Abstract: A method is disclosed for reloading a plurality of shotmeters supplying fluid material to a plurality of robots from a bulk supply. The method is capable of alternating which of the shotmeters is being reloaded at any given time. This greatly reduces the capacity requirements of the bulk supply. The method includes the steps of activating one of the shotmeters to define a primary shotmeter. The material in the primary shotmeter is then dispensed. Once the primary shotmeter is emptied, the other of the two shotmeters associated with the robot is activated and becomes the primary shotmeter. This shotmeter then dispenses the material. A request is forwarded to the system programming logic controller to reload the emptied shotmeter. Once approval is received, the emptied shotmeter is reloaded. The system programming logic controller only allows the emptied shotmeter to reload when the emptied shotmeter is the only one of the plurality of shotmeters relying on the bulk supply at that time.

Abstract: A method of determining position information of a workpiece relative to a robot includes the ability to move the workpiece into a variety of orientations relative to the robot during the touch sensing location procedure. The position information is then used for performing a robot operation including coordinated motion. A coordinated reference frame is defined with respect to a moveable positioner that supports the workpiece. Known kinematic relationships between the positioner and the robot are used to control operation of the robot within the coordinated reference frame throughout the touch sensing location procedure. By moving the workpiece relative to the robot during the touch sensing location procedure, a greater variety of workpieces can be processed and relatively complicated workpiece configurations can be accurately determined. The robot operating parameters are modified according to the determined position information.

Abstract: A take-up device for automatically taking-up slack in a control cable. The take-up device includes a cable mount mounted to one end of a control cable. A compression spring engages the cable mount and continuously biases the cable mount to a slack take-up position to tension the control cable. In the preferred embodiment, the cable mount is biased so that one end of the control cable moves toward the other end of the control cable in order tension the control cable. A threaded tube engages the cable mount to retain the cable mount in the slack take-up position. The take-up device is characterized by a torsion spring automatically moving the threaded tube into engagement with the cable mount as the compression spring biases the cable mount to the slack take-up position thereby automatically preventing the cable mount from returning to a slackened position.

Abstract: A laser enclosure assembly for providing a safe operating environment for an operator during the laser manipulation of a workpiece. The enclosure assembly generally includes a housing having a ceiling and a floor platform, and a pair of discs rotatably supported by the housing. The enclosure assembly further includes a partition having top and bottom ends respectively near the ceiling and the floor platform of the housing and extending between the discs to define an active chamber and a passive chamber within the housing on opposite sides of the partition. The workpiece is manipulated between the active and passive chambers to ensure the safe operating environment for the operator during the laser manipulation of the workpiece.

Abstract: A 3-D camera system (10) includes a light source (12) and a grating (14) spaced at a predetermined distance from the light source (12). The light source (12) and grating (14) project a shadow of the grating (14) on an object (16). Images of the object (16) with the grating (14) shadows projected thereon are captured by a sensor (18) in a video camera (17). A processor (19) converts the images to a three dimensional bit map of the object (16). The light source (12) includes a plurality of at least three rows of light sources (20) defining a matrix (22) whereby different rows of the matrix (22) may be illuminated to produce different grating (14) shadows on the object (16).

Abstract: An integral cutting tool (10) for trimming a flash portion (12) from a peripheral edge (14) of a blow-molded plastic part (16). The cutting tool (10) has a main section (18) which has a circular cross-section. The cutting tool (10) also has a cutting tip (20) with a distal end (22) and cutting edges (24). Between the main section (18) and the cutting tip (20) is an intermediate contoured section (26) which has a smooth surface. The cutting edges (24) on the cutting tip (20) extend from the end (22) of the cutting tip (20) up to the smooth contoured section (26). The contoured section (26) engages the shape of the part (16) to position the cutting tip (20) relative to the part (16) during the cutting of the flash (12).

