Patent Application
20100126293
The present invention relates to the field of robotic tool positioning assemblies and, in particular, to a robotic tool positioning assembly having two or more arms each adapted to adjust the position of a respective tool along a semi-circular path.
In the manufacturing industry, robotic systems are used to perform a variety of tasks, including positioning workpieces, positioning tools with respect to workpieces, and assembling workpieces using tools. In such systems, accurate positioning of the tool with respect to the workpiece is critical and is thus an important design consideration. Another important design consideration is minimizing the time required to complete any single manufacturing operation. For this reason, it is known to utilize two or more robotic tools to simultaneously perform a single manufacturing operation in order to reduce the time required to complete that manufacturing operation. However, since robotic tools are often large and heavy, it is often difficult to position and support two robotic tools with respect to one another such that a single manufacturing operation may be performed using two robotic tools simultaneously. This is especially true when the robotic tools must move relative to one another with respect to two or more axes during the course of the manufacturing operation. For example, when the robotic tools must install a plurality of components along a semi-circular arc, each tool must move independent of the other in the X direction and the Y direction. Furthermore, robotic tools are often only usable over a limited range of working heights, imposing further constraints on geometric designs of robotic tool positioning systems. Accordingly, there remains a need for a robotic tool positioning system that is capable of accurately positioning two or more robotic tools with respect to a workpiece, wherein the robotic tools are moveable independent of one another.
The invention provides a robotic tool positioning system for positioning a first tool and a second tool. The robotic tool positioning system includes an inner shaft, a first tool arm, a first drive assembly, a tubular outer shaft, a second tool arm, and a second drive assembly.
The inner shaft that extends from an upper end to a lower end, and has a stepped profile defined by an upper portion having a first diameter and a lower portion having a second diameter that is smaller than the first diameter. A first tool arm is connected to the lower portion of the inner shaft at the lower end thereof and extends radially outward therefrom. The first tool arm has a first tool supporting surface disposed at a tool elevation for supporting the first tool thereon. The first drive assembly is configured to rotate the inner shaft about a shaft axis to selectively position the first tool along a semi-circular path.
The tubular outer shaft extends from an upper end to a lower end and has a bore formed therethrough, wherein the lower portion of the inner shaft extends through the tubular outer shaft. The second tool arm is connected to the tubular outer shaft at the lower end thereof. The second tool arm has a second tool supporting surface disposed at the tool elevation for supporting the second tool thereon. The second drive assembly is configured to rotate the tubular outer shaft about the shaft axis to selectively position the second tool along a semi-circular path.
A stepped portion may formed on the second tool arm between an inner portion of the second tool arm and the second tool supporting surface of the second tool arm, wherein an upper surface of the inner portion of the second tool arm is disposed above the tool elevation. Furthermore, a diagonal shoulder may be formed on the second tool arm, the diagonal shoulder extending inward from the stepped portion toward an inner end of the second tool arm, wherein the diagonal shoulder of the second tool arm is configured to engage a side surface of the first tool arm to restrain the first tool arm against rotating past the second tool arm.
Alternatively, a stepped portion may be formed on the first tool arm between an inner portion of the first tool arm and the first tool supporting surface of the first tool arm, wherein an upper surface of the inner portion of the first tool arm is disposed below above the tool elevation. Furthermore, a diagonal shoulder may be formed on the first tool arm, the diagonal shoulder extending inward from the stepped portion toward an inner end of the first tool arm, wherein the diagonal shoulder of the first tool arm is configured to engage a side surface of the second tool arm to restrain the second tool arm against rotating past the first tool arm.
An inner end of the second tool arm may be disposed above an inner end of the first tool arm.
The tubular outer shaft and the upper portion of the inner shaft may be equal in diameter.
The first drive assembly may have a first worm gear connected to the upper portion of the inner shaft, a first worm that meshingly engages the first worm gear to rotate the inner shaft, and a first robotic drive mechanism connected to the first worm for providing torque thereto. The second drive assembly may have a second worm gear connected to the tubular outer shaft, a second worm that meshingly engages the second worm gear to rotate the tubular outer shaft, and a second robotic drive mechanism connected to the second worm for providing torque thereto. Furthermore, the first worm gear and the second worm gear may be equal in diameter.
