Pneumatic Tool Changer Interlock for Safe Decoupling at the Tool Stand
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Solution Overview
Problem
Current robotic tool changers in industrial settings face safety concerns due to the risk of inadvertent decoupling of robotic tools from the robot arm, which can lead to accidents, and existing safety measures like interlock circuits and redundancy add complexity and cost.
Innovation Solution
A robotic tool changer design where the power for decoupling is only available when the tool is safely disposed in its tool stand, eliminating the need for interlock circuits and redundancy by ensuring that decoupling can only occur when the tool is properly positioned, using separate power sources for coupling and decoupling operations and routing decoupling pneumatic fluid through the tool stand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If interlock circuits and redundancy measures are implemented to prevent inadvertent decoupling, then safety is improved, but device complexity increases
Solution Approach 1:
The patent extracts the safety function from complex interlock circuits and redundancy measures, implementing it instead through the fundamental pneumatic power supply architecture. The decoupling operation requires a specific pneumatic signal that can only be generated when the tool is properly positioned in the tool stand, thereby eliminating the need for separate safety circuits while maintaining high reliability.
Solution Approach 2:
The system uses its own pneumatic power supply infrastructure to enforce safety constraints. The decoupling pneumatic signal is self-regulated based on the physical position of the tool, with the pneumatic system automatically preventing decoupling attempts when the tool is not properly positioned, without requiring external safety monitoring systems.
2Reliability
If interlock circuits and redundancy measures are implemented to prevent inadvertent decoupling, then safety is improved, but cost increases
Solution Approach 1:
The patent removes the need for expensive interlock circuits and redundancy measures by integrating safety functionality into the existing pneumatic power supply system. The same pneumatic infrastructure that powers the coupling mechanism also controls decoupling, eliminating the need for separate safety components and reducing overall system cost.
Solution Approach 2:
The pneumatic power supply system performs multiple functions: it powers both coupling and decoupling operations, and simultaneously enforces safety constraints by controlling when decoupling can occur. This multi-functionality eliminates the need for dedicated safety components, reducing manufacturing cost while maintaining safety.
3Reliability
If separate power sources are used for coupling and decoupling operations, then safety is improved by preventing inadvertent decoupling, but device complexity increases
Solution Approach 1:
The patent merges the decoupling power source with the tool stand's pneumatic system, so that the same pneumatic infrastructure that supports the tool also provides the decoupling signal. This combination reduces overall system complexity compared to having entirely separate power sources, while still maintaining the safety benefit of requiring a distinct pneumatic signal for decoupling.
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
This design ensures inherently safe operation by preventing inadvertent decoupling of robotic tools from the robot arm, reducing complexity and cost by eliminating the need for redundant safety circuits, and maintaining tool safety during software errors or misoperations.
Implementation Method 1
A pneumatic coupling mechanism is disclosed that utilizes a single pneumatic fluid supply for both coupling and decoupling operations of the coupling mechanism
Data Source
AI summary
A robotic tool changer ensures inherently safe decoupling operation by only providing pneumatic fluid to a decouple port of a pneumatic coupling mechanism in the case that the tool changer is seated on, and properly aligned with, a tool stand. Pneumatic fluid to decouple the pneumatic coupling mechanism is routed from an air source to the tool stand. A pass-through in the tool stand returns the pneumatic fluid to a pneumatic path in the tool changer leading to a decouple port of the pneumatic coupling mechanism. Hence, the tool changer must be seated on the tool stand for the decouple port to receive pneumatic fluid to operate. Furthermore, a safety coupling is interposed on the pneumatic path between the tool stand and the decouple port. The safety coupling requires the tool changer to be seated on, and properly aligned with, the tool stand to effect the flow of pneumatic fluid—otherwise, the pneumatic fluid is bled to the atmosphere.