Tool Changer Z-Shape Slots Harsh Environment Automation
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Solution Overview
Problem
Existing automatic tool changers for robotic systems are not designed to operate effectively in environments with grit or abrasive buildup, leading to potential sticking issues and inefficiencies in tool exchange processes.
Innovation Solution
A tool changer system featuring a base with Z-shaped slots, a hose coupler with L-shaped slots, and an adapter with internal passageways and pins for secure coupling and decoupling, allowing for reliable engagement and disengagement with a robot arm, even in dusty or gritty conditions, using a resilient gasket for sealing and locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional automatic tool changers are used in harsh environments with grit or abrasive buildup, then tool exchange automation is maintained, but sticking issues occur and reliability deteriorates
Solution Approach 1:
The tool changer is divided into separate functional components: a base unit with Z-shaped slots, a hose coupler with L-shaped slots, and an adapter with pins. This segmentation allows each component to perform its specific function independently, reducing the complexity of the overall system and improving reliability in harsh environments where complete disassembly and reassembly are needed.
Solution Approach 2:
The patent inverts the traditional approach by using a passive base structure with fixed Z-shaped slots instead of an active robotic gripper. The adapter with pins actively engages with these slots, reversing the roles of active and passive elements. This inversion simplifies the mechanism and eliminates sticking issues associated with traditional robotic grippers in abrasive environments.
2Loss of substance
If secure coupling mechanisms are implemented to prevent material loss, then sealing and locking are improved, but device complexity increases
Solution Approach 1:
The patent uses Z-shaped slots that extend in multiple dimensions, allowing pins to engage through a combination of vertical and horizontal movements. This dimensional approach creates secure locking without requiring complex multi-step coupling mechanisms, as the Z-shape inherently provides both sealing and locking functions through its geometry.
Solution Approach 2:
The adapter acts as an intermediary component between the base and the hose coupler. It contains pins that engage with both the Z-shaped slots of the base and the L-shaped slots of the hose coupler, providing a simple mechanical mediation that secures the connection and prevents material loss without adding significant complexity.
3Ease of operation
If Z-shaped slots are used for adapter positioning and release, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The Z-shaped slots are designed to work with dynamic motion sequences: the adapter is first positioned vertically to engage the pins with the slots, then rotated horizontally to lock into place. This dynamic engagement process allows for easier operation while the manufacturing precision is concentrated in the critical pin-slot interface rather than the entire slot geometry.
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 secure, sealed connections and efficient tool changes in harsh environments without manual or additional powered actuators, ensuring reliable operation and preventing material loss during tool exchanges.
Implementation Method 1
a gasket that is compressed as the adapter is attached to the hose coupler to create a seal and lock the adapter into place
Data Source
AI summary
A tool changer includes a base, a hose coupler that is configured to be mounted to a robot arm and an adapter. Movement of a robot arm may be utilized to selectively couple and decouple the components of the tool changer to each other whereby tool changes can be accomplished without manual operations.