Abstract: A waterborne paint bell applicator is movable to and from a docking position and includes a paint receptacle connected to a paint canister. A paint filling station has a plurality of paint injectors each connected to a different color paint supply and being movable to the docking position for engagement with the paint receptacle for filling the paint canister with paint. A servomotor drives a piston in the canister.

Abstract: A servo spot welding control system and method to efficiently weld a pair of workpieces together. The system includes a robot movable about the workpieces, a weld gun, servomotors, a transformer, and a controller. The weld gun is mounted on the robot and includes at least two pairs of electrodes. Each pair of electrodes includes a stationary electrode and a moveable electrode. The servomotors are operatively connected to the movable electrodes. The controller actuates the robot to move the robot into position. The controller also actuates the servomotors to clamp the workpieces and to selectively sequence electric current from the transformer to form multiple spot welds on the workpieces.

Abstract: A method is disclosed for providing a steady transition state for an integral pneumatic dispensing system that is related to a robot. The method dispenses a single material using a pneumatic dispensing system having a single output including first and second shotmeters having first and second meters, first and second encoders and first and second pressure transducers. The method includes the step of loading the first shotmeter with the material. Once loaded, a pressure is applied to the material. The material is then dispensed out of the first shotmeter by forcing the material through the single output. Once the material in the first shotmeter is dispensed to a predetermined volume, the method begins to transition the flow of material from the first shotmeter to the second shotmeter. The transition includes the control of the volume being dispensed and the pressure applied to the material.

Abstract: An apparatus and a method for controlling a paint canister filling operation includes a controller for determining a total volume of paint required for a painting operation, calculating a required piston position and actuating a motor to move a piston in the interior of the canister to the required position. The controller opens a supply valve connected between the canister interior and a paint supply to fill the canister and monitors the torque applied by the motor to maintain the piston at the required position. When the torque exceeds a set point representing the torque value required to maintain the piston at the required position when the total required paint is in the canister interior, the controller closes the supply valve.

Abstract: A method for painting a panel using a paint applicator defines a painting pattern with a plurality of points on a surface of a panel to be painted, the pattern extending in a predetermined direction and the points defining opposite edges of the pattern extending in a predetermined direction, with at least one edge of the pattern being adjacent an edge of the panel. The applicator is moved relative to the panel to apply the paint in the painting pattern having a desired film thickness. The pattern including a first plurality of pattern segments and a second plurality of reinforcing segments, the pattern segments being connected together each extending between an associated pair of the points on the opposite edges of the pattern, and the reinforcing segments each extending between an associated pair of the points adjacent the edge of the panel. A plurality of different painting patterns can be stored in a memory for selecting the one pattern to be used.

Abstract: A parts feeding system (14) for moving parts (10) relative to a support plane (12) is provided. A robot (16) having a base (18) is disposed on the support plane (12) and operable within an envelope (22) having a limit (24) that extends at an acute angle (B) relative to the support plane (12). First and second part support trays (42,44) are stacked one above the other to support the parts (10) thereon in a stacked position (48). The second part support tray (44) is movable to a stored position (50) which uncovers the first part support tray (42) immediately therebelow. Each of the part support trays (30) includes a front edge (34) facing toward the base (18) in the stacked position (48). The front edge (34) of each of the part support trays (30) is disposed a greater distance from the base (18) than the part support tray (30) therebelow to define a receding stacked relationship.

Abstract: An intelligent power assisted manual manipulator controllable by operator inputs from an operator for moving an object is provided. The manipulator includes a movable base supporting a lift mechanism for moving the object. The manipulator also includes at least one servomotor for actuating at least one of the movable base and the lift mechanism for moving the object. An operator control mechanism for receiving the operator inputs is supported on the lift mechanism. A plurality of force sensors are disposed between the operator control mechanism and the lift mechanism for sensing said operator inputs and actuating at least one of the at least one servomotor. The movable base includes an overhead rail defining a generally horizontal first axis and a carriage supported on the overhead rail and movable along the first axis. The lift mechanism includes a turret assembly supported on the carriage having a generally vertical second axis, and a generally horizontal third axis.

Abstract: A cleaning system and method for a bell atomizer spray head provides an air/solvent mixture to an exterior surface of a bell cup through shaping air passages and outlets during a color change or bell cleaning operation. In the alternative, cleaning passages can be provided for the air/solvent mixture to exit adjacent the bell cup exterior.

Abstract: A method is disclosed for providing a steady transition state for an integral pneumatic dispensing system that is related to a robot. The method dispenses a single material using a pneumatic dispensing system having a single output including first and second shotmeters having first and second meters, first and second encoders and first and second pressure transducers. The method includes the step of loading the first shotmeter with the material. Once loaded, a pressure is applied to the material. The material is then dispensed out of the first shotmeter by forcing the material through the single output. Once the material in the first shotmeter is dispensed to a predetermined volume, the method begins to transition the flow of material from the first shotmeter to the second shotmeter. The transition includes the control of the volume being dispensed and the pressure applied to the material.

Abstract: The subject invention is an optical detection assembly (26) for detecting dispensed material (28). The detection assembly (26) includes a housing (38) having a number of optical sensors (42) mounted to the housing (38). A material applicator (30) is mounted within a central opening (44) of the housing (38) and extends through the opening (44) such that the sensors (42) substantially surround the applicator (30) to continuously detect the material (28) being dispensed through the applicator (30). The subject invention also includes the method of detecting the material (28) being dispensed upon a workpiece (32) utilizing a robotic apparatus (20) having an articulated arm (24) with the housing (38) mounted to the arm (24).

