Patent Application
20250134006
It can be dangerous or even fatal to use tools at great heights or distances. Even at the height of a household stepladder, losing balance and falling, or unstable operation with common tools often results in accidents. Preparing the work site with scaffolds, boom trucks, rigging, work platforms, etc. for the workers, before work can even commence in a safe manner, can be expensive, as this kind of work is usually contracted out to licensed professionals. Tools such as drills, power nail guns, staple guns, wrenches, screwdrivers, scraping and cleaning apparatus, may require operator use from a safe distance.
The disclosure describes a remote tool positioner, including an end effector adapter configured for mounting to a distal end of a pole having a length extending from a proximal end to the distal end, an end effector configured for mounting to the end effector adapter and engaging a workpiece, a tool lift configured for traveling along the length of the pole and an elongate flexible member configured for hauling the tool lift along the length of the pole.
The disclosure also describes a tool positioning system including a pole, an end effector adapter, an end effector, a tool lift and an elongate flexible member. The pole has a length between proximal and distal ends. The end effector adapter is mounted to a distal end of the pole. The end effector is mounted to the end effector adapter and is configured to engage a workpiece. The tool lift is mounted to the pole and is configured for traveling along a length thereof. The elongate flexible member is threaded through the end effector adapter and tethered to the tool lift.
Further, the disclosure describes a tool positioner including, configured for mounting near a distal end of a pole having a length, an end effector configured for engaging a workpiece and a tool lift configured for traveling along the length of the pole.
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, example constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those having ordinary skill the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
The following detailed description illustrates embodiments of the present disclosure and manners by which they can be implemented. Although the best mode of carrying out the present disclosure has been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
It should be noted that the terms “first”, “second”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
Known pole-mounted gas and electric chain saws useful for trimming trees are only usable at relatively short distances, 3m maximum. Such saws weigh between 3-6 kg and, when lifted from a horizontal position, may resist rotation with a moment equal to the product of 3 meters and 6 kg which is 18 kg-m. It may be possible for a physically fit operator to generate such a moment by exerting 18 kg of force from each hand with the hands spaced by 1m. However, should a pole extending 10m, 15m or 20m be provided, use could not be considered by even a team of people. Additionally, flexion of such a long pole would be severe, and potentially uncontrollable even when raised to a near vertical position where the moment due the weight would be minimal.
A variant of a powered pole is to replace the heavy powered chain saw with a lightweight serrated blade. These are also common and popular and may extend to 6-7m high. However, the operator must reciprocate the handle in a sawing motion, which can be very tiring and imprecise.
Disclosed embodiments overcome the limitations of short-range pole-mounted tools enabling vertical pole lengths of 10-20 m. Because the tool can be deployed to the worksite elevation after the distal end of a lightweight telescoping or segmented pole has been raised and attached to the worksite or workpiece, the moment needing to be overcome by the operator is significantly reduced.
Additional aspects, advantages, features and objects of the present disclosure will be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
While disclosed embodiments are described in the context of remote operation of saws commonly used to trim tree branches, cut wood, cut brush, etc, they may find effective use in deploying other types of tools.
End effector adapter 140/150 (
A pole 130 suitable for use in association with disclosed remote tool positioning components may be provided with other components or separately. Pole 130 defines a length between proximal and distal ends and may be comprised of a number of segments 131, 133, 135 and 137. The segments may be arranged for telescoping and relative sliding. Alternatively, the segments may be of locking design with each segment being nearly equal in diameter. Locking segment design poles are screwed into one another to make a single long pole. Poles of either variety as well as suitable others not specifically listed herein may be constructed from any of a variety of strong, light-weight materials. In an example, fiberglass or extruded aluminum are used for poles up to 10m in deployed length while medium-to-high modulus carbon-fiber construction is used for poles exceeding 15 to 20 m.
End effector adapter 140/150, which may define a longitudinal axis 901, is configured for mounting to a distal end of a pole such as pole 130. As an example, end effector adapter 140/150, by way of coupler 141, may thread onto standard ¾ in-4G Acme screw threads often provided to ends of deployable poles such as those described by way of example above. In another example, coupler 141 may attach to a pole by press fit. End effector adapter 140/150 includes means for aligning tool lift 110/120 with end effector adapter 140/150 and/or the work piece (for example, limb 300). In an example, end effector adapter 140/150 includes a plurality of external splines 142 configured for engagement by an internal spline provided to tool lift 110/120.
End effector adapter 140/150 may include proximal 140 and distal 150 portions relatively rotatable against an aligning torque about longitudinal axis 901 to thereby form a swivel joint. In an example, the aligning torque is supplied by a first magnet assembly 147 provided to proximal portion 140 of end effector adapter 140/150 and a second magnet assembly 157 provided to distal portion 150 of end effector adapter 140/150 with aligned North and South poles to thereby form a magnetically aligned swivel joint. First and second magnet assemblies 147 and 148, which may each include one or multiple individual magnets, may be provided to pockets formed in the end effector adapter 140/150. With the small alignment torque when first approaching the desired work piece with the end effector 160 in a receptive state, end effector adapter 140/150 and end effector 160 may be easily rotated by simply rotating the pole handle.
