Abstract: A method and system for the flexible assembly of components into an assembly at an assembly station within an assembly area in an adaptive, programmable fashion. Several programmable locators mounted on a platform work cooperatively to receive and support components or parts having critical positioning features at approximate locations. The programmable locators then move the components so that the critical positioning features and hence the components are at desired locations. Thereafter, part position and orientation are constrained at retaining locations while the components are in their desired locations. Processing equipment at least partially joins the retained components either at the assembly station or at a separate processing station. One of the programmable locators may provide one of the retaining locations.

Abstract: A method and system for the flexible assembly of components into an assembly at an assembly station within an assembly area in an adaptive, programmable fashion. Several programmable locators mounted on a platform work cooperatively to receive and support components or parts having critical positioning features at approximate locations. The programmable locators then move the components so that the critical positioning features and hence the components are at desired locations. Thereafter, part position and orientation are constrained at retaining locations while the components are in their desired locations. Processing equipment at least partially joins the retained components either at the assembly station or at a separate processing station. One of the programmable locators may provide one of the retaining locations.

Abstract: A method and system for transfer of fluids, such as paint, using a fluid canister carried by a transfer device, such as a robot, instead of having paint lines connected to a delivery device, such as a spray gun, carried by the robot. A novel mechanism for initially docking and then filling the canister from a fluid outlet of a pressurized source of fluid without straining the robot is provided. Also, a novel mechanism for cleaning the canister between canister fillings is provided so that paint colors can be changed without loss of productive robot time. In one embodiment, the canister is integrated with the robot. Also, a novel, non-contact sensor is provided for providing a signal to allow the metering of the paint entering or/and discharged from the canister.

Abstract: Method and system are provided for cleaning a paint supply line and changing paint colors by inserting and propelling a termination piston or slug having an outer diameter which forms a sliding fit within the supply line to wipe paint off the interior walls of the supply line. Preferably, the supply line is elastic and the termination piston squeegees the paint off the interior walls. In order to more fully clean the supply line prior to changing paint colors, a predetermined amount of cleaning fluid such as a solvent is injected into the supply line behind the termination piston from a common passage of a manifold. A leading piston or slug is then inserted immediately ahead of a new paint color in the supply line. The pistons may be disposable or may be reused by recirculating them by means of shuttle assemblies and a return line. The manifold is fitted with various valves to selectively supply pressurized air, solvent and two or more paint colors to the supply line.

Abstract: Method and system are provided for the productive utilization of paint in a paint supply line, changing paint colors and cleaning paint lines by inserting and propelling a termination piston or slug having an outer diameter which forms a sliding fit within the supply line to wipe pair off the interior walls of the supply line. Preferably, the supply line is elastic and the termination piston squeegees the paint off the interior walls. A manifold is fitted with various valves to selectively supply pressurized air, solvent and two or more paint colors to the supply line. A process controller controls the timing of the valves of the manifold. The method and system can also be used to retrofit existing color changers in an economical yet environmentally sound fashion.

Abstract: A limited mobility transporter (10) is disclosed having a linkage mechanism (12) with four links (14,16,18,20) pivotally connected at their ends to form a four bar linkage. Engagers (22) are mounted at pivotal connections (A,B,C,D) of the links (14,16,18,20) for selectively engaging a mounting surface (24). An actuator assembly (26) rotates the links (14,16,18,20) about the engaged pivotal connections (A,B,C,D). A programmable controller (28) controls a sequence of movements whereby the transporter (10) is movable about the mounting surface (24) by simultaneous engagement of selected engagers (22) and rotation of the links (14,16,18,20) about the selected engagers (22) in a coplaner fashion to the mounting surface (24). In one embodiment, the engagers (22) comprise a shot pin assembly and the mounting surface (24) includes receptacles for receiving the shot pins. In other embodiments, the engagers (22) are electromagnetic anchors or suction cups.

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 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: 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 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 robot comprising a base, an arm assembly and first and second spaced robot parts are mounted on the robot so that the first robot part pivots with respect to the second robot part about a pivotal axis and a ribbon of flexible cables are connected to and extend between the robot parts in a direction substantially normal to and towards the pivotal axis to provide a ribbon of cables which have an effective length between the robot parts which does not change during pivoting. The cables are clamped in spaced apart positions by a directing mechanism and a retainer mechanism so that the effective length does not change and the cables do not rub each other during pivoting. The directing mechanism comprises a weldment including a pair of interconnected holders which direct the cables from an axis parallel to the pivotal axis to the normal direction towards the pivotal axis.

Abstract: A robot including a balancing mechanism with a spring assembly which exerts a variable force to compensate for the gravitational moment transferred to the mechanism during relative rotation between an arm assembly of the robot and the rest of the robot about a pivotal axis. A spring of the spring assembly 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 that pivotally supports the arm assembly on the rest of the robot for movement about the pivotal axis. The spring assembly has a longitudinal axis which extends towards and is substantially perpendicular to the pivotal axis. The moment arm is connected to the arm assembly at an attachment point offset from the pivotal axis. A first sprocket wheel is mounted on a drive gear of the arm assembly to rotate therewith and a second sprocket wheel is pivotally mounted at the free end of the spring assembly.

Abstract: A robot, including an arm assembly and an energy-storing balancing mechanism which is connected to the arm assembly at a pair of attachment points so that the arm assembly is substantially balanced within a quadrant of arm assembly motion on both sides of a neutral position of the arm assembly relative to the rest of the robot. The balancing mechanism includes a spring assembly having a longitudinal axis which extends towards and is substantially perpendicular to a pivotal axis about which the arm assembly pivots from its neutral position. The spring assembly is preferably connected by a pair of internally slotted links for slidably and pivotally connecting the spring assembly at the attachment points. Each attachment point is only effective (i.e. experiences the pulling force of the spring assembly) during a single quadrant of arm assembly motion.

Abstract: A robot-laser system having a minimum number of mirrors for reflecting a laser beam from a fixed laser beam source to a desired location wherein the mirrors are mounted within the hollow, servo-controlled parts of the robot to move therewith. Only a single mirror is mounted within its associated controlled part to reflect the laser beam as it travels between adjacent controlled parts. The robot has a number of degrees of freedom constituted by two orthogonally related linear movements along intersecting longitudinal axes and two orthogonally related rotary joints having intersecting pivotal axes. Preferably, two of the mirrors are mounted so that the laser beam strikes and is reflected from both points of axes intersection within two of the controlled parts. In one of the disclosed embodiments a mirror mounted in the base of the robot reflects the laser beam from the source to the other mirrors.

Abstract: A robot-laser system having at least one mirror under active program control for reflecting a laser beam from a fixed laser beam source to a desired location. Preferably, first and second mirrors are mounted on an outer arm of the robot to move therewith and rotate relative thereto. A third mirror reflects the laser beam to the first and second mirrors. A programmable servo system automatically moves each of the mirrors relative to and in synchronization with movement of the moving parts of the robot. Each of the mirror is mounted for rotation about a pair of intersecting axes so that the laser beam strikes the point of intersection. In one of the disclosed embodiments a fourth mirror reflects the laser beam from the source to the other mirrors.