Abstract: A robotic crash protector device is configured for heavy payload applications. The device includes a housing, a piston and an actuator movably mounted within the housing, a cam member secured within the housing in fixed relation to the housing's base, and a switch. The cam member includes a cam surface with some portions being closer to the housing's base than other portions. The actuator includes bearing members that are configured to, responsive to a rotational force imparted to the actuator, move along the cam surface and thereby collectively displace the piston. The switch detects this displacement and indicates a crash. When moving along the cam surface, the bearing members are each configured to engage the surface along a line of contact, rather than at a single point. With forces imparted to each bearing member and the cam surface distributed across a line, the components better endure heavy payload applications.

Abstract: A quick disconnect tooling apparatus for releasably latching an end effector tool to a manipulator. The present invention provides a base module connectable to a manipulator, and a tool module connectable to the end effector tool. A power source coupling has a first portion coupled to the base module, and a second portion coupled to the tool module, wherein the first and second portions of the power source coupling may cooperatively engage one another to allow for the passing of power between the manipulator and the end effector tool.

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 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 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 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 compliant service transfer module, which transfers services such as electricity, data, pneumatic fluid, etc., between a robotic arm and an attached tool, aligns service transfer points as the two units of the module mate, when the units are misaligned. A floating structure disposed in the first unit is operative to move laterally within a chamber in the housing of the first unit, to align service transfer points with the corresponding service transfer points of a second unit, when the two units are mated together but are not fully aligned. The floating structure protrudes from the first housing, and in the case of misalignment, contacts an angled inner wall of a chamber in the housing of the second unit, which moves the floating structure laterally to align the service transfer points. The floating structure returns to a default, centered position when the two units are not mated together.

Abstract: In a robotic tool coupler, 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 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: The non-axial force exerted on a pneumatic tool by a non-axial air supply is balanced to allow for uniformly radially distributed compliance forces on the tool. An annular air ring is disposed around the pneumatic tool, covering an air inlet port. Air is supplied by any route to a first air passage that supplies the air to the interior of the annular air ring, exerting a force on the annular air ring. Air flows in the annular space of the air ring, entering the tool air inlet port to drive the pneumatic tool. One or more second air passages are connected to the annular air ring in an even radial distribution. Each second air passage is connected to the air source, or terminates in an air blockage, creating a column of pressurized air that exerts a force on the annular air ring equal to the first air passage. The forces exerted on the air ring are thus balanced with respect to the axis of the tool.

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.

Abstract: A Force/Torque (FT) sensor includes memory for storing calibration data associated with the FT sensor. Force and torque analog signals are output to a data acquisition (DAQ) system. The digital calibration data is output to the DAQ system as a digital bitstream comprising a series of predetermined voltage levels driven for predetermined durations. The DAQ system interprets the series of voltage levels on the calibration input as a digital bitstream, receives and quantizes the force/torque signals, and calibrates the force/torque signals using the calibration data. Alternatively, the calibration signals may be routed to a standard serial port on the DAQ system. For small form factor FT sensors, the calibration data may be stored in an associated power supply unit.

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: 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 coupling system includes a first connecting unit including a piston movable along a longitudinal axis. The piston includes a multifaceted contact surface comprising a tapered locking surface; an initial actuating surface having an angle with respect to the axis not greater than the angle of the tapered locking surface; and a failsafe surface interposed between the tapered locking surface and the initial actuating surface. The system includes a second connecting unit having a plurality of rolling members disposed in a retention chamber including at least one angled surface operative to lock the first and second units together when the rolling members are forced against the angled surfaces by the tapered locking surface. The piston contact surface may additionally include a step surface, generally normal to the longitudinal axis, and a retention surface generally parallel to the axis.

Abstract: A pneumatically driven deburring device having a housing and a pneumatic motor mounted therein which is adapted to receive and drive a deburring tool. A pivot bearing is mounted within the housing adjacent the pneumatic motor. A motor support is held within the pivot bearing and extends therefrom where the motor support connects to the pneumatic motor. An air inlet is disposed adjacent the pivot bearing and is communicatively connected thereto. Air for driving the pneumatic motor is directed through the air inlet, and through a hollow portion of the motor support to where air is directed into the pneumatic motor. Because the motor support is supported or contained within the pivot bearing, it follows that the motor support articulates with the pivot bearing and hence the pneumatic motor moves with the articulating motor support.

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.

Abstract: A robotic deburring tool having a housing. Mounted within the housing is a pneumatic motor that includes a backwall and a drive shaft. Secured to the terminal end of the drive shaft is a deburring tool. A pivot-bearing is mounted in the housing adjacent the backwall. A connector extends from the backwall of the pneumatic motor and connects to the pivot bearing, thereby permitting the pneumatic motor to freely articulate radially in any direction while preventing free rotation about the bearing's longitudinal axis. A compliance device extends around the pneumatic motor at a location between the backwall and the deburring tool secured to the drive shaft. The compliance device restricts the movement of the pneumatic motor while applying a compliance force to the pneumatic motor as the pneumatic motor moves with the pivot bearing.

Abstract: A multi-position electrical connector for a robotic tool changer includes a bracket mountable to a robotic tool changer master or tool module, a coupling interface in a fixed position with respect to the bracket, and a cable interface moveable to a plurality of positions with respect to the bracket. Both the coupling interface and the cable interface include a plurality of electrical contacts, which are electrically connected. In one embodiment, the cable interface is disposed at substantially 90 degrees to the coupling interface, and is rotatable about an axis of the coupling interface. The cable interface may be fixed in one of a plurality of positions around the coupling interface. In one embodiment, a selected position is fixed by mating a retention member on one of the cable interface and the bracket, with a recess on the other of the cable interface and the bracket.

Abstract: A robotic tool changer with an improved safety interlock includes a master unit, a tool unit, and a coupler movable between coupled and decoupled positions and operative to couple the master and tool units. A circuit for actuating the coupler is associated with the tool unit, for connection to an interlock that closes when the tool is safely parked in a tool stand. The circuit enables the coupler to assume the decoupled position when the master and tool units are coupled and the circuit is closed. The robotic tool changer additionally includes a circuit operative to enable the coupler to assume the decoupled position when the master unit is decoupled from the tool unit.