Abstract: A gripping tool assembly disposed on the wrist section of a robot for gripping and moving various objects between a pick-up zone and a drop-off zone. The gripping tool assembly includes a frame having a top portion and a bottom portion with a pair of parallel lift arms secured to the bottom portion of the frame and projecting outwardly from the frame for supporting the object. A clamp is movably mounted to the frame for vertical movement between the top and bottom portions relative to the lift arms to sandwich the object between the clamp and the lift arms. The gripping tool assembly is characterized by a pusher movably mounted to the frame along a hollow tine. The pusher is mounted to a lead screw disposed within the tine wherein the lead screw horizontally moves the pusher relative to the lift arms for pushing the object toward the distal ends of the lift arms.

Abstract: A robot calibration system includes a calibration sensor that provides an indication of when a first reference point that remains fixed relative to a robot base is a fixed distance from a second reference point that is located on the robot arm. The robot arm is moved through a plurality of orientations and each time that the fixed distance between the two reference points is achieved, robot joint position information is determined. The preferred calibration sensor includes a string that extends between the two reference points and activates a signal generator each time that the string is taut as caused by the orientation of the robot arm. The generated signal indicates that the two reference points are separated by the fixed distance. The determined robot joint positions are then used to determine a calibration factor which varies depending on the needs of a particular situation.

Abstract: A method of controlling movement of a robot includes moving only the wrist portion about two of the wrist axes to achieve a repeated and cyclical movement, such as a back-and-forth movement of the tool relative to a preselected path. Since only the wrist is moved, the range of available tool positions can be determined. In most instances, the desired position of the tool as it deviates from the path is outside of the range of available tool positions, given that only the wrist will move. The method of this invention includes determining a target position within the range of available positions that best corresponds to the desired position of the tool. A unique inverse kinematics solution, which includes fixing one of the wrist axes, is used to determine the wrist orientation required to place the tool into the target position.

Abstract: A robotic system for handling a plurality of items includes a conveyor that moves the items along a central longitudinal axis of the conveyor. A robot base is supported on a rail directly above the conveyor. The robot is moveable along the rail so that it moves along the axis of the conveyor. The robot includes a three-axis arm that is supported for movement relative to the robot base. The robot arm has equal, symmetric access to either side of the conveyor. The robot base does not rotate relative to the conveyor axis.

Abstract: An apparatus 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. 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 controlling a robot system (20) includes using a camera (40) to generate a first, two-dimensional image of a marking (42) on a workpiece (32). A second, two-dimensional image of the marking (42) is generated from a second perspective. The two images are then used to generate a three-dimensional location of the marking in real space relative to the robot (22). Since the visible marking (42) corresponds to a desired path (48), the three-dimensional location information is used to automatically program the robot (22) to follow the desired path.

Abstract: A robot assembly (10) for opening and holding an automotive door including a base (12) movably mounted to a platform (14). An inner robot arm (18) is pivotally mounted to the base. An outer robot arm (20) is pivotally mounted to the inner arm (18). A tool arm (22) is pivotally mounted to the outer robot arm (20). The tool arm (22) includes a shaft (58) presenting a second tool arm axis (A.sub.4) for rotation about the second tool arm axis (A.sub.4). A sphere (90), presenting first, second and third sphere axes (A.sub.5,A.sub.6,A.sub.7), is mounted to the distal end of the shaft (58) for rotatably supporting a magnet tool (118). A pin (104) extends from the sphere (90) for preventing the rotation of the tool (118) about the first sphere axis (A.sub.) which is parallel to the second tool arm axis (A.sub.4). The tool (118) is positioned in a home position relative to the second tool arm axis (A.sub.4) by a biasing spring (70) operatively connected to the shaft (58).

