Magnetic Tool Coupler Structure for Compact Robot Tool Changing
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Solution Overview
Problem
Conventional tool changers for robots are bulky, costly, and noisy due to their reliance on pneumatic systems, which hinders efficient and accurate tool exchange.
Innovation Solution
A tool change system utilizing a non-magnetic housing with a magnet module, metal bars, and magnetic terminals and pins to form magnetic flux loops, enabling compact, reliable, and fast tool exchange without the need for additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pneumatic system is used for tool changing, then the tool changer can achieve reliable tool exchange, but the structure becomes large and additional equipment is required, resulting in high cost and noise
Solution Approach 1:
The patent replaces the pneumatic system with a magnetic coupling system. The magnetic coupling device uses magnetic attraction forces between magnetic components (magnetic rings, magnetic blocks) to achieve tool holder gripping and release, eliminating the need for pneumatic cylinders, valves, and air supply systems. This substitution reduces structural complexity, removes noise sources, and lowers cost while maintaining reliable tool exchange functionality
Solution Approach 2:
The patent extracts and removes the pneumatic system components (compressor, tanks, valves, hoses) from the tool changer structure. By eliminating these additional equipment elements and replacing them with integrated magnetic coupling components, the system achieves compactness and reduces complexity while preserving the essential tool exchange function
2Reliability
If a pneumatic system is used for tool changing, then the tool changer can achieve reliable tool exchange, but noise is generated
Solution Approach 1:
The patent replaces the noisy pneumatic system with a silent magnetic coupling system. Magnetic attraction and repulsion forces operate without mechanical impact, air compression, or valve actuation noises. The magnetic coupling device achieves reliable tool holding and release through controlled magnetic field changes, eliminating noise generation while maintaining functional reliability
3Reliability
If a pneumatic system is used for tool changing, then the tool changer can achieve reliable tool exchange, but the structure becomes large
Solution Approach 1:
The patent removes the bulky pneumatic system components (cylinders, air tanks, valve assemblies) from the tool changer. The magnetic coupling device uses compact magnetic rings and blocks that can be integrated directly into the tool holder and tool changer body, dramatically reducing the overall volume and making the system more compact while maintaining reliable tool exchange capability
Solution Approach 2:
The patent merges the magnetic coupling components directly into the tool holder and tool changer structure. The magnetic rings are integrated into the tool holder body, and magnetic blocks are incorporated into the tool changer, eliminating the need for separate pneumatic actuators and mounting hardware, thus reducing the overall system size
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 allows for efficient and reliable tool change operations by distributing magnetic forces between the tool coupler, changer, and mounter, reducing noise and cost while improving operational reliability.
Implementation Method 1
the metal bar and the pair of terminals may be configured to form a first magnetic flux loop with the magnet module, and the fixing bar and the pair of mounting pins may be configured to form a second magnetic flux loop with the magnet module
Implementation Method 2
a magnet module embedded in the housing... a pair of terminals provided at both ends of the metal bar, wherein the pair of terminals are magnetic materials, wherein the pair of terminals face the magnet module
Data Source
AI summary
A tool system including a housing fastened to a tool, the housing being formed of a non-magnetic material, a magnet module embedded in the housing, a pair of mounting grooves in the housing and located below the magnet module, a changer body provided on a manipulator, the changer body being formed a non-magnetic material, a metal bar mounted on the changer body, a pair of terminals provided at both ends of the metal bar, the pair of terminals being formed of magnetic material, the pair of terminals facing the magnet module, a fixing bar outside the housing, the fixing bar being formed of a magnetic material, and a pair of mounting pins extending vertically from both ends of the fixing bar, the pair of mounting pins being formed of magnetic materials, and the pair of mounting pins are inserted into the pair of mounting grooves is provided.