Abstract: A handwheel assembly includes a housing. A shaft having a central axis is rotatably supported by the housing. A locking device is rigidly attached to the housing. A rotary gear is circumferentially disposed over the shaft. A handwheel is circumferentially disposed over the shaft. The rotary gear and handwheel are operable to slide along the shaft from a first locked position to a second unlocked position. In the first locked position, the rotary gear is engaged with the locking device to rotationally lock the shaft. In the second unlocked position, the rotary gear is disengaged from the locking device to allow the shaft to rotate.

Abstract: A handwheel assembly includes a housing. A shaft having a central axis is rotatably supported by the housing. A locking device is rigidly attached to the housing. A rotary gear is circumferentially disposed over the shaft. A handwheel is circumferentially disposed over the shaft. The rotary gear and handwheel are operable to slide along the shaft from a first locked position to a second unlocked position. In the first locked position, the rotary gear is engaged with the locking device to rotationally lock the shaft. In the second unlocked position, the rotary gear is disengaged from the locking device to allow the shaft to rotate.

Abstract: A robotic tool changer and systems and methods for controlling the operation of a robotic tool changer are provided. The tool changer, methods, and systems include a robot-side component mountable to a robot arm end interface; a tool-side component adapted to engage a tool; a first slave module associated with the robot-side component and adapted to communicate with a first master module; and a second master module associated with the robot-side component and adapted to communicate with a second slave module associated with the tool. The second slave module may include a temporary power supply, for example, a battery or a capacitor, for instance, a super capacitor. Aspects of the invention are advantageous for performing high-speed robotic connections and disconnections, and for providing tool and tool changer performance information gathering.

Abstract: Automated handling systems and methods for using the handling systems for handling a work piece in a machining process, for example, an electrical discharge machining (EDM) process, are provided. The handling systems include a robotic manipulator adapted to grasp a work piece and locate the work piece in a machining operation, such as, an EDM machining operation. The robotic manipulator includes tooling having gripping devices adapted to grasp and position the work piece so that the work piece can be transferred and positioned, for example, precisely positioned, whereby accurate machining of the work piece can be practiced with little or no custom tooling. Methods for handling a work piece are also disclosed.

Abstract: A robotic arm-end gripping device having a belt-driven drive train is provided. The gripping device includes a set of opposing gripping arms, a variable speed motor, a motor controller adapted to control the operation of the variable speed motor, a drive train driven by the variable speed motor, the drive train comprising a drive belt, a plurality of sheaves, and a plurality of belt clamps mounted to the drive belt and operatively connected to the opposing gripping arms, and a robot arm-end interface. The gripping device may include a fail-safe method and apparatus for prevent the dropping of the gripped article. The belt drive and associated controls provide smooth and rapid operation. The gripping device may be adapted to any arm-end tooling.

Abstract: Automated handling systems and methods for using the handling systems for handling a work piece in a machining process, for example, an electrical discharge machining (EDM) process, are provided. The handling systems include a robotic manipulator adapted to grasp a work piece and locate the work piece in a machining operation, such as, an EDM machining operation. The robotic manipulator includes tooling having gripping devices adapted to grasp and position the work piece so that the work piece can be transferred and positioned, for example, precisely positioned, whereby accurate machining of the work piece can be practiced with little or no custom tooling. Methods for handling a work piece are also disclosed.

Abstract: Automated gripping devices and methods for using the gripping devices for handling a work piece in a machining process, for example, an electrical discharge machining (EDM) process, are provided. The gripping devices include at least one movable plate have a jaw that cooperates with a stationary jaw to hold a work piece. The movable plate is guided and supported by rods that pass through bearings in the movable plate and provide stiffness and positioning accuracy to the movable plate. The movable plate may be translated by a lead screw driven by a drive train, for example, a motor-driven belt drive train. The gripping devices may be used to manipulate and position a work piece in any machining process, but are uniquely capable of enhancing the handling of work pieces in the EDM machining process. Methods for handling work pieces are also disclosed.