Distal portion 150 of end effector adapter 140/150 may include a repositionable locking ball joint having a socket 151 for grasping a ball 153 (
End effector adapter 140/150 may take any of a variety of shapes suitable for indirectly coupling an end effector to a pole at a desired alignment including but not limited to conical or frustoconical.
End effector 160 is configured for mounting to end effector adapter 140/150 to engage a workpiece. End effector 160 may further include gripping means. In an example, such gripping means includes a pair of gripping jaws. Each gripping jaw may be formed from two of jaw members 166, 167, 168, 169 which each extend from what might be considered a wrist, ramus or base to a distal tip.
Several gear teeth, such as involute gear teeth 164, may be formed at the base of each jaw member 166, 167, 168, 169. Stand-offs 165 maintain jaw members of jaw member pairs spaced apart. The first pair of jaw members 168, 169, associated stand-offs 165 and a worm gear 163 may form one rigid assembly configured for rotation about axis 903 by driving of worm gear 163 by worm 162 rotated by motor 161. The second pair of jaw members 166, 167 and associated stand-offs 165 may similarly form one rigid assembly configured for rotation about an axis parallel with 903.
Worm 162 is attached to the armature shaft of motor 161 such that rotation of worm 162 about a first axis 902 is configured to drive worm gear 163 to rotate about a second, perpendicular axis 903 and, by a torque transmitted to one of the jaw members 166, 167, 168, 169, pivot a first pair thereof (for example, 168, 169) inward or towards a closed state. Second pair of jaw members 166, 167 pivots towards or away from the first pair in response to pivoting of first pair 168, 169 by way of meshing of involute gear teeth 164 of respective jaw members of the cooperating pair.
Worm gearing may enable a self-locking feature when stopped, thus requiring no power in the locked, or clamped position on a workpiece. Control receiver electronics and a small power source such as a battery (not visible) may be located within end effector 160. Motor 161, and thereby end effector 160, may be activated by remote control.
Jaw members 166, 167, 168 and 169 as well as stand-offs 165 may be formed from any of a variety of durable, lightweight materials including but not limited to thin metal, such as aluminum, or molded reinforced plastic. In an example, motor 161 takes the form of a DC motor.
While shown and described by way of example as a conventional jawed gripper, end effector 160 could take any of a variety of forms. In one example, for attachment to ferrous metal structure, an electromagnet or other magnetically actuated device could be provided. In another example, for other surfaces, a flat or curved pad onto which adhesive or hot melt glue is dispensed could be provided such that, upon contact, a firm, but removable, bond is made. In yet another example, for planar wood surfaces, a robotic attachment device using anchoring screws for the attachment mode could be deployed.
Tool lift 110/120 is configured for mounting to a pole 130 for traveling along the length thereof. Tool lift 110/120 may further include a tube or sleeve 110 configured to encompass the pole with a lumen 119 and slide therealong as well as a tool arm 120.
Tool lift 110/120 may further include a socket 113 provided to sleeve 110 and configured for receiving and/or encompassing a ball 121 of tool arm 120 to provide for a locking positional joint. Socket cap 114 contains ball 121 within socket 113. The provision of such a joint allows the operator to achieve the desired angle of attack when using the tool by roughly aligning tool lift 110/120 to tool 200 before raising into the final, distal position. Robotic actuators may be added to this locking positional joint 113/114/121 to adjust the degrees of freedom once the tool is lifted. A tool platform 123 is mounted to neck 122 extending from ball 121.
Holders of various shapes and/or sizes may accommodate the chosen tool. In an example, tool arm 120 has a tube clamp 128 including an expandable compound bearing surface comprised of first 128a and second 128b clamp blocks. Bearing surface 129 defines a central axis rotatable within a plane parallel with the length of the pole. Tube clamp 128 is configured to hold some aspect of tool 200 to be used. As an example, tube claim 128 could be attached to the chain saw handle which would normally be grasped by a human hand for operation. Bearing surface 129 of clamp blocks 128a and 128b may be shaped to closely conform to the tool handle, for example, as a human hand would. Rotating the tool about the handle being gripped can be remotely achieved by providing for clamp blocks 128a and 128b to rotate about an axis 904.
Tube clamp 128 may be configured for controlled rotation about an axis transverse or oblique to both the length of the pole and a central axis 905 of the sleeve 110. In an example, tube clamp 128 may be configured for motorized rotation about an axis 904. A large spur gear 126 rigidly attached to clamp block 128a is driven by small spur gear 127 attached to an output of a geared servo motor 124 such as the commonly available RC servo motor. Adapter plate 125 carries the pivoting shaft, geared servo motor 124 and small spur gear 127, and is attached to and supported by tool platform 123. For example, a motor 124 may be provided to rotate tube clamp 128 about axis 904. A larger diameter spur gear 126 fixed to a bottom surface of tube clamp 128a may be driven by a small diameter spur gear 127 rotated by motor 124. The remote tool positioner may further include a remote controller for activating the motor.
