Abstract: A robotic tool changer in which the coupling mechanism is actuated using magnetic force is provided. In one exemplary embodiment, a robotic tool changer may include a tool unit operatively connected to a robotic tool and a master unit operative to connect to a robotic arm. The master unit may include a housing and a piston. The piston may be disposed at least partially within the housing and configured to place the master unit in one of a coupled state and a decoupled state. Further, the master unit may be operative to assume the coupled state or the decoupled state in response to altering an orientation of magnetic fields to provide a first magnetic force that moves the piston to the coupled state or provide a second magnetic force that moves the piston to the decoupled state.

Abstract: A force/torque sensor includes a number n of deformable beams connecting the TAP to the MAP, wherein n?4. At least four of the n deformable beams are instrumented with strain gages affixed to surfaces of the beams, such that each beam outputs two gage signals. The eight gage signals are grouped into four sets of six gage signals, such that each set includes the gage signals from three of the four instrumented beams. Each set of six gage signals is multiplied by a calibration matrix to yield a set of six force and torque values. The four sets of force and torque values are compared. If one set disagrees with the other three by greater than a predetermined tolerance, a sensor fault is signaled.

Abstract: A robotic tool changer includes a locking feature, and may be made washable by sealing against fluid incursion. The tool changer comprises a master unit and one or more tool units, and it transitions between decoupled and coupled states by rotation of one part relative to another. The rotation displaces rolling members in the master unit, such as balls, from a retaining surface to a locking surface which is sized and positioned to force the rolling members against a coupling surface of the tool unit. A deformable pin interposed between the retaining and locking surfaces resists movement of the rolling members therebetween, requiring the application of force. The pin remains deformed, and continues to exert a force on the rolling members, when the robotic tool changer is in the coupled state, providing a locking feature which automatically and positively resists any inadvertent decoupling of the tool changer.

Abstract: Alignment modules attached to a robotic tool changer assist spatial orientation and alignment of a robot arm relative to a robotic tool for location training. A three-axis spatial orientation sensor is first attached to an alignment module affixed to a tool unit. The sensor is “zeroed,” or calibrated to the spatial orientation of the tool unit. The sensor is transferred to a corresponding surface of an alignment module affixed to a master unit. The orientation of the robot arm is adjusted to eliminate sensor error signals indicating deviations from the zeroed orientation of the tool unit. An optical signal, such as a cross line laser beam, is then projected between the alignment modules. The x- and y-axis position of the robot arm is adjusted to align the optical signal with alignment markings. When the master and tool units are aligned, the robot arm is advanced in the z-axis direction until the master unit abuts the tool unit.

Abstract: A manually actuated robotic tool changer comprises master and tool units, each adapted to be connected to a different one of a robotic arm and a robotic tool. The tool changer includes a plurality of rolling members retained in one of the units and a piston mounted in one of the units and moveable in an axial direction. The piston includes a multi-faceted cam surface including an initial contact surface, a locking surface, and a failsafe surface interposed between the initial contact surface and the locking surface. When the piston is in a locked position in the tool changer, the cam surface is operative to contact the rolling members in one of the units and to urge each rolling member against a surface of the other unit to couple the master and tool units together.

Abstract: A compliance compensator apparatus provides a mechanically compliant coupling between, e.g., a robot arm or robotic tool and a mechanical load. The compliance compensator apparatus comprise a base component and a compliance component attached to the base component and independently moveable in several aspects. The compliance component may move, with respect to the base component, axially, transversely, rotationally, and skew, in response to mechanical force from an engaged load. When the load is disengaged, the compliance compensator apparatus returns to a reset position wherein the compliance component is spaced apart from, but parallel to, the base component.

Abstract: 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.

Abstract: A compensation device configured to be positioned between a robotic arm and a robotic tool. The device may be configured to directly attach to the tool, or may be configured to be positioned away from the tool. The device generally includes a first section that connects to the robotic arm and a second section that connects to the tool. The second section is movable relative to the first section to provide for the tool to be positioned at various orientations. The second section may comply rotationally about a first axis. The second section may be movable in a second plane. In one embodiment, the second plane is perpendicular to the first axis.

Abstract: A manually actuated robotic tool changer includes a first housing having a generally cylindrical piston with a central axis partially extending from the first housing, the piston rotatable about the axis. A plurality of tabs are disposed about the circumference of a portion of the piston extending from the first housing. A second housing has a bore to receive a portion of the piston. A plurality of locking lugs are disposed about the bore. The tool changer is manually actuated from an unlocked position wherein the piston assumes a position with respect to the first housing such that the extending portion of the piston may be moved within the bore with the tabs moving between the locking lugs, to a locked position wherein the piston is rotated with respect to the first housing such that the tabs move beneath the locking lugs to lock the first and second housings together.