Abstract: A method and system for allowing a remote computer to communicate with a programmable controller having a memory for storing a plurality of types of data objects includes an interface module at the controller for receiving a request from the remote computer for one of the data objects stored in the programmable controller. A data converter module determines the type of the data object being requested and automatically converts the data into a comprehensible format based on the type of the data object. The interface module then generates a user display in response to the request for transmission to the remote computer. The remote computer includes a display for displaying the user display so as to allow a user to access the comprehensible format of the requested data.

Abstract: A multi-axis electric spraying robot adapted for use in a hazardous environment includes a base having a first pressurized compartment and an arm assembly having a second pressurized compartment in which compartments electric motors are respectively located. The arm assembly is supported for movement on the base at one end thereof. The arm assembly includes a wrist adapted for connecting the opposite end of the arm assembly with a spraying tool. One electric motor is provided to drive each axis. The compartments are pressurized to prevent flammable gases or vapors from entering the first and second compartments during operation of the robot.

Abstract: The subject invention is an optical detection assembly (26) for detecting dispensed material (28). The detection assembly (26) includes a housing (38) having a number of optical sensors (42) mounted to the housing (38). A material applicator (30) is mounted within a central opening (44) of the housing (38) and extends through the opening (44) such that the sensors (42) substantially surround the applicator (30) to continuously detect the material (28) being dispensed through the applicator (30). The subject invention also includes the method of detecting the material (28) being dispensed upon a workpiece (32) utilizing a robotic apparatus (20) having an articulated arm (24) with the housing (38) mounted to the arm (24).

Abstract: An apparatus and a method for compliant positioning of an object during an assembly operation wherein the apparatus includes a base plate, a locator plate for mounting an object such as a clamp or a tool spaced from the base plate and a plurality of linear actuators connected between the base plate the locator plate by universal joints providing six degrees of freedom of movement. According to the apparatus and the method a control is connected to the actuators for selectively moving the locator plate to a predetermined position relative to the base plate for contacting a component to be assembled with an object mounted on the locator plate. Tow or more of the actuators can be mechanically coupled to move the locator plate with less than six degrees of freedom. The control is responsive to a force applied to the locator plate through the object during assembly of the component for actuating the linear actuators to change the applied force.

Abstract: A method of teaching a robot a desired operating path and a lead-through teach handle assembly are disclosed. A mounting mechanism mounts the entire handle assembly to an arm of the robot. The handle assembly also includes a handle that is supported by the mounting mechanism. A robot operator utilizes the handle assembly and grasps the handle to apply an external force to move the robot arm, or the operator, without the handle assembly, directly holds a tool connected to the robot arm to apply the external force at the tool. The handle assembly is characterized by a universal joint that interconnects the handle and the mounting mechanism and that accommodates orientation changes of the handle relative to the mounting mechanism that result from translational and rotational movement of the robot arm as the user is teaching the robot. The external force applied at the tool is estimated with either a force sensor disposed on the handle assembly or by monitoring the torque of motors used to move the robot.

Abstract: An apparatus and a method for compliant positioning of an object during an assembly operation wherein the apparatus includes a base plate, a locator plate for mounting an object such as a clamp or a tool spaced from the base plate and a plurality of linear actuators connected between the base plate the locator plate by universal joints providing six degrees of freedom of movement. According to the apparatus and the method a control is connected to the actuators for selectively moving the locator plate to a predetermined position relative to the base plate for contacting a component to be assembled with an object mounted on the locator plate. Two or more of the actuators can be mechanically coupled to move the locator plate with less than six degrees of freedom. The control is responsive to a force applied to the locator plate through the object during assembly of the component for actuating the linear actuators to change the applied force.

Abstract: A method of determining contact positions of a robot relative to a workpiece in a workspace of the robot. The method utilizes the contact positions to determine a location of the workpiece in the robot workspace. The method also monitors an integral operating parameter within the robot, such as motor torque, to determine the contact positions of the robot relative to the workpiece and to locate the workpiece.

Abstract: A robotic manipulator having a gripping tool assembly for separating a thin sheet of metal from a stack of metal sheets. The assembly comprises a frame mounted to a lift arm. A separating device is pivotally mounted to the frame for grasping and lifting a corner of the top metal sheet to create an initial separation of the sheet from the stack. A plurality of stationary suction lifters are secured to the frame for grasping and lifting the remaining portions of the top sheet. The gripping tool assembly is characterized by first and second air hoses or nozzles mounted to the frame with the first air nozzle positioned above the second air nozzle whereby the first air nozzle provides pressurized air toward the corner of the sheet to assist in the initial separation of the sheet and the second air nozzle provides pressurized air below the sheet after the initial separation of the sheet from the stack.

Abstract: A spray assembly for applying material to an object is provided. The assembly includes a plurality of spray nozzles each having spray openings for applying material to the object. Four nozzles are provided having two orientations each orientation with two spray widths. The assembly also includes a plurality of valves for controlling the flow of material through each of the spray openings. A manifold supports the plurality of spray nozzles and the valves and defines a feed bore and a spray bore extending between the feed bore and each of the nozzles. Water passages are integral with the manifold to regulate the temperature of the material flowing through the spray bores.

Abstract: A method of controlling a powered manipulator in a plurality of workspaces is disclosed. The manipulator includes a handle, a motor, a force sensor, and is in combination with a processor controlling the manipulator. The method includes the steps of imparting force on the control handle, sensing direction and magnitude of the force, and sending data of the force to the processor. The data is processed to establish movement commands for the manipulator. The processor is programmed to establish at least one virtual constraint in a first workspace for limiting movement of the manipulator to prevent an operator from moving the manipulator to a limit of this workspace. After the manipulator is moved in this workspace, the manipulator is relocated from the first workspace into a second workspace different from the first workspace where the manipulator is then moved again.