Abstract: A method is provided for aligning an articulated beam delivery device, such as a robot, by utilizing an electronic, high resolution television camera as a transducer for measuring small beam deviations at relatively short distances. A display monitor coupled to the camera is located in view of an operator of the robot to provide direct visual feedback for use during the aligning method. The aligning method includes the step of transmitting a collimated optical beam so that the beam travels along a first base path and is deflected by an adjustable mirror supported on an arm assembly having first and second axes of the robot for rotation therewith about the first axis and thence along a second beam path. The beam is also deflected by at least one other mirror supported within a wrist mechanism of the robot to travel along a third beam path to a beam exit end of the robot.

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: A device for delivering a collimated beam of electromagnetic energy, such as a laser beam, including a focusing lens which is rotatable about a first axis offset from a focal axis of the lens. Rotation of the lens about the first axis causes a laser beam traveling along the first axis to be deflected to travel along a focus beam axis which intersects the focal axis at a focal point which, in turn, traces a curve on the workpiece. The first axis is parallel to the focal axis and is offset a variable first distance therefrom. The lens is also rotatable about a second axis also offset from and parallel to the focal axis. Rotation of the focusing lens about the second axis alters the first distance between the first axis and the focal axis in order to vary the radius of the curve traced on the workpiece.

Abstract: A method and system for automatically determining the position and orientation of an object by utilizing as few as a single digital image generated by as few as a single camera without the use of a structured light. The digital image contains at least three non-colinear geometric features of the object. The three features may be either coplanar or non-coplanar. The features or targets are viewed such that perspective information is present in the digital image. In a single camera system the geometric features are points, and in a multi-camera system, the features are typically combinations of points and lines. The location of the features are determined and processed within a programmed computer together with reference data and camera calibration data to provide at least three non-parallel 3-D lines. The 3-D lines are utilized by an iterative algorithm to obtain data relating to the position and orientation of the object in 3-D space.

Abstract: An end effector device is mounted on the arm of a robot for movement through a predetermined motion relative to control axes of the robot under control of a robot controller which also controls a driver of the device to apply at least one variable programmed drive force to a first part relative to a second part at a work station. Preferably, the driver includes a screwdriver which is driven by an electric motor which, in turn, is controlled to apply a variable programmed torque at a variable programmed speed to a screw. The screwdriver and its electric motor are mounted on a slide for movement between extended and retracted positions relative to a base of the device. An air cylinder is coupled to the slide and is controlled to linearly move the slide so that the screwdriver applies a variable programmed axial force to the screw. The driver has a drive compartment formed therein which is maintained under a negative pressure for receiving and retaining the screw.

Abstract: Method and system for the automated assembly of power train components along a plurality of interconnected, closed loops within cells of the system wherein parts and/or subassemblies of the components are assembled on the same assembly pallet on which they were robotically kitted. Along some of the loops, the assembly pallets are automatically transferred from kitting stations to assembly stations and from the assembly stations to an unload station where the components or subassemblies are robotically unloaded. The unloaded assembly pallets are then automatically transferred from the unload station to the kitting stations to repeat the assembly process. A mechanical guided vehicle system (MGVS) asynchronously conveys the assembly pallets along the closed loops which form guide tracks between the different stations. An automated guided vehicle system (AGVS) preferably transports part storage pallets to the system from a receiving area.

Abstract: An apparatus for mastering a robot includes two balls, each of which has a spherical surface configured to simultaneously contact its respective set of mutually orthogonal locating surfaces of a fixture only when the robot is in a predetermined reference position and orientation. The fixture is mounted on a pedestal of the robot base in a fixed spatial position. One of the balls is mounted for movement with a free end of an outer arm of an arm assembly of the robot. The robot also includes a wrist mechanism. A first end of the wrist mechanism is connected to the free end of the outer arm and a second end of the wrist mechanism is adapted to support a tool. The second ball is mounted for movement with the second end of the wrist mechanism.