Various other uses of the present invention will become more apparent by referring to the following detailed descriptions and drawings, and which:
Referring to the drawings, the present invention will now be described in detail with reference to the disclosed embodiments.
The first housing 30 includes a first or top panel 36 and a second or bottom panel 38, which are connected to the top and bottom ends, respectively, of a body 40 of the first housing 30. An upper shaft opening 42 may be formed through the top panel 36 of the first housing 30 in substantial alignment with the shaft axis 11 to allow a portion of the inner positioning shaft 32 to extend upward out of the first housing 30. Alternatively, the upper shaft opening 42 could be omitted, and the inner positioning shaft 32 could terminate within the first housing 30, below the top panel 36 of the first housing 30. A lower shaft opening 44 is formed through the bottom panel 38 of the first housing 30 to allow a portion of the inner positioning shaft 32 to extend downward out of the first housing 30.
The inner positioning shaft 32 is substantially cylindrical, and extends from a first or upper end 52 to a second or lower end 54 of the first housing 30. The inner positioning shaft 32 includes a first or upper portion 56 that meets a second or lower portion 58 at a shoulder 60 that extends substantially perpendicular to the shaft axis 11 and serves to change the diameter of the inner positioning shaft 32 and thus provide a stepped profile for the inner positioning shaft 32. In particular, the upper portion 56 of the inner positioning shaft 32 is larger in diameter than the lower portion 58 of the inner positioning shaft 32.
The first drive assembly 34 is operable to provide a drive torque to the inner positioning shaft 32 of the first tool positioner 12. The first drive assembly 34 includes a housing 62, a first worm gear 64, a first worm 66, a first drive shaft 68 and a first motor 70, as shown in
The first worm gear 64 is disposed on or fabricated integrally with the upper portion 56 of the inner positioning shaft 32. Thus, the first worm gear 64 is disposed within the first housing 30 such that the teeth of the first worm gear 64 are radially arrayed around the shaft axis 11. Accordingly, the first worm gear 64 rotates with respect to the shaft axis 11 in unison with the inner positioning shaft 32.
The first worm 66 is disposed in operable engagement with the first worm gear 64, and extends along a first drive axis 35 substantially perpendicular to the shaft axis 11. The first worm 66 includes at least one tooth that encircles the first worm 66 in a substantially helical configuration for meshing engagement with the teeth of the first worm gear 64.
In order to drive the first worm 66, the first worm 66 is disposed on the first drive shaft 68, which extends along the first drive axis 35. The first drive shaft 68 is disposed both in the first housing 30 of the first tool positioner 12, as well as in the housing 62 of the first drive assembly 34, and thus passes through the drive opening 46 in the first housing 30 of the first tool positioner 12. The first drive shaft 68 operatively connects the first worm 66 to the first motor 70 for torque transmission from the first motor 70 to the first worm 66. The first motor 70 serves as a robotic drive mechanism, and thus may be any type of robotically controllable motor, such as an electronic stepper motor, that can be computer controlled according to a predetermined or dynamically generated program, or in response to operator commands. The first motor 70 may be coupled to the first drive shaft 68 by an appropriate fitting (not shown), by a bevel gear set (not shown), a belt drive (not shown), or any other suitable conventional structure.
Turning again to
The second housing 80 includes a first or top panel 86 and a second or bottom panel 88, which are connected to the top and bottom ends, respectively, of a body 90. An upper shaft opening 92 may be formed through the top panel 86 in substantial alignment with the shaft axis 11 to allow a portion of the outer positioning shaft 82 to extend upward out of the second housing 80 and to allow the inner positioning shaft 32 of the first tool positioner 12 to extend into the second housing 80 and through the outer positioning shaft 82. A lower shaft opening 94 is formed through the bottom panel 88 of the second housing 80 to allow a portion of the outer positioning shaft 82 and a portion of the inner positioning shaft 32 to extend downward out of the second housing 80. In order to support the outer positioning shaft 82 within the second housing 80, an upper bearing 98 and a lower bearing 100 are provided in the second housing 80 adjacent to the top panel 86 and the bottom panel 88, respectively.
