Magnetic Tool Changer Piston Eliminates External Power
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Solution Overview
Problem
Existing robotic tool changers require continuous external motive force to maintain tool coupling, which can be unsafe and costly, and may fail if the external power source is interrupted.
Innovation Solution
A magnetic force-driven piston mechanism is used in the tool changer, where polymagnetic members with oppositely oriented magnetic fields align to provide motive force for coupling and decoupling, eliminating the need for external power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical springs or pneumatic pressure are used to drive the piston in the coupling mechanism, then continuous motive force is provided to keep the tool unit locked to the master unit, but the system requires external power sources, increases complexity, weight, and cost, and may fail if the power source is interrupted
Solution Approach 1:
The magnetic coupling mechanism uses permanent magnets to provide continuous motive force without requiring external power sources. The magnets inherently generate the magnetic field needed to drive the piston and maintain coupling, making the system self-sufficient and eliminating complex power supply infrastructure.
Solution Approach 2:
The patent replaces traditional mechanical spring-based or pneumatic pressure-based drive systems with a magnetic field-based system. This substitution eliminates the need for mechanical power transmission components, reducing complexity while maintaining reliable continuous force application.
2Force
If mechanical springs are used to drive the piston, then continuous motive force is provided, but a large force must be applied to retract the piston against the spring force, which may be excessive for hand-actuated tool changers
Solution Approach 1:
The magnetic coupling mechanism allows dynamic control of the coupling force. The operator can easily decouple the tool unit by overcoming the magnetic attraction, and the system naturally maintains coupling strength when engaged. This dynamic balance makes the system both strong when coupled and easy to operate when decoupling.
Solution Approach 2:
The magnetic field provides periodic attraction and release cycles during operation. The magnets naturally cycle between engaged and disengaged states, providing strong holding force during coupling and allowing easy release during decoupling, creating an operational rhythm that is both safe and user-friendly.
3Reliability
If pneumatic fluid is used to drive the piston, then continuous motive force is provided, but any failure of the pneumatic source, supply lines, O-rings, or the like may result in loss of pressure, presenting a safety hazard as the tool unit may become decoupled
Solution Approach 1:
The magnetic coupling mechanism uses simple permanent magnets that have no consumable parts requiring replacement. Unlike pneumatic systems with O-rings, seals, and supply lines that can fail and require maintenance, the magnetic system uses durable magnets that provide reliable coupling without vulnerable components.
Solution Approach 2:
The patent replaces the pneumatic fluid system with a magnetic field system, eliminating pressure vessels, supply lines, valves, and seals. This substitution removes the safety hazards associated with high-pressure pneumatic systems while maintaining reliable continuous force application for tool coupling.
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 magnetic force mechanism ensures reliable and safe tool coupling and decoupling without requiring continuous external power, reducing complexity, weight, and costs associated with power sources.
Implementation Method 1
A magnetic force-driven piston mechanism is used in the tool changer, where polymagnetic members with oppositely oriented magnetic fields align to provide motive force for coupling and decoupling
Data Source
AI summary
A robotic tool changer in which the coupling mechanism is actuated using magnetic force is provided. In one exemplary embodiment, a robotic tool changer may include a tool unit operatively connected to a robotic tool and a master unit operative to connect to a robotic arm. The master unit may include a housing and a piston. The piston may be disposed at least partially within the housing and configured to place the master unit in one of a coupled state and a decoupled state. Further, the master unit may be operative to assume the coupled state or the decoupled state in response to altering an orientation of magnetic fields to provide a first magnetic force that moves the piston to the coupled state or provide a second magnetic force that moves the piston to the decoupled state.