Abstract: A compensation device configured to be positioned between a robotic arm and a robotic tool. The device may be configured to directly attach to the tool, or may be configured to be positioned away from the tool. The device generally includes a first section that connects to the robotic arm and a second section that connects to the tool. The second section is movable relative to the first section to provide for the tool to be positioned at various orientations. The second section may comply rotationally about a first axis. The second section may be movable in a second plane. In one embodiment, the second plane is perpendicular to the first axis.

Abstract: A compensation device that is positioned between a robot and a robotic tool. The device 10 generally includes a first section that connects to the robot and a second section that connects to the tool. The second section is movable relative to the first section for the tool to comply to accommodate variations in its positioning. The second section 12 may comply rotationally about x, y, and z orthogonal axes relative to the first section.

Abstract: A utility coupler comprises a coupling unit that is coupled to a tool unit via the reciprocal linear actuation of a hooking cam member in the coupling unit engaging a latching pin in the tool unit. The hooking cam member includes a composite cam surface operative to couple and hold the two units together as the latching pin engages different surfaces of the composite cam surface. Failsafe features prevent the inadvertent decoupling of the units.

Abstract: 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.

Abstract: In a robotic tool changer, a rotating cam surface ring having a plurality of surfaces formed therein urges a plurality of ball members in one tool coupling unit radially to contact a coupling surface in the other tool coupling unit. Mechanical energy captured and stored upon decoupling the units is used by an actuation mechanism, upon manual initiation, to at least partially automatically couple the two units by partially rotating the rotating cam surface ring. Further manual rotation of the cam member exerts a radial force through the ball members onto the coupling surface. A component of that force is directed by the coupling surface toward the opposite tool coupling unit, locking the two units together.

Abstract: A manually actuated robotic tool changer includes a rapid coupling mechanism. The tool changer includes a master unit having a piston moveable along its axis between an unlocked position and a fully locked position, and a tool unit that is coupled to the master unit when the units are adjacent and the piston is moved to the fully locked position. A piston movement control mechanism selectively allows free axial motion of the piston between the unlocked position and a nearly locked position, when the control mechanism is actuated. The piston may be biased toward the locked position, allowing the master and tool units to be rapidly coupled by positioning the units adjacently, actuating the control mechanism to allow the piston to rapidly advance to a nearly locked position, releasing the control mechanism to restrict free axial motion of the piston, and manually advancing the piston to a fully locked position.

Abstract: A manual robotic tool changer provides a compact, lightweight means to manually selectively couple a robotic tool, such as a surgical tool, to a robot arm. The tool changer includes numerous safety features to prevent inadvertent decoupling of the robotic tool. These include a dual-button handle locking mechanism operative to lock the tool changer closed in the fully coupled position, and requiring simultaneous actuation of both of two latch buttons to unlock; a one-way clutch mechanism that prevents rotation of the coupling mechanism towards the decoupled position, unless the handle is actuated to unlock the tool changer; and a spring biasing the tool changer to an at least partially coupled state when no force is applied to the handle, thus requiring a positive force against the spring, moving the handle to a fully open position, to insert or remove a robotic tool.

Abstract: In a robotic tool coupler, a rotating cam member having a plurality of surfaces formed therein urges a plurality of ball members in one tool coupling unit radially to contact an angled surface in the other tool coupling unit. Further rotation of the cam member exerts a radial force through the ball members onto the angled surface. A component of that force is directed by the angled surface toward the opposite tool coupling unit, locking the two units together. The cam member may include a failsafe surface and/or a failsafe lobe to maintain the two units locked together in the event of a loss of power to positively actuate the cam member.

Abstract: A robotic tool changer comprises first and second units, operative to be separately attached to a robot and a robotic tool, and further operative to be selectively coupled together and decoupled. The first and second units are coupled and decoupled by an electric motor. Power from the electric motor may be applied to couple and decouple the first and second units in a variety of ways.

Abstract: A linearly actuated switch assembly is adjustably disposed in a housing stem bore of a robotic crash protector device. An actuation plate is disposed over the central bore of the contact surface. As the piston moves toward the housing base in response to a crash force or torque applied to the actuator, the actuation plate moves in an axial direction, and contacts and actuates the switch. The actuation plate is biased towards the contact surface by an actuation spring disposed between the actuation plate and a spring plate that is rigidly affixed to the housing stem. This arrangement allows the actuation plate to “float” with respect to the fixed spring plate. In particular, the actuation plate may assume the orientation of the piston, which may be canted from its default orientation—normal to the device central axis—by uneven application of force by the actuator.

Abstract: A tool changer comprising a master module and a tool module includes a rapid-connect communication bus between the master and tool modules. A unique tool identification number, along with other tool-related information, may be transmitted from the tool module to the master module within about 250 msec of the master and tool modules coupling together. The master module includes a robotic system communications network node connected to the rapid-connect communication bus, and operative to transmit data between the tool and the network via the communication bus. The need for a separate network node in the tool module is obviated, reducing cost and reducing the start-up time required to initialize such a network node upon connecting to a new tool. The rapid-connect communication bus may be a serial bus.