The outer positioning shaft 82 is generally cylindrical and tubular and extends from a first or upper end 102 to a second or lower end 104. The outer positioning shaft 82 has a bore 106 that is substantially cylindrical and extends axially through the outer positioning shaft 82 along the shaft axis 11 of the tool positioning system 10. The inner diameter of the bore 106 of the outer positioning shaft 82 is complementary to the outer diameter of the lower portion 58 of the inner positioning shaft 32, such that the lower portion 58 of the inner positioning shaft 32 may be disposed at least partially within the bore 106 of the outer positioning shaft 82 and extend through the outer positioning shaft 82. The maximum degree of axial insertion of the inner positioning shaft 32 into the bore 106 of the outer positioning shaft 82 is limited by engagement of the upper end 102 of the outer positioning shaft 82 with the shoulder 60 of the inner positioning shaft 32. Furthermore, the outer diameter of the outer positioning shaft 82 may be substantially equal to the outer diameter of the upper position 56 of the inner positioning shaft 32, which allows the first housing 30 and the second housing 80 to be identical in construction, since the geometric configuration of the inner positioning shaft 32 between the bearings 48, 50 of the first housing 30 is substantially identical to the geometric configuration of the outer positioning shaft 82 between the bearings 98, 100 of the second housing 80.
The second drive assembly 84 is operable to provide a drive torque to the outer positioning shaft 82 of the second tool positioner 14. The second drive assembly 84 includes a housing 112, a second worm gear 114, a second worm 116, a drive shaft 118 and a second motor 120, as shown in
The second worm gear 114 is disposed on or fabricated integrally with the outer positioning shaft 82. Thus, the second worm gear 114 is disposed within the second housing 80 such that the teeth of the second worm gear 114 are radially arrayed around the shaft axis 11. Accordingly, the second worm gear 114 rotates with respect to the shaft axis 11 in unison with the outer positioning shaft 82. The second worm gear 114 is substantially identical to the first worm gear 64, and the first and second worm gears 64, 114 are of substantially equal diameter.
The second worm 116 is disposed in operable engagement with the second worm gear 114 and extends along a second drive axis 85 that extends substantially perpendicular to the shaft axis 11. The second worm 116 includes at least one tooth that encircles the second worm 116 in a substantially helical configuration for meshing engagement with the teeth of the second worm gear 114. The second worm 116 is substantially identical to the first worm 66, and the first and second worms 66, 116 are of substantially equal diameter.
In order to drive the second worm 116, the second worm 116 is disposed on the second drive shaft 118, which extends along the second drive axis 85. The second drive shaft 118 is disposed both in the second housing 80 of the second tool positioner 14, as well as in the housing 112 of the second drive assembly 84 and thus passes through the drive opening 96 in the second housing 80 of the second tool positioner 14. The second drive shaft 118 operatively connects the second worm 116 to the second motor 120 for torque transmission from the second motor 120 to the second worm 116. The second motor 120 serves as a robotic drive mechanism and thus may be any type of robotically controllable motor, such as an electronic stepper motor, that can be computer controlled according to a predetermined or dynamically generated program, or in response to operator commands. The second motor 120 may be coupled to the second drive shaft 118 by an appropriate fitting (not shown), by a bevel gear set (not shown), a belt drive (not shown), or any other suitable conventional structure.
