Abstract: A robotic tool has a longitudinal shaft, defining a longitudinal axis when the shaft is in a default, centered position. A lockout rod is moveable between first and second positions. In the first position, the lockout rod allows the longitudinal shaft to move with 360 radial degrees of compliance about the longitudinal axis. In the second position, the lockout rod limits compliance of the longitudinal shaft to only one radial angle from the longitudinal axis. In one embodiment the lockout rod is positioned adjacent (e.g., above or below) part of one ring of a 2-axis concentric ring gimbal. The lockout rod is shaped so as to not contact any part of the gimbal in the first position, allowing compliance in a full 360 radial degrees. In the second position, the lockout rod limits the motion of one ring of the gimbal, limiting compliance of the shaft to motion of the other ring, which is necessarily limited to only one radial angle.

Abstract: A torque sensor comprises a transducer plate having a center area and periphery connected by a plurality of spokes and instrumentation beams. The transducer plate exhibits mechanical compliance under axial torque, but stiffness under off-axis loads. Strain gages attached to instrumentation beams detect deformation caused by axial torques. The instrumentation beams may be asymmetric, allowing strain gages to be placed in regions of high sensitivity to axial torques and low sensitivity to off-axis loads. The strain gage responses from some off-axis loads are designed to be coupled to, or linearly dependent on, the strain gage responses of other off-axis loads. This reduces the number of strain gages necessary to resolve the loads. The spokes and beams are cost-effectively formed by removing adjacent transducer plate material in simple shapes.

Abstract: To substantially eliminate torsional freeplay in a robotic tool changer having a ball-lock coupling mechanism, scallop-like features in the form of cross-contact recesses are formed in at least one of, and preferably both of, a bearing race in a tool assembly at the points of contact of rolling members, and in the opposing inner surfaces of bores containing the rolling members in a master assembly. The cross-contact recesses are sized and shaped to receive a rolling member, but have a central void, or channel, perpendicular to the rolling member's motion in torsional freeplay, which does not contact the rolling member. The cross-contact recess contacts the rolling member at contact areas on either side of the central void.

Abstract: A pneumatic robotic tool, such as grinder, sander, etc., implements passive force control and compliance using two or more double-acting pneumatic pistons distributed about a pneumatic motor within the tool housing. The multiple pistons facilitate a compact design, reducing tool stack height, as compared to prior-art, single-piston designs. In one embodiment, filtered breather vents and an air pressure equalization passage maintain ambient atmospheric pressure throughout the tool, while preventing the infiltration of dust and other particulates. In one embodiment, a hard port rigidly affixed to the tool housing is provided for at least motor supply pneumatic fluid. The motor supply air is transferred from the hard port to the pneumatic motor via a flexible pneumatic fluid tube within the tool housing. In one embodiment, the pneumatic motor discharge air is vented from the tool housing in a sealed passage that accommodates the tool compliance motion, and prevents dust infiltration.

Abstract: In a Force/Torque sensor employing strain gages, a hardware temperature compensation procedure substantially eliminates thermal drift of a plurality of load-sensing strain gages with changes in temperature, using trimming resistors and a single, unstressed strain gage. The strain gages are connected in a quarter-bridge configuration, in multiple parallel stages. An unstressed strain gage in quarter-bridge configuration is connected in parallel. Trimming resistors are added across one or more of the unstressed and load-sensing strain gages in a compensation procedure that substantially eliminates thermal drift of the load-sensing strain gages over a predefined temperature range.

Abstract: A compliance mechanism for holding a robotic finishing tool implements passive force control and compliance using one or more double-acting pneumatic pistons. A desired application force is set and maintained by controlling pneumatic pressure in chambers both fore and aft of the one or more double-acting pneumatic pistons. The pressures in the fore and aft chambers are dynamically controlled, e.g., in response to changes in spatial orientation of the robot arm and tool, to maintain a desired compliance force applied by the robotic finishing tool to a workpiece. An external regulator maintains the fore and aft chamber pressures, for a given spatial orientation, throughout the holder's range of compliance motion. The compliance mechanism includes a plurality of piston bores; the number of active pistons may be adjusted for a given operation, e.g., in response to the finishing tool weight.

