The present invention relates to devices, systems, and methods for aligning an end effector of an industrial robot, and more particularly, aligning a saw blade and water jet end effector.
Industrial robots are conventionally used in many industries to increase manufacturing quality and output. Among the various industries that utilize industrial robots, the granite and related marble industries are using industrial robots at an increasing rate to accommodate more intricate cutting patterns. One use of industrial robots within the granite and related marble industries is for accurately cutting slabs of material for use in residential and commercial table tops and countertops.
Conventionally, industrial robots used for cutting slabs of material use an end effector that is a combination rock-cutting saw blade and water jet cutting head. In such a configuration, the saw blade is used to cut straight sections of stone material at a high rate of speed and the water jet is used to cut curves and corners, but at a slower rate of speed. Generally, a cut pattern is imported from a computer aided drafting program and converted into a set of cutting instructions. From these cutting instructions, the combination rock-cutting saw blade and water jet cutting head cuts a design from a slab of material. In most cases, the cut piece of material includes edges and features that have dimensions that fall within a dimensional tolerance in order for that cut piece of material to meet the requirements of the end user. For example, a cut piece of material may require that an edge for the opening for the sink must have a dimension that meets the designed cut pattern within a certain dimensional tolerance in order for the sink to be placed correctly within the end user's kitchen.
In order for a cut piece of material having tight dimensional tolerances to be cut effectively and efficiently, the end effector of the industrial robot must be properly aligned. Proper alignment can mean that the saw blade and the water jet nozzle of the end effector are located and aligned in real space in accordance to where the saw blade and the water jet nozzle of the end effector are located and aligned in virtual space, according to the robotic controller. In other words, proper alignment means that the end effector is where the robotic controller thinks it is.
In the industry, an industrial robot typically requires at least an initial alignment, or calibration, when it is installed or moved. An industrial robot also needs periodic alignment due to wear and tear misalignment, collision misalignment, and other sources of misalignment. In particular to an industrial robot having an end effector that is a combination rock-cutting saw blade and water jet cutting head, the saw blade and water jet have further alignment requirements such as replacement saw blade alignment.
The most prevalent method of aligning the end effector within the industry is to use laser alignment. Laser alignment involves using a laser alignment emitter/receiver to measure end effector movements and orientation with the help of a computer program. Currently, laser alignment systems are very costly and complex, thus only make economic sense for very large operations with many industrial robots.
Embodiments disclosed herein are directed to devices, systems and methods of aligning an end effector that is a combination rock-cutting saw blade and water jet cutting head of an industrial robot. The present invention provides a device, system and method for aligning the combination rock-cutting saw blade and water jet cutting head without the need for a laser alignment system.
The embodiments disclosed herein include a system for aligning an end effector of an industrial robot having a plurality of axes. The system further includes the end effector coupled to a distal end of the industrial robot. The end effector can include a bracket coupled to the distal axis of the industrial robot wherein the bracket further includes a plurality of datum mounting pads. The end effector also includes a water jet cutting tool coupled to a first end of the bracket, and a saw cutting tool coupled to a second end of the bracket. The end effector includes one or more alignment members coupleable to the bracket at the datum mounting pads and configured to align the water jet cutting tool and the saw cutting tool.
In one embodiment, the one or more alignment members is a saw alignment member removably coupleable to the bracket and the saw cutting tool.
In another embodiment, the one or more alignment members is a saw alignment member removably coupleable to the bracket and the saw cutting tool.
In another embodiment, the saw alignment member includes one or more datum mounts and a post aperture.
In yet another embodiment, the datum mounts of saw alignment member are configured to engage with the datum mounting pads of the bracket.
In some embodiments, the datum mounts of saw alignment member are configured to threadably engage with the datum mounting pads of the bracket.
In one embodiment, the water jet alignment member includes an alignment brace and a nozzle centering block, wherein the alignment brace removably couples to the bracket at a first end of the alignment brace and the nozzle centering block removably couples to a second end of the alignment brace and the water jet cutting tool.
In an embodiment, the alignment brace further includes an upper brace member and a lower brace member wherein the upper brace member and lower brace member are disposed at an angle less than 90 degrees to each other.
In one embodiment the alignment brace further includes a centering block track and the nozzle centering block further includes a centering aperture and rails. In this embodiment, the rails of the nozzle centering block slidably engage with the centering block track of the alignment brace and the centering aperture slidably engages with the water jet cutting tool.
In one embodiment, the water jet cutting tool couples to the bracket with a bracket mount and a mounting frame.