Abstract: A robot wrist and spray head applicator assembly (10) comprising a base (18) presenting an arm axis (A) and supported on a robot arm (16). A housing (22) is supported by the base (18) for rotation about the arm axis (A). A tool support member (30) has a tool axis (B) and is rotatably supported by the housing (22) for rotation about a transverse axis (C) which is disposed at an acute angle relative to the arm axis (A) for movement between a straight ahead position in which the tool axis (B) is generally parallel to the arm axis (A) and a transverse position in which the tool axis (B) is transverse to the arm axis (A). A spray head (38, 38') is rotatably supported by the tool support member (30) for rotation about the tool axis (B) and the spray head (38, 38') and includes a needle valve (44) movable between open and closed positions for controlling flow.

Abstract: An apparatus (10) and method for selecting a fluid material to be supplied to a material applicator (24) from a plurality of fluid materials (23), the material applicator being located in a hazardous area (12), includes a control circuit (26) located in a non-hazardous area (11) for generating a coded address signal representing a selected fluid material and for generating a predetermined amount of electrical power, a valve selection circuit (27) located in the non-hazardous area and connected to the control circuit and being responsive to the coded address signal for generating the predetermined amount of electrical power at a selected one of a plurality of outputs corresponding to the coded address signal, and a valve actuation circuit (28) located in the hazardous area and including a separate valve (22) connected to each of the valve selection circuit outputs.

Abstract: An apparatus (50) and method for dispensing fluid material (55) from a dispensing gun (53) onto a workpiece (17) includes a metering cylinder (56) having a metering chamber formed therein with a pair of variable volume chamber portions (66,67), a valve assembly (52) connected to a supply of fluid material (51), the dispensing gun and to the chamber portions, and a control (58) connected to a meter actuator (60) connected to the metering cylinder and a valve actuator (59) connected to the valve assembly. The control (58) controls the meter actuator (60) and the valve actuator (59) in first and second modes of operation to dispense the fluid material (55) from the dispensing gun (53) by alternately drawing from the supply of fluid material (51) through the valve assembly into a first one of the chamber portions and forcing the fluid material from a second one of the chamber portions through the valve assembly to the dispensing gun.

Abstract: An apparatus for interfacing between a human operator and a manufacturing cell having a plurality of mechanical units for assembling components and subassemblies includes a video monitor responsive to display signals for generating to the human operator a graphic display of information related to a selected one of a plurality of mechanical units in the manufacturing cell. An input device such as a mouse is responsive to the human operator for generating command signals representing desired changes to the graphic display including information as to which of the mechanical units is selected, which style of components is selected and an amount and direction of a software shim to be applied to the selected mechanical unit. A data processing means is connected to the video monitor and to the input device, is responsive to the command signals for generating control signals and is responsive to position signals for generating the display signals.

Abstract: An apparatus for interfacing between a human operator and a manufacturing cell having a plurality of mechanical units for assembling components and subassemblies includes a video monitor responsive to display signals for generating to the human operator a graphic display of information related to a selected one of a plurality of mechanical units in the manufacturing cell. An input device such as a mouse is responsive to the human operator for generating command signals representing desired changes to the graphic display including information as to which of the mechanical units is selected and a size and direction of application of a software shim to be applied to the selected mechanical unit. A data processing means is connected to the video monitor and to the input device, is responsive to the command signals for generating control signals and is responsive to position signals for generating the display signals.

Abstract: A variable form spray system includes a robot manipulator, a masking tool assembly integrated with the manipulator, sealer supply hardware which supplies spray material to the manipulator and sealer recovery hardware which recovers material sprayed and skived by the masking tool assembly. Spray pattern form is controlled by collecting overspray using adjustable skive manifolds of the assembly on each side of the spray pattern which function to vacuum off the edges of the airless spray pattern. The positions of the skive manifolds are programmable.

Abstract: A system and method for packaging a plurality of substantially rigid sheet-like members. The system includes apparatus for carrying out the method steps of applying a liquified material to a selected location on a surface of each of the plurality of sheet-like members, cooling the liquified material to form a removable solid element adhering to the selected location on the surface, and stacking the plurality of sheet-like members for packaging such that the solid elements act as interleaving spacers therebetween protecting the sheet-like members from handling and shipping damage.