Robotic Tool Changer Power Control to Prevent Contact Arcing
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Solution Overview
Problem
The existing robotic tool changers face issues with electrical contact wear due to transient electric arcs during the coupling and uncoupling process, as the electrical power must be shared between the master and tool modules, leading to arcing and reduced contact life.
Innovation Solution
A power switch circuit is implemented to suppress power application to the tool electrical signal module during coupling and uncoupling, using a separate circuit parallel to the master electrical signal module's power supply, allowing the master module to actuate the coupler while preventing arcing across the electrical contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical power is shared between master and tool modules during coupling and uncoupling, then the master module can actuate the coupler, but transient electric arcs form across the electrical contacts accelerating wear
Solution Approach 1:
The power supply system is segmented into two separate circuits: a first circuit that continuously powers the master electrical signal module for coupler actuation, and a second circuit that powers the tool electrical signal module only during stable coupling states. This segmentation allows independent control of power delivery to each module, enabling the master module to function during uncoupling while preventing arcing at the tool module contacts.
Solution Approach 2:
The system performs preliminary actions by maintaining power to the master electrical signal module before uncoupling occurs, ensuring the coupler can be actuated. Simultaneously, power to the tool electrical signal module is preemptively interrupted to prevent arcing before it can occur during the uncoupling transition.
2Adaptability or versatility
If electrical power is continuously supplied to both modules, then full functionality is maintained, but arcing occurs during coupling and uncoupling transitions
Solution Approach 1:
The power supply system transitions from a static continuous power delivery model to a dynamic controlled power delivery model. The second circuit is dynamically activated only when the system detects a stable coupled state, and deactivated during coupling and uncoupling transitions. This dynamic approach maintains tool module functionality when needed while eliminating harmful arcing during transitions.
Solution Approach 2:
A control mechanism acts as an intermediary between the power supplies and the tool electrical signal module, regulating power delivery based on coupling state. This intermediary controls the second circuit to provide power only when appropriate, preventing direct harmful interactions (arcing) while maintaining necessary functionality.
3Ease of operation
If power supplies remain on during coupling and uncoupling, then the master module can control the coupler, but contact wear accelerates reducing electrical life below mechanical life
Solution Approach 1:
The power distribution is segmented into continuous supply for the master module and conditional supply for the tool module. This segmentation preserves the master module's ability to control the coupler throughout all states while restricting tool module power only to stable coupled states, thereby preventing contact wear during transitions and extending electrical contact lifespan toward its mechanical life limit.
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 solution enables the electrical contacts to reach their mechanical life by preventing arcing during the coupling and uncoupling process, thereby extending their lifespan beyond their electrical life.
Implementation Method 1
transient electric arcs form across the electrical contacts of the master electrical signal module and the tool electrical signal module during the coupling/uncoupling process
Data Source
AI summary
A robotic tool changer removably attaches a robotic tool to a robotic arm. The changer includes a tool module connected to the robotic tool, and a master module connected to the robotic arm. To attach and detach the robotic tool, the changer couples and uncouples the tool module and the master module. A master electrical signal module (ESM) affixes to the master module and a tool ESM affixes to the tool module. In accordance with design requirements, the changer applies the same power supply to both the master ESM and the tool ESM. The changer, however, selectively suppresses application of the power supply to the tool ESM, while maintaining application of the power supply to the master ESM, during the coupling or uncoupling of the master module and the tool module. In doing so, the changer enables such coupling and uncoupling, while also preventing the formation of transient electric arcs.