Rotary Tool Changer Locking for Quiet Continuous Rotation
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Solution Overview
Problem
Existing tool changing systems are limited by their inability to rotate tools endlessly, require complex and noisy power sources, and are costly due to the need for precise alignment and multiple mating tool couplers.
Innovation Solution
An automatic tool changer system with a solenoid-driven mechanism that allows continuous rotation of tools, uses a compact design, and supports a wide tolerance for alignment precision, featuring a modular and versatile design with magnetic detent members and a mating tool coupler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If pneumatic power is used for tool changing, then tool gripping force is improved, but noise level increases and device size increases
Solution Approach 1:
The patent replaces the pneumatic mechanical system with an electromagnetic system. The electromagnetic tool changer uses magnetic fields generated by electromagnets to grip and release tools, eliminating the need for noisy pneumatic components like air compressors and valves while maintaining sufficient gripping force for tool attachment and detachment.
Solution Approach 2:
The patent eliminates pneumatic systems entirely in favor of electromagnetic actuation. By using controlled electromagnetic fields instead of compressed air, the system achieves tool manipulation without the noise, vibration, and space requirements associated with pneumatic infrastructure.
2Use of energy by moving object
If wires or tubes run through the rotating portion of the tool changer, then power transmission is achieved, but continuous rotation is prevented due to tangling
Solution Approach 1:
The patent replaces mechanical power transmission through wires and tubes with electromagnetic power transmission. Electromagnets mounted on the stationary housing can actuate tool retention mechanisms through magnetic fields that penetrate the rotating tool interface, allowing the tool to rotate continuously without physical connections that would tangle or break.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary between the stationary power source and the rotating tool interface. The electromagnetic actuator uses magnetic field lines as the medium to transmit force and control signals across the air gap, enabling wireless power and control transmission that accommodates unlimited rotation.
3Reliability
If precise alignment is required for tool changer and tool coupler, then locking reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs self-aligning features such as tapered surfaces on the tool interface that guide the tool coupler into proper alignment automatically during insertion. This equipotential approach ensures that regardless of minor variations in manufacturing tolerances or assembly positioning, the components naturally settle into the correct locked configuration without requiring ultra-precise initial alignment.
Solution Approach 2:
The tool changing system incorporates self-aligning and self-latching mechanisms that automatically compensate for alignment variations. The tapered interfaces and elastic retention elements enable the system to self-correct positioning errors, eliminating the need for expensive high-precision machining and alignment procedures during manufacturing and assembly.
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
Enables quiet, compact, and cost-effective tool changes with infinite tool rotation, suitable for a broad range of applications, including tasks that require continuous tool spinning.
Implementation Method 1
solenoid means mounted separately from said body for actuating said engagement actuator
Implementation Method 2
magnetic detent members
Data Source
AI summary
Embodiments of an automatic tool changer system are described. An automatic tool changer can be mounted on a robot or machine to enable automatic switching between various tools. Embodiments of an automatic tool changer system described in this invention allow infinite rotation of the tool. The system comprises an automatic tool changer and a mating tool coupler. The automatic tool changer includes a body with a passageway and at least one port housing a detent member. The detent member is movable between a locked position for engaging a tool and an unlocked position for releasing it. A solenoid is configured to drive the detent member directly or drive an engagement actuator that facilitates the detent members' movement. The mating tool coupler includes a pocket configured to receive the body of the automatic tool changer and one or more indentations that align with the detent member to secure the tool during operation. The system further includes optional rotational blockers and a tool base for stabilizing and enabling more complex tools, cavities for additional sensors, and features such as a tapered surface for alignment, a rotary seal for environmental protection, and a spring alignment structure for biasing components into position. The invention enables automatic tool exchange in a quiet, compact form factor while allowing for continuous rotation of components and broad adaptability to various tool designs.