BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an embodiment of the control module and control architecture.
FIG. 2 is a perspective view of an embodiment of the drive module.
FIG. 3 is a perspective view of a modular positioning robotic system utilizing an H-frame.
FIG. 4 is a perspective view of a modular positioning robotic system utilizing a turntable.
FIG. 5 is a perspective view of a modular positioning robotic system utilizing a Farris wheel in the horizontal position.
FIG. 6 is a perspective view of a modular positioning robotic system utilizing an H-frame without a drive unit.
FIG. 7 is a sectional view of the adjustability of the H-frame positioning module.
FIGS. 8 and 9 are sectional views of the H-frame clamping system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described as it applies to its preferred embodiment. It is not intended that the present invention be limited to the described embodiment. It is intended that the invention cover all modifications and alternatives, which may be included within the spirit and scope of the invention.
Referring to the drawings, numeral 10 generally refers to a control module. Numeral 12 refers to the positioning module generally and numeral 14 refers to the drive module.
The control module 10, as seen in FIG. 1, has input/output port 16 that connect to the drive module 14 and positioning module 12. The control module 10 also interfaces with the robotic controller 18. The robotic controller 18 can be connected to the controller via a hardware connection or via other means.
The robotic controller 18 connects to a robot 20. In the specific example disclosed by FIG. 1, a robot 20 is connected to a welder 22. Other attachments for the robot 20 are contemplated. These attachments could include manipulators, sprayers, etc.
The control panel 10 connects to the power distribution panel 24. Additionally, the control panel 10 connects to the operation station 26. A connection to the operation station has both inputs and outputs that facilitate communication between the control panel 10 and the operation station 26. The operation station 26 can include inputs for cycle start, positioning and adjustment of the positioning module, error fault reset, etc. The operation station could also include outputs such as a display or indicator lights that would indicate the device status.
In addition to communicating with the operation station 26, the control module can also have direct input from remote sensors 28. The sensors 28 could include light curtains, gates, reamers or wire snips. These sensors 28 would be external to the sensors integrated into the robot 20, positioning module 12 or drive module 14.
The control module 10 communicates with the external devices via the control architecture 30. The control architecture 30 is comprised of a programmable logic controller (PLC) 32, communication bus 34 and a separate input/output board 36. The PLC 32 is essentially a small computer utilizing a microprocessor. The PLC manages and controls the stored information to effectively utilize input and output signals. Further, the PLC 32 coordinates the multiple modules by measuring the position of the drive module and positioning module. Further, the control module interacts with the robot controller that controls the minor axis of rotation. A personal computer would be sufficient to store and operate the modules.
The control architecture 30 also contains a communication bus 34. The bus 34 facilitates communication between the external modules and the PLC 30. There are many standards of communication that could be utilized, but the present embodiment prefers to use Ethernet communication or industrial protocol communication to form an open device level network. It is contemplated that the bus 34 could be a traditional ribbon cable as well as a wireless communication system. Additionally, traditional cabling could be utilized to effect communication between the varied modules and input devices.
The PLC 30 also connects to a block of input/output points 36. The input and output block 34 connect external input devices to the PLC 34. In addition, simple logic can also be integrated into the I/O block 36. An example of a more intelligent I/O block would be a SLICE I/O point system where signals along the block can be converted to logic that could be manipulated and sent across Ethernet connections to the PLC 30.
FIG. 2 discloses a drive unit 14. The drive unit 14 is generally comprised of a frame 38, a clevis plate 40 and brake assembly 42. The drive module also includes an assembly 44 for rotating the clevis plate 40 through at least 180° of rotation. The clevis plate 40 is fashioned to have multiple attachment points 46 that facilitate mounting the positioning module 12 on the drive module 14.
FIG. 3 discloses the drive module 16 attached to a control pallet 70. The control pallet 70 is a mechanical structure used to mount the control module 10, controller 18, welder process equipment, valve packages and electrical enclosures. The control pallet is preferably designed to conform with the modular concept as shown such that a single control pallet 70 design is utilized across the multiple tool types.
FIG. 3 also discloses the positioning module 12 mounted to the drive module 14. FIG. 3 specifically discloses an H-frame 50 positioning module. The H-frame design 50 is shaped like an “H” with each open end 52 of the “H” used to mount head 54 and tailstock 56 positioning mechanisms. The head and tailstocks 54, 56 are used to rotate fixtures to position the products such that the robot 20 has access to the products. The dimensions of the H-frame 50 can be fixed such that an H-frame's length and width are permanently fixed after assembly. Additionally the H-frame 50 can be adjustable. The length, width, and rotation diameter of the H-frame 50 can each be independently adjusted after assembly.