An internal alignment guide 115 is formed in tool lift 110/120 such that, when lifted into engagement with alignment features 142 of end effector adapter 140/150, operator 400 can exert considerable torque in rotating the tool while working. In an example, internal alignment guide 115 is an internal spline configured for engagement with splines of end effector adapter 140/150.
The tool lift may further include an anchor point for elongate flexible member 144. In an example, the anchor point is an eyelet 112a, 112b. In another example, the anchor point is a hook (not shown). Considering most portable, battery-powered electric tools, have a weight of approximately 1-6 kg, the weight of tool lift 110/120 is considered negligible at 200-300g.
Elongate flexible member 144 may be threaded through end effector adapter 140/150 and tethered or anchored to tool lift 110/120 at one end while a second end is available for grasping by an operator for hauling tool lift 110/120 and any supported tool along the length of the pole 130 to a top locking position after end effector 160 has firmly and solidly attached itself to the chosen workpiece. In an example, elongate flexible member 144 runs through and around a pulley sheave 143 located within end effector adapter 140/150 and is attached to tool lift 110/120 at one or both of anchor points 112a, 112b. In a further example, the pulley sheave is a low-friction variety.
A cleat or hook may be provided to secure the operator end of elongate flexible member 144 to hold the tool in an elevated position along the length of the pole. Alternatively, a latch/release mechanism may be fitted between tool lift sleeve 111 and end effector adapter 140/150, so that a first hard tug of elongate flexible member 144 latches and a second hard tug releases the tools lift sleeve 111. In yet another alternative, a ball detent or an electrical latch release mechanism be could fitted to the pole, end effector adaptor 140/150 and/or tool lift 110/120.
A hand-held remote controller 170 (
One or more of any of a variety of control hardware arrangements may reside within remote controller 170. First example control hardware arrangement 180a (
A second control hardware arrangement 180b (
A third control hardware arrangement 180c (
Additionally, any of the first 180a, second 180b and/or third 180c control hardware may pre-programmed to only allow tool deployment and/or operation after successful gripping or attachment parameters have been met, or only after proper setup.
Described positioners and positioning systems may be suitable for use in association with any of a variety of methods for positioning, operating and/or controlling a tool. According to an example method illustrated by way of example in
The tool lift may be mounted by slidably encompassing the pole with a sleeve portion of the tool lift. A relative angle between the sleeve and a tool arm extending therefrom may be adjusted with a ball-and-socket joint. A compound bearing surface of a tube clamp of the tool arm may be sufficiently expanded to receive a tool handle for gripping of the same.
The elongate flexible member may be threaded through the end effector adapter by guiding and supporting the elongate flexible member with a pulley sheave having a rotational axis transverse to the length of the pole. The elongate flexible member may be tethered to the tool lift by attaching to an anchor point.
Before the pole is deployed, the end effector is positioned on the ground with respect to three axes of rotation to an approximate measure based on the position of the operator 400, any objects obstructing the workpiece, and the best angle of attachment to the workpiece. Positioning may be achieved by, for example, one or more rotations of a ball-and-socket joint.
The pole is positioned so the end effector is in capture range of a workpiece, such as a tree limb 300. This may require the operator 400 to rotate the pole to rotate the end effector. Proximal and distal portions of the end effector adapter may remain aligned at a swivel joint due to an aligning torque about a longitudinal axis of the end effector adapter. The aligning torque may be supplied with a first magnet assembly provided to a proximal portion of the end effector adapter and a second magnet assembly provided to a distal portion of the end effector adapter. Referring to
The tool, attached to a tool lift, remains near ground level until positive attachment of end effector is secured. By maneuvering the deployable pole before positioning the tool, the weight of tool may act to counterbalance the moment of extensible pole and the end effector, as the operator would be holding onto the pole at some positions located along the length.
After the deployable pole and its associated end effector are firmly locked onto the workpiece, the operator can pull the free end of the elongate flexible member to raise the tool assembly to the top of pole and a slidable fit in an alignment with the end effector adapter (
The tool rotational angle about the pole axis can also be adjusted. Proximal and distal portions of the end effector adapter may be relatively rotated about a longitudinal axis of the end effector adapter and against the aligning torque. Since the magnets exert little rotational force, the operator would not notice the torque needed to rotationally turn the handle to thus position the tool.
The rotational angle between the tube clamp of the tool arm and the sleeve may be adjusted about an axis transverse to the length of the pole and a central axis of the sleeve (
Referring to
Once the work piece has received the work, the tool may be inactivated, the tool lift lowered to near the proximal end of the pole, the end effector may be disengaged from the work piece and the distal end of the pole may be relocated to address a new work piece or lowered to conclude use.
The actions are only illustrative and other alternatives can also be provided where one or more actions are added, one or more actions are removed, or one or more actions are provided in a different sequence without departing from the scope of the claims herein.
Embodiments of the disclosure are susceptible to being used for various purposes, including, though not limited to, enabling users to reduce dangerous situations of using tools at a remote distance.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.
