Robotic Tool Changer Power Control Arc Suppression
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Solution Overview
Problem
The existing robotic tool changers face issues with transient electric arcs forming across electrical contacts during the coupling and uncoupling process, leading to premature wear and reducing the electrical life of contacts below their mechanical life, despite design requirements that mandate shared power supplies for both the master and tool electrical signal modules.
Innovation Solution
A power switch circuit is implemented to suppress the application of power to the tool electrical signal module during coupling and uncoupling, while maintaining power to the master electrical signal module, using a separate circuit parallel to the one powering the master module, thereby preventing arcing and allowing the contacts to reach their mechanical life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power is supplied to both master and tool electrical signal modules during coupling/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, and a second circuit that powers the tool electrical signal module only when needed. This segmentation allows independent control of power delivery to each module, enabling the master module to remain powered for coupler actuation while the tool module is depowered during coupling/uncoupling to prevent arcing.
Solution Approach 2:
The power supply system transitions from a static, continuous power delivery mode to a dynamic, conditional power delivery mode. The second circuit is selectively enabled or disabled based on the coupling state of the master and tool modules, allowing the system to adapt power distribution to operational requirements and eliminate arcing conditions.
2Adaptability or versatility
If a single power supply is used for both master and tool modules, then design requirements are met, but arcing occurs during contact making/breaking
Solution Approach 1:
The single power supply is segmented into two separate circuits with independent control. The first circuit continuously powers the master module, while the second circuit powers the tool module only when the master and tool modules are coupled. This segmentation maintains compliance with the shared power supply requirement while eliminating the harmful arcing effect.
Solution Approach 2:
A control mechanism acts as an intermediary between the power supply and the tool electrical signal module, selectively enabling or disabling the second circuit based on the coupling state. This intermediary control prevents direct power application to the tool module during coupling/uncoupling operations, thereby preventing arcing while maintaining shared power supply architecture.
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 effectively prevents arcing during the coupling and uncoupling process, allowing the electrical contacts to reach their mechanical lifespan while conforming to design requirements for shared power supplies, thus extending their operational 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.