In yet another embodiment, a method for aligning an end effector of an industrial robot having a plurality of axes is disclosed. The method for aligning an end effector of an industrial robot having a plurality of axes includes loosening the coupling of a saw cutting tool and a water jet cutting tool to a bracket of the end effector, wherein the end effector is coupled to a distal end of the industrial robot. Further, the method includes coupling a water jet alignment member to the bracket and the water jet cutting tool and coupling a saw alignment member to the bracket and the saw cutting tool. The method also includes tightening the coupling of the saw cutting tool and the water jet cutting tool to the bracket of the end effector and removing the water jet alignment member and the saw alignment member from the end effector.
The above summary is not intended to describe each illustrated embodiment or every implementation of the subject matter hereof. The figures and the detailed description that follow more particularly exemplify various embodiments.
Subject matter hereof may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying figures, in which:
While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.
Embodiments disclosed herein are directed to devices, systems and methods of aligning the saw blade and water jet cutting head of an end effector of an industrial robot. In embodiments, a 6 axis industrial robot is discussed, yet, industrial robots having more or less axes can be used the disclosed embodiments. In embodiments, the industrial robots discussed herein can be operated using a robotic controller. The robotic controller can comprise a programmable central processing unit, a memory, a user interface, and various inputs for communication with other programmable central processing units. In embodiments, the user interface can include a teaching pendant, for example.
In embodiments, base 102 can be rotatably coupled to first arm 104 at first axis 120. First axis 120 includes a servomotor 122, reduction gear 124, and position sensor 126. In embodiments, servomotor 122 and reduction gear 124 are configured to rotate first arm 104 with respect to base 102. Further, position sensor 126 is configured to relay axis position information, with high accuracy in some embodiments, to the robotic controller. The robotic controller uses the axis position information sent from position sensor 126 to control motion and speed of motion of first arm 104 at first axis 120.
In embodiments, first arm 104 can be rotatably coupled to second arm 106 at second axis 130. Second axis 130 includes a servomotor 132, reduction gear 134, and position sensor 136. In embodiments, servomotor 132 and reduction gear 134 are configured to rotate second arm 106 with respect to first arm 104. Further, position sensor 136 is configured to relay position information, with high accuracy in some embodiments, to the robotic controller. The robotic controller uses the position information sent from position sensor 136 to control motion and speed of motion of second arm 106 at second axis 130.
In embodiments, second arm 106 can be rotatably coupled to third arm 108 at third axis 140. In this embodiment, third axis 140 is powered by a servomotor 142, reduction gear 144, position sensor 146, and hinged arm 148 arranged adjacent to second axis 130. In embodiments, servomotor 142 and reduction gear 144 are configured to rotate third arm 108 with respect to second arm 106 via hinged arm 148. Further, position sensor 146 is configured to relay position information, with high accuracy in some embodiments, to the robotic controller. The robotic controller uses the position information sent from position sensor 146 to control motion and speed of motion of third arm 108 at third axis 140.
In embodiments, third arm 108 can rotate about its own axis and thus forms fourth axis 150. Fourth axis 150 includes a servomotor 152, reduction gear 154, and position sensor 156. In embodiments, servomotor 152 and reduction gear 154 are configured to rotate third arm 108 about itself. Further, position sensor 156 is configured to relay position information, with high accuracy in some embodiments, to the robotic controller. The robotic controller uses the position information sent from position sensor 156 to control rotation and speed of rotation of third arm 108.
In embodiments, fourth arm 110 can be rotatably coupled to third arm 108 at fifth axis 160. In this embodiment, fifth axis 160 is powered by a servomotor 162, reduction gear 164, position sensor 166, and shaft 168 arranged adjacent to third axis 140. In embodiments, servomotor 162 and reduction gear 164 are configured to rotate fourth arm 110 with respect to third arm 108 via shaft 168. Further, position sensor 166 is configured to relay position information, with high accuracy in some embodiments, to the robotic controller. The robotic controller uses the position information sent from position sensor 166 to control motion and speed of motion of fourth arm 110.
In embodiments, end effector 112 can rotate about fourth arm 110 at sixth axis 170. Sixth axis 170 includes a servomotor 172, reduction gear 174, and position sensor 176. In embodiments, servomotor 172 and reduction gear 174 are configured to end effector 112 about fourth arm 110. Further, position sensor 176 is configured to relay position information, with high accuracy in some embodiments, to the robotic controller. The robotic controller uses the position information sent from position sensor 176 to control rotation and speed of rotation of end effector 112 about fourth arm 110.
