Magnetic Robotic Tool Changer With All-Round Mechanical Locking
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Solution Overview
Problem
Existing robotic tool changer systems face issues with unstable magnetic coupling and misalignment during tool change due to lack of retaining structures and inaccurate locking mechanisms, leading to potential tool drop and misalignment.
Innovation Solution
A robotic tool changer system utilizing magnetic coupling force and all-round mechanical locking, where a first coupling unit with a first magnetic unit and locking unit aligns and engages with a second coupling unit through magnetic attraction and guided mechanical locking, ensuring precise alignment and stable fixation without continuous alignment force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If magnetic attraction is used to connect the coupler and tool changer, then the coupling process is simplified, but the coupler may drop due to collision in operation because there is no retaining structure
Solution Approach 1:
The coupling system is divided into two functional parts: magnetic attraction for coupling and mechanical locking for retaining. The locking structure includes separate locking elements and locking grooves that engage independently from the magnetic coupling, providing a segmented approach where each mechanism performs its specific function without interfering with the other.
Solution Approach 2:
The patent combines magnetic coupling and mechanical locking into a single integrated system. The magnetic coupling unit and locking structure work together simultaneously, where the magnetic force provides initial attraction and alignment while the mechanical locking elements provide secure retention, creating a hybrid coupling mechanism that leverages both magnetic and mechanical principles.
2Reliability
If locking elements are used to lock the tool changer parts, then the connection is secured, but misalignment may occur during the tool change process due to vibration or unstable clamping before complete locking
Solution Approach 1:
The magnetic coupling acts as a preliminary action that establishes alignment and secure connection before the mechanical locking elements fully engage. The magnetic force maintains precise positioning during the transition phase, preventing misalignment that would otherwise occur due to vibration or unstable clamping before complete locking is achieved.
Solution Approach 2:
The magnetic coupling serves as an intermediary mechanism between the approach phase and the final locked state. It provides a transitional holding force that maintains alignment precision during the critical period when mechanical locking elements are engaging, acting as a mediator that bridges the gap between initial approach and final secure locking.
3Manufacturing precision
If the robot arm continuously exerts force for alignment, then precise coupling is achieved, but the system complexity and continuous force requirement increase
Solution Approach 1:
The magnetic coupling units are designed to self-align and self-lock through their inherent magnetic attraction and mechanical locking geometry. The locking elements automatically engage with the locking grooves when the coupling units approach each other under magnetic attraction, eliminating the need for continuous external alignment force and reducing system complexity.
Solution Approach 2:
The patent replaces the need for continuous mechanical alignment control with a passive magnetic coupling mechanism. Instead of requiring the robot arm to continuously exert alignment force, the magnetic fields provide automatic alignment and positioning, substituting active mechanical control with passive magnetic field-based self-alignment.
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
Ensures stable and precise tool change by maintaining alignment and fixation through magnetic coupling and mechanical locking, preventing tool drop and misalignment, and allowing for easy detachment without vibration or shaking.
Implementation Method 1
a first coupling unit and a second coupling unit can be coupled to each other via a magnetic coupling force between a first magnetic unit and a second magnetic unit
Data Source
AI summary
A robotic tool changer system through magnetic coupling force and all-round mechanical locking includes a first coupling unit, a plurality of second coupling units, and a plurality of tool changer grippers. The first coupling unit is fixed to a robot arm. The first coupling unit includes a first locking unit and a first magnetic unit. Each second coupling unit is detachably connected to one of the tool changer grippers and includes a second locking unit and a second magnetic unit. When the first coupling unit is moved to approach one of the second coupling units at a predetermined distance, the first coupling unit and the second coupling unit are coupled to each other by a magnetic coupling force, then the first coupling unit and the second coupling unit are fixed to each other through all-round mechanical locking of the first locking unit and the second locking unit.