Abstract: An apparatus for transporting a plurality of fasteners in an automated changing system, i.e., in a robotic tool changing system, wherein the system includes a tooling adaptor assembly adapted to be coupled and decoupled to and from a robot adaptor assembly. The transport apparatus includes a first member which has a first passage formed therethrough and a second member which has a second passage formed therethrough. Both the first and second members are mutually adapted for alignment to one another when the adaptor assemblies are coupled. When the adaptor assemblies are coupled together, the first and second members form an interface fitting so that the plurality of fasteners, i.e., studs, may pass therethrough, and ultimately be transported to a tool, i.e., a stud welding gun.

Abstract: A single axis force sensor assembly for sensing compressive and tensile forces along a first axis includes a first member having a center hub and a plurality of arms extending radially outward therefrom. Each of the plurality of arms terminate at a peripheral flange of the first member. Strain sensing gauges are mounted to at least one of the plurality of arms so as to detect mechanical deformation of the arm or arms to which the gauges are attached. A second member is joined to the center hub such that the first and second members are oriented generally parallel to one another. A gap extends between the first member and the second member. A circuit carrying substrate may be physically incorporated as a part of the force sensor assembly, i.e., above and adjacent to the plurality of arms. A circuit of the circuit carrying substrate is electrically connected to the strain sensing gauges.

Abstract: A high power electrical interface unit for a robotic tool changing system has a housing, a high power electrical connector in the housing for attachment to a high power electrical cable, and a replaceable high power electrical contact removably attachable to the electrical connector. The electrical contact extends into an opening in the housing and may be replaced through the opening without other disassembly of the interface unit. The contact may be threadably attachable to the connector, and the interface unit may include a member for preventing the electrical connector from rotating when the contact is threaded to the connector. The contact may include a head portion having a spheroidal or spherical contact surface, and a side surface configured for ready engagement by a hand tool such as a socket wrench. The interface unit may be removably secured to either a robot or tooling adaptor, or the interface unit may be integral to the robot or tool adaptor.

Abstract: An automated exchangeable parts feeding system which permits rapid exchange of parts presentation devices so that different size and shape parts can be handled on the parts feeding system. The automated exchangeable parts feeding system includes a parts presentation device having a tool exchange unit attached thereto, and a base exchange unit. The exchange units are mutually adapted to be coupled and decoupled to and from one another. At least one of the exchange units is controllably operable for coupling and decoupling. A robot arm or a pick and place device grasps and places the presentation device on the base exchange unit. The robot arm or pick and place device also functions to grasp and remove the presentation device from the base exchange unit. A control source coordinates the operation of at least one of the exchange units and the robot or pick and place device. The automated exchangeable parts feeding system further includes an optical detector, e.g.

Abstract: Pin-and-socket signal cable connectors of the type exemplified by D-SUB series connectors can be quickly mated and unmated many thousands of times without damage to their terminals and without misalignment errors, by so forming the terminals of one or both of the connectors of a connector pair that they can move with respect to their connector body against a spring bias, and that the pins and sockets mate in abutting relationship rather than in frictional engagement. Modified connectors and adapters for standard connectors are disclosed.

Abstract: An overload detection device (100) adapted for mounting between the end of a robot arm (104) and tooling (106) employs an interlocking pneumatic chamber subassembly (1) and a stemmed plate (2) pneumatically secured in a unique "engaging registration" relationship under normal loading conditions. An annular metal bearing member (16) fixed to the chamber subassembly (1) has an elevated sealing surace (56) which provides an airtight seal only when the components are in engaging registration. An excessive load upsets the engaging registration relationship allowing air to immediately escape and the normally rigid coupling provided by the overload detection device (100) to become compliant. The reduction in pressure is concurrently sensed by a specially designed, externally mounted removable pressure sensor (3). The pressure sensor (3) includes a small snap-acting electrical switch (24) which is actuated by a loose fitting unsealed piston (27).

Abstract: An exchange system is provided for connecting a remote, manipulable element, such as a robot arm tool gripper, to a central control source, such as a robot arm and its associated programmable control. An upper exchange unit attaches to the robot arm and receives control signals which pass through the body of the upper unit to a matable lower exchange unit. A plurality of lower exchange units are provided, each attached to an individual tool gripper and relaying control signals to the gripper. The mating upper and lower exchange units provide for serial connection of the robot arm to any desired one of an array of tool grippers and for communication of control signals through the mated units to each tool gripper without the need for separate control umbilicals between each tool gripper and the control signal source.