Abstract: A laser robot system including an offset robot. The system includes a laser beam generator for generating a laser beam. The robot includes a pedestal having a vertical first axis and a hollow base support on the pedestal for rotation about the first axis and for receiving the laser beam along the first axis. A single computer-based controller controls the laser beam generator, a drive system of the robot and an air source which is in fluid communication with the base of the robot. The air source pressurizes the laser beam path through the robot, thereby preventing contamination of the beam path. A hollow arm support in the form of a swing block is laterally supported on the base for rotation relative to the base about a horizontal second axis which intersects the first axis. A robot arm is elongated along a third axis which is obliquely angled to and intersects the second axis. The robot arm is laterally supported on the swing block for pivotal rotation therewith relative to the base about the second axis.

Abstract: Method and system for the automated assembly of power train components along a plurality of interconnected, closed loops within cells of the system wherein parts and/or subassemblies of the components are assembled on the same assembly pallet on which they were robotically kitted. Along some of the loops, the assembly pallets are automatically transferred from kitting stations to assembly stations and from the assembly stations to an unload station where the components or subassemblies are robotically unloaded. The unloaded assembly pallets are then automatically transferred from the unload station to the kitting stations to repeat the assembly process. A mechanical guided vehicle system (MGVS) asynchronously conveys the assembly pallets along the closed loops which form guide tracks between the different stations. An automated guided vehicle system (AGVS) preferably transports part storage pallets to the system from a receiving area.

Abstract: A three-axis wrist mechanism has first, second and third independent rotational axes with two points of mutual intersection which are offset from each other, the first axis being inclined at a fixed angle relative to at least one input drive axis of an input drive mechanism. The drive axis extends along the robot arm to which a first housing of the wrist mechanism is fixedly attached. A second housing is supported on the first housing for rotation about the first axis and a third housing is supported on the second housing for rotation about the second axis. A tool-support member having a tool-mounting surface is supported on the third housing for rotation about the third axis. Gear trains of the mechanism provide the independent rotation of the second and third housing structures and the tool support member to permit selective positioning of the tool-mounting surface in a work envelope.

Abstract: A multiple joint robot part comprising a mechanical wrist mechanism utilizes universal joints to effect simultaneous rotations about three mutually perpendicular axes to thereby impart pitch, yaw and roll motions to a robotic end effector attached thereto. All of the wrist motions are kinematically independent, and the pitch and yaw motions are activated by means of linear motion actuators. Pitch and yaw bend angles are traversed gradually in two or more stages to allow a generous bend radius for internally routed service lines to the end effector.

Abstract: In a robot including a first robot part which pivots with respect to a second robot part about a pivotal axis, a cable routing system includes a multitude of flexible cables which are retained at spaced apart positions by first and second retainers so that the cables are spaced around the outside of a cylinder whose axis coincides with the pivotal axis. A first connector mechanism connects that first retainer to the first robot part so that the first retainer rotates with the first robot part about the pivotal axis during pivoting. A second connector mechanism connects the second retainer to the second robot part so that the second retainer is movable axially toward the first retainer against the biasing action of a spring along the pivotal axis and prevented from rotating about the pivotal axis during pivoting. Each of the retainers includes a slotted disk which separates and guides the cables.

Abstract: A method and system are disclosed for the automated accumulation and loading of parts wherein an automated part transfer apparatus is utilized to successively pick up predetermined arrangements of spaced parts from a shuttle at a pair of unloading stations. The part transfer apparatus preferably includes a gantry robot which places the parts in predetermined positions in a container located in the work envelope of the robot. The robot continues to load the parts until the container is full. In the disclosed embodiment, the method and system are utilized for racking automotive parts after they exit a sheet metal processing machine. Preferably, the parts are vertically accumulated in spaced relationship at an accumulator station in which the shuttle aids in the stacking process. A part indexing mechanism also aids in the stacking process at the accumulator station.