Abstract: A robotic tool changer includes master and tool assemblies. When the master and tool assemblies are coupled, rolling members project from the master assembly and contact opposed sloped surfaces of a plurality of cutouts formed in a bearing race in the tool assembly. By contacting opposed sloped surfaces of a plurality of cutouts with the rolling members, torsional freeplay between the master and tool assemblies is eliminated or minimized.

Abstract: A utility coupler that includes a coupling unit and a tool unit that can be selectively engaged together. The coupling unit may include a body, a cam member, a handle, and one or more utility couplings. The tool unit may include a body, a latching pin, and one or more utility couplings. In operation, the coupling unit may be placed into a decoupled position with the handle in a first position. The coupling unit may be moved into proximity of the tool unit. The handle may be moved to a second position causing the cam member to engage with the latching pin and couple the coupling unit to the tool unit. The utility couplings engage together to pass the one or more utilities to the industrial equipment.

Abstract: A linkage assembly to connect a tool to a robotic device. The linkage assembly includes a body and a first linkage pair with first and second links that are configured to be connected to a first section of the tool. The linkage assembly also includes a second linkage pair that includes first and second links that are configured to be connected to a second section of the tool. The first linkage pair are powered to provide a force to move the tool relative to the body. The second linkage pair supports the tool and moves with the first linkage pair. Each of the first and second linkage pairs are pivotally connected to the body and may maintain parallel positioning during the movement.

Abstract: A robotic force/torque (FT) sensor restricts the conduction of heat, generated by an attached tool, through the FT sensor body to a radial direction. Heat from the tool is channeled to the center of the FT sensor body by a thermally conductive member. Additionally, heat from the tool is insulated from portions of the FT sensor body other than its center by a thermally insulating member. Transducers, such as strain gages attached to the surfaces of deformable beams, are disposed at a substantially equal distance from the center of the FT sensor body. Accordingly, as heat conducts through the FT sensor body from the center radially outwardly, all transducers experience substantially equal thermal load at any given time.

Abstract: A tool changing system that includes a tool mount adapter and a tool holder. The tool mount adapter is configured to be attached to a tool and selectively engage and disengage a tool bit. The tool provides movement to the engaged tool bit to perform work on a workpiece. The tool holder is positioned in proximity to hold the tool bit when the tool bit is not engaged by the tool. The tool holder can also selectively engage and disengage the tool bit.

Abstract: A motor brush quick change assembly that includes brush units and electrical spring contacts. The brush units include a carrier with a housing and a brush. The electrical spring contacts are connected to an electrical device. Each of the brush units is configured to be removably attached to the electrical device to contact one of the electrical spring contacts. The brush unit thus provide for both a mechanical and electrical connection to the electrical device. The brush units are configured to prevent the need for separate electrical leads that require separate attachment and detachment to the electrical device. This design provides for straight-forward removal and replacement that can be performed by a robotic device or an operator.

Abstract: Strain gages on a robotic force/torque sensor are individually temperature compensated prior to resolving the gage outputs to estimate force and torque loads on the sensor. Thermal sensors are mounted proximate each strain gage, and the initial gate and thermal sensor outputs at a known load and temperature are obtained. The force/torque sensor then undergoes warming, and strain gage and thermal sensor outputs are again obtained. These gage and thermal sensor outputs are processed to calculate coefficients to a temperature compensation equation, such as by using a least squares algorithm. Each strain gage output is compensated using the temperature compensation equation, and the temperature-compensated outputs of the strain gages are then combined to resolve temperature-compensated force and torque values.