Industrial robot 100 is further configured for cutting slabs of material, such as granite or marble. For this use, end effector 112 can include a bracket 180, a saw motor 182, rock-cutting saw 184, and water jet cutting head 186. In embodiments, bracket 180 of end effector 112 is configured to couple to fourth arm 110 at sixth axis 170. Bracket 180 is also configured to water jet cutting head 186 at a first end and support saw motor 182 at a second end, which is opposite the first end. Further, rock-cutting saw 184 couples to an output shaft of saw motor 182.
In some embodiments, the centroid of a saw blade of saw 184, i.e., the radial center of the saw blade and the center of the thickness of the saw blade, fall on the axis of rotation of sixth axis 170. Yet, in other embodiments, the saw blade is offset from sixth axis 170. In this embodiment, water jet cutting head 186 is arranged opposite saw 184. In embodiments, water jet cutting head 186 is configured to deliver a mixture of water and an abrasive, such as garnet, at high enough pressures such that the abrasive mixture forms a cut in the work piece. In embodiments, saw 184 is used to cut straight sections of the work piece at a high rate of speed and water jet cutting head 186 is used to cut curves and corners, but at a slower rate of speed.
In embodiments, top panel 190 and bottom panel 192 are arranged parallel to each other each having a first end, a second end, a first side, a second side, a top, and a bottom. The first ends of top panel 190 and bottom panel 192 are located adjacent to saw 184 and the second ends are located opposite the first end. Further, the top and bottom of top panel 190 and bottom panel 192 are dimensionally broad while the first end, second end, first side and second side comprise the width of top panel 190 and bottom panel 192. Both first side panel 194 and second side panel 196 include a first end, a second end, a first side, a second side, a top, and a bottom. The first ends of first side panel 194 and second side panel 196 are located adjacent to saw 184 and the second ends are located opposite the first end. Further, the first side and second side of first side panel 194 and second side panel 196 are dimensionally broad while the first end, second end, top and bottom comprise the width of top panel 190 and bottom panel 192. Cross support 198 includes a first end, a second end, a first side, a second side, a top, and a bottom. Further, the first and second end of cross support 198 dimensionally broad while the first side, second side, top and bottom comprise the width of cross support 198.
In embodiments, top panel 190 is coupled to the second side of first side panel 194 at the first side and bottom panel 192 is coupled to the second side of first side panel 194 at the first side. Further, top panel 190 is coupled to the first side of second side panel 196 at the second side and bottom panel 192 first side of second side panel 196 at the second side. In embodiments, top panel 190 and bottom panel 192 are substantially parallel to each other and substantially perpendicular to first side panel 194 and second side panel 196. In embodiments, the first side of cross support 198 couples to the second side of first side panel 194, the second side of cross support 198 couples to the first side of second side panel 196, the top of cross support 198 is coupled to the bottom of top panel 190, and the bottom of cross support 198 is coupled to the top of bottom panel 192.
In embodiments, top panel 190 includes a collar 200 configured to removably couple bracket 180 to sixth axis 170. In embodiments, collar 200 is arranged on top panel 190 such that the centroid of saw 184 falls on the axis of rotation of sixth axis 170. In alternative embodiments, collar 200 can be arranged at another location on top panel 190. For example, collar 200 can be centrally arranged on top panel 190 such that sixth axis 170 supports end effector 112 with even weight distribution.
In embodiments, manifold 224 is configured to both support mix chamber 226 and nozzle 228, as well as provide fluid, in the form of high pressure water, to mix chamber 226 and nozzle 228 via internal fluid channel. In embodiments, mix chamber 226 is configured to transfer high pressure water to nozzle 228 as well as provide a mixing aperture for abrasive insertion. At mix chamber 226, the high pressure water is mixed with the abrasive such that an abrasive and high pressure water mixture is sent to nozzle 228. In embodiments, nozzle 228 is configured to collimate and focus the high pressure water and abrasive mixture, such that stream of high pressure water and abrasive capable of cutting stone is delivered to the surface of the work piece at high concentration.
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In use, alignment of water jet cutting head 186 and saw 184 with respect to bracket 180 can be accomplished using water jet alignment member 188 and saw alignment member 189. A user can align water jet cutting head 186 and saw 184 in any order. In embodiments, a user can align water jet cutting head 186, as depicted in
In embodiments, a user can align saw 184, as depicted in
Because a large portion of alignment needs for an industrial robot used for cutting stone revolve around aligning the tooling of the end effector, utilizing an aligning system that includes a water jet alignment member 188 and a saw alignment member 189 can remove the need for an industrial robot owner to also purchase a laser alignment system. Further, using a water jet alignment member 188 and a saw alignment member 189 to align the tooling of the end effector, a faster and less intrusive alignment can be attained when compared to setting up a laser alignment system.
Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.
Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.
Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.