Safe Tool Changer With Dual Processing Circuitries
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Solution Overview
Problem
Existing tool changers for robots require physical cabling between tool stands and robot controller cabinets, leading to increased costs and complexity, and may malfunction due to faulty input signals, necessitating an improved safety mechanism.
Innovation Solution
A tool changer system with a master unit equipped with two separate processing circuitries and sensors, which independently verify the tool's attachment and position using multiple redundant channels, ensuring safe decoupling only when both circuits agree, reducing the risk of malfunctions and eliminating the need for physical cabling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical cabling is used between tool stand switches and robot controller cabinet for safe control, then safety interlocking is achieved, but device complexity and installation complexity increase
Solution Approach 1:
The patent replaces the mechanical/electrical cabling system with a wireless communication system. Tool stands equipped with sensors communicate their status (tool presence, tool position) wirelessly to the robot controller using radio frequency or other wireless protocols, eliminating the need for physical cables while maintaining safety interlocking functionality.
Solution Approach 2:
The robot controller integrates multiple functions: it acts as both the control system for robot operations and the safety monitoring system for tool changer interlocking. The same processor and communication interfaces handle both robotic task control and safety signal reception, reducing the need for separate dedicated safety cabling infrastructure.
2Device complexity
If a single processing circuitry is used for tool changer control, then device complexity is reduced, but reliability decreases due to potential signal failures
Solution Approach 1:
The safety control function is segmented into multiple independent monitoring channels within the robot controller. Each channel independently processes signals from specific tool stands or sensor types, allowing the system to cross-check results and detect inconsistencies. This modular approach to safety monitoring enhances reliability without requiring separate physical control systems.
Solution Approach 2:
The robot controller implements continuous feedback monitoring of tool changer status through wireless sensors. The system constantly receives updates on tool presence and position, compares these against expected states, and can trigger safety interlocks or alerts when discrepancies are detected, creating a self-verifying control system.
Data Source
AI summary
A tool changer set out having a master unit and a tool unit. The master unit comprises a safety controller with two separate processing circuitries, a coupler and at least two coupling sensors. The tool unit comprises at least one tool unit sensor, the at least one tool unit sensor provides two output signals sent to the safety controller. The at least two coupling sensors individually detect if the tool unit is coupled to the master unit and the output signals are sent to the safety controller. The two separate processing circuitries are arranged to receive a request to decouple the tool unit, determine whether the tool unit is coupled to the master unit and whether the tool unit is in the tool stand, send the result of the determinations to other processing circuitry, receive a result of determinations and send a decouple signal.