatic system with a rapidly responsive magnetic system. The magnetic flux responds instantaneously to magnet rotation, enabling rapid tool coupling and decoupling speeds while maintaining sufficient coupling force through magnetic field control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Volume of moving object

If a compact magnetic system is used, then the size is reduced and noise is eliminated, but the magnetic flux path control must be precise

Engineering Contradiction:

Improvetool changer sizeVSAvoidmagnetic flux path

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent employs a dynamic core structure with movable poles that can be positioned at different angles relative to the rotating magnet. This dynamic configuration allows precise control of the magnetic flux path through mechanical adjustment, achieving the required manufacturing precision in a compact design

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent introduces a magnetic core as an intermediary between the magnet and the tool. The core with its configurable poles acts as a mediator that directs and controls the magnetic flux path precisely, enabling accurate magnetic field control in the compact system

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables rapid, precise, and reliable tool changes with improved operational reliability and reduced size and noise, minimizing cogging torque and enhancing the efficiency of robot operations.

Implementation Method 1

a core configured to derive a path of a magnetic flux by the magnet

Methodology Applied

Scientific EffectMagnetic flux: Magnetic Field

Implementation Method 2

a bar-shaped magnet disposed in the housing; a core configured to derive a path of a magnetic flux by the magnet

Methodology Applied

Scientific EffectMagnetism: Magnetism

Data Source

PatentUS11738470B2Tool changer and tool change system having the same

Publication Date: 2023.08.29 LG ELECTRONICS INC

AI summary

A tool changer in accordance with the present disclosure comprises: a housing fastened to a manipulator of a robot, wherein the housing is a non-magnetic material; a bar-shaped magnet disposed in the housing; a motor configured to rotate the magnet on a rotation shaft perpendicular to a longitudinal direction of the magnet; and a core configured to derive a path of a magnetic flux by the magnet. The core comprises: a pair of first poles facing both poles of the magnet, when the magnet rotates to be elongated in a first direction; a bridge configured to connect the pair of the first poles and disposed in the housing, wherein the bridge is a magnetic material; a pair of second poles facing the both poles of the magnet, when the magnet rotates to be elongated in a second direction perpendicular to the first direction; and a pair of terminals connected to the second poles and facing a magnetic body disposed outside the housing.