FIG. 7 shows how the H-frame can be adjusted to change responsive to a change in the fixture and part combination. The main base 80 of the H-frame is designed to attach to either a drive module 14 or a stationary base 76. The main parallel frame 82 is mounted to the main base 80 of the H-frame.
The first 86 and second 88 legs of the T-member 84 of the H-frame are inserted into the parallel frame 82. The arms 52 are inserted into the T-member 84 to form the H-frame 50. The head and tailstock positioning members 54 are attached to the ends of the arms 52.
The H-frame is generally constructed of square metal tubular members. The frame of the H-frame could also be constructed of other geometrical tubular members, such as circular or octagonal. Additionally, the members could also be constructed of combinations of tubular and solid material. The frame does not necessarily need to be constructed of metal. Dependent upon the requirements of the fixture and part combination, i.e., weight, length, width and turning diameter, the H-frame could be constructed of plastics, ceramics, wood, etc.
The mechanism for clamping the different components together is simple and repeatable. FIGS. 8 and 9 show the clamp comprising an I-bolt 90 and a standard bolt 92. The standard bolt 92 passes through the I-bolt 90 that is passed through hole 94 along the walls of the tube. The two bolts are 90 degrees from each other, and as a result, the clamping system utilizes a coordinate system that allows for clamping in the x and y directions. The z position, or length of the combined member, can be adjusted by loosening and tightening the clamping bolts. The position can become fixed by drilling additional holes through the frame once the correct position has been determined for a fixture and part combination.
FIG. 3 further discloses a robot riser 58. The robot riser 58 is attached to the frame 38 of the drive module 14. The riser 58 does not rotate, and instead is fixed positionally. The riser 58 rises through the center of the H-frame 50. FIG. 3 depicts the riser 58 as having two mounting surfaces 60. The riser 58 could have any number of surfaces 60 to facilitate mounting the correct number of robots 20.
FIG. 3 also depicts a spacer module 62. Spacer module 62 provides mechanical structure support to join, align, and support the drive module 14, the control pallet 70 and screen 64. The spacer modules help to adjust and control the footprint of the modular positioning robotic system 8. Additionally, the spacer 62 enables screen 64 to be built to shield personnel from the movement of the system as well as blocking any light generated by the welder 22.
FIG. 6 discloses a similar work cell as depicted in FIG. 3. In FIG. 6, the drive unit 14 is replaced with a stationary mounting base 76. This system is utilized when the operator loads the two open ended arms 52 by traveling back and forth between the two sets. In a stationary model, there is no major exchange axis as the frame does not rotate.
FIG. 4 discloses the modular positioning robotic system 8 having a positioning module 14 utilizing a turntable 66. The turntable 66 mounts to the clevis top plate 40. The diameter of the turntable is typically fixed. When a different diameter table is needed, a different turntable 66 can be mounted to the drive module 14. The change in diameter of the turntable 66 may require a change of the spacer module 62 to properly position the drive module 14 relative to the control pallet 70 and safety shield 64.
FIG. 5 discloses another version of the modular positioning robotic system 8 having a position module 12 that utilizes a Ferris wheel frame 68. Similar to the H-frame 50, the Ferris wheel frame 68 can be a fixed dimension or adjustable. The Ferris wheel frame's 68 length, width and rotational diameter can be each independently adjusted if the Ferris wheel frame 68 is adjustable.
As seen in FIG. 5, the Ferris wheel frame mounts to an upright drive module 14. The Ferris wheel frame rotates about an axis 72. The Ferris wheel frame has arms 74, that head and tailstock 54, 56 connectors that attach to fixtures (not shown) that hold parts to be manipulated by the robotic arm 20 (not shown in FIG. 5).
The preferred embodiment is specifically designed with a control module 10 and drive module 14 that can have either an H-frame positioning module 54 or a turntable module 66 as the third module. The two styles of positioning modules are designed to be easily interchangeable. Additionally it is contemplated that the Ferris wheel style positioner 68 could easily be modified to swap into an existing system.
A general description of the present invention as well as the preferred embodiment and alternative embodiments of the present invention have been set forth above. Those skilled in the art to which the present invention pertains will recognize and be able to practice additional variations in the methods and systems described which fall within the teachings of this invention.
Patent Application
20080046120