Abstract: A robotic tool changer ensures inherently safe decoupling operation by only providing pneumatic fluid to a decouple port of a pneumatic coupling mechanism in the case that the tool changer is seated on, and properly aligned with, a tool stand. Pneumatic fluid to decouple the pneumatic coupling mechanism is routed from an air source to the tool stand. A pass-through in the tool stand returns the pneumatic fluid to a pneumatic path in the tool changer leading to a decouple port of the pneumatic coupling mechanism. Hence, the tool changer must be seated on the tool stand for the decouple port to receive pneumatic fluid to operate. Furthermore, a safety coupling is interposed on the pneumatic path between the tool stand and the decouple port. The safety coupling requires the tool changer to be seated on, and properly aligned with, the tool stand to effect the flow of pneumatic fluid—otherwise, the pneumatic fluid is bled to the atmosphere.

Abstract: A force/torque sensor includes a plurality of serpentine or spiral deformable beams connecting a TAP and MAP. These classes of shapes increase the overall length of the deformable beams, which reduces their stiffness. In addition to the deformable beams is a plurality of straight overload beams, each connected at a first end to one of the TAP and MAP, and separated from the other of the TAP and MAP at the second end by an overload gap of a predetermined width. Over a first range of forces and torques, strain gages on the deformable beams transduce compressive and tensile strains into electrical signals, which are processed to resolve the forces and torques. Over a second range of forces and torques greater than the first range, the overload beams close the overload gap, establishing rigid contact to both the TAP and MAP. The stiffness of the sensor in the second range of forces and torques is greater than over the first range.

Abstract: An axially and radially compliant deburring tool holds a commercially available end tool holder, which in turn holds a variety of commercially available interchangeable deburring end tools, such as those commercially available for the hand deburring market. The axially and radially compliant deburring tool exhibits axial compliance in response to an external force by allowing a longitudinal sleeve holding the end tool holder to move longitudinally along a longitudinal axis of the tool, against a bias force. The axially and radially compliant deburring tool exhibits radial compliance in response to an external force by interaction between a cam contact member and a concave cam surface, both under the bias force and hence operative to return the commercially available to a centered, extended position in the absence of external forces.

Abstract: A robotic tool changer includes a locking mechanism that enhances safety. More particularly, the locking mechanism is an “over center” locking mechanism that maintains a constant lock force on a tool. The lock force exerted on the tool by the locking mechanism remains substantially constant, even after a motor providing power to the robotic tool changer is removed, and after the robotic tool changer experiences mechanical wear.

Abstract: In an inherently safe robotic tool changer, a master unit couples to a tool unit via a first power source, and decouples from the tool unit using a separate, second power source. The second power source is only available when an attached tool is safely disposed in a tool stand. In embodiments where the first power source is not selectively applied, such as the constant bias provided by a spring, a detent mechanism maintains the master unit in a decoupled state when the master unit is removed from the tool unit. The detent mechanism allows the master unit to couple to a different tool unit upon physically abutting the new tool unit.

Abstract: A force/torque sensor comprising a Tool Adapter Plate (TAP) connected to a Mounting Adapter Plate (TAP) by one or more radially-spaced, deformable beams features a pair of strain gages affixed to only one surface of each beam. The two strain gages are affixed to, e.g., the top surface on either side of, and spaced away from, a neutral axis of the beam. This enables a very compact sensor design, in one embodiment, machined from a single piece of metal stock. The two sensors may be connected in a quarter bridge topology. In one embodiment, another pair of strain gages is affixed to the same side of the beam, and the four gages are wired in a half-bridge topology.

Abstract: A modular approach to an electrical power and/or signal passing utility module is presented. A universal receptacle is fixedly disposed in bores in both of first and second signal connector blocks. A threaded socket member and a nonconductive guide bushing are installed, as needed, in receptacles in the first block, and a threaded pin member is installed in corresponding receptacles in the second block. The nonconductive guide bushing insulates the sockets, and guides pin posts into the socket as the two blocks abut. A compliant member such as an o-ring provides compliance of the socket and pin assemblies in the signal connector blocks, making the assemblies self-aligning. The socket and pin assemblies are field-replaceable by use of a simple tool.