Abstract: A method and apparatus are disclosed for the automated loading of parts wherein multiple gantry robots are utilized to pick up automotive parts from movable transfer beds and placed into predetermined positions in containers which are serially indexed through the work envelopes of the robots until the containers are full. In the disclosed embodiment, the method and system are utilized for racking automotive parts after they exit a sheet metal stamping machine. Preferably, empty containers are automatically delivered to a container queue such as by an automatic guided vehicle system (AGVS) at an unloading station adjacent the robots. Thereafter each AGV is moved to a loading station to receive and retain thereon containers loaded with parts by the gantry robots.

Abstract: A robot including a balancing mechanism or balancer with a compression spring which flexes to compensate for the gravitational moment between an arm assembly and a base of the robot. The compression spring is chosen to have a force-deflection characteristic to account for the gravitational moment and the geometry of the mechanism. The arm assembly has a pivotal connection which pivotally supports the arm assembly on the base of the robot for movement about a pivotal axis. The mechanism can be adjusted for various arm assembly lengths and/or payloads. The mechanism includes a spring support, a connecting rod having a longitudinal axis and connected to the spring support for communicating motion of the spring support to the arm assembly at an attachment point offset from the pivotal axis. The resulting balancing mechanism is relatively compact, which lends itself to robotics applications where space is limited.

Abstract: A control system and method including an integrator coupled with a rate-varying multiplier which operate in parallel with a conventional controller. Because the integration is rate-variable, the resulting control system has the benefits of an integral position control without the problems of integral windup and subsequent overshoot. The system and method have less following and steady state error, faster settling time and better tolerance to noise than traditional PD and PID controls in controlling dynamic manipulators such as robots. Also, because the integrations are performed in a rate-variable manner, errors due to mechanical static friction, i.e. "sticktion", are substantially reduced without sacrificing dynamic performance of the system.

Abstract: A three-axis wrist mechanism has three independent rotational axes with two points of mutual intersection which are offset from each other. The offset provides a generous bend radius for the wrist. First and second housing structures contain the first and second axes while the third axis is disposed within a tool support member. The first housing structure is adapted to be mounted to an outer tubular member of the arm of a robot to rotate independently of the rest of the mechanism. Gear trains of the mechanism provide the independent rotation of the second housing structure and the tool support member to permit selective positioning of a tool-mounting surface of the tool support member within a work envelope.

Abstract: Method and apparatus are disclosed for the automated filling of a container mounted on a vehicle with a fluid. In one embodiment of the fluid fill device the container is part of an engine cooling system, and in the other embodiment of the fluid fill device the container is part of an air conditioning system. Each of the fluid fill devices includes a housing in which a pair of spool valves are mounted. One of the spool valves controls the flow of vacuum and the other spool valve controls the flow of the fluid. A coupling mechanism including a movable piston releasably and fluidly connects its respective device to its container during evacuation and filling cycles. The device receives control signals from a pressurized air source to control movement of the spool valves and the pistons. If the container and the vehicle on which it is mounted are particularly well located, the device can be utilized in a hard automation system.

Abstract: A method and system are provided for automatically locating an object at a vision station by performing an edge-detecting algorithm on at least a portion of the gray-scale digitized image of the object. Preferably, the algorithm comprises an implementation of the Hough transform which includes the iterative application of a direction-sensitive, edge-detecting convolution to the digital image. Each convolution is applied with a different convolution mask or filter, each of which is calculated to give maximum response to an edge of the object in a different direction. The method and system have the ability to extract edges from low contrast images. Also, preferably, a systolic array processor applies the convolutions.

Abstract: A method for changing the tooling in a robot-based material transfer system is disclosed as well as a system utilizing the method. The tooling is changed to accommodate the transfer of material such as automotive parts having different configurations within the system. Initially, end effectors of gantry robots and/or transfer beds of the system are placed in at least one container which is indexed through the work envelopes of the robots. Then, at least one specially designed container containing new tooling is indexed into the work envelopes. The robots are controlled to remove the new tooling from the containers and to place the new tooling in operative positions in the system. In the disclosed embodiment, one of the robots utilizes a special transfer bed gripper to replace the old transfer beds with new transfer beds. Preferably, an automatic guided vehicle system (AGVS) moves containers to and from loading and unloading stations in the material handling system.