As shown in
The inner end 130 of the first tool arm 20 is configured to be connected to the inner positioning shaft 32 of the first tool positioner 12 such that the first tool arm 20 extends substantially perpendicular to the inner positioning shaft 32 of the first tool positioner 12. In particular, a mounting aperture 140 extends through the first tool arm 20, from the top surface 134 of the first tool arm 20 to the bottom surface 136 of the first tool arm 20, at the inner end 130 thereof. Thus, the first tool arm 20 may be seated over the lower end 54 of the inner positioning shaft 32. The first tool arm 20 is rigidly connected to the lower end 54 of the inner positioning shaft 32 of the first tool positioner 12 by any suitable fastening structure. Accordingly, rotation of the inner positioning shaft 32 in response to the drive torque provided by the first drive assembly 34 causes rotation of the first tool arm 20 around the shaft axis 11.
The outer end 132 of the first tool arm 20 includes a first tool supporting surface 142 that is configured to support the first tool 1. The first tool supporting surface 142 may be at substantially the same elevation as and substantially coincident with the top surface 134 of the first tool arm 20. For example, the first tool supporting surface 142 of the first tool arm 20 may include a first tool aperture 144 that extends through the first tool arm 20 from the tool supporting surface 142 of the first tool arm 20 to the bottom surface 136 of the first tool arm 20. The first tool aperture 144 is configured to supportably receive the first tool 1 at a predetermined elevation, and the first tool 1 may be fixed in position with respect to the first tool arm 20 by a friction fit, or by any suitable fasteners. However, it should be understood that the first tool aperture 144 is not necessary, in that other structures could be provided to support the first tool 1 at a predetermined elevation.
As shown in
The inner end 150 of the second tool arm 22 is configured to be connected to the outer positioning shaft 82 of the second tool positioner 14 such that the second tool arm 22 extends substantially perpendicular to the outer positioning shaft 82 of the second tool positioner 14. In particular, a mounting aperture 168 extends through the second tool arm 22, from the top surface 154 of the second tool arm 22 to the inner bottom surface 160 of the second tool arm 22, at the inner end 150 thereof. Thus, the second tool arm 22 may be seated over the lower end 104 of the outer positioning shaft 82. The second tool arm 22 is rigidly connected to the lower end 104 of the outer positioning shaft 82 of the second tool positioner 14 by any suitable fastening structure. Accordingly, rotation of the outer positioning shaft 82 in response to the drive torque provided by the first drive assembly 34 causes rotation of the second tool arm 22 around the shaft axis 11.
The second tool supporting surface 156 is disposed at the outer end 152 of the second tool arm 22 and is configured to support the second tool 2. For example, the second tool supporting surface 156 of the second tool arm 22 may include a second tool aperture 170 that extends through the second tool arm 22 from the tool supporting surface 156 of the second tool arm 22 to the outer bottom surface 162 of the second tool arm 22. The second tool aperture 170 is configured to supportably receive the second tool 2 at a predetermined elevation, and the second tool 2 may be fixed in position with respect to the second tool arm 22 by a friction fit, or by any suitable fasteners.
The second tool arm includes a stepped portion 172, which is defined between the shoulder 158 and the diagonal shoulder 164. An inner portion 174 of the second tool arm 22 is defined between the inner end 150 of the second tool arm 22 and the diagonal shoulder 164, and has a substantially continuous elevation. The diagonal shoulder 164 begins outward of the mounting aperture 168 and extends at an angle, such as 30 degrees, with respect to the side surfaces 166 of the second tool arm. Thus, the width of the stepped portion 172 widens as the diagonal shoulder 164 progresses toward the outer end 152 of the second tool arm 22. An outer portion 176 of the second tool arm 22 is defined between the outer end 152 of the second tool arm 22 and the shoulder 158, and has a substantially continuous elevation. The shoulder 158 extends between the side surfaces 166 of the second tool arm 22 and may have a shape that is straight, arcuate, segmented or any combination thereof. The shoulder 158 may extends substantially perpendicular to the side surfaces 166 of the second tool arm, or at an angle thereto.
The elevation of the second tool arm 22 drops between the inner end 150 of the second tool arm 22 and the outer end 150 of the second tool arm 22 at the stepped portion 172. The elevation of the second tool supporting surface 156 of the second tool arm 22, which is located in the outer portion 176 of the second tool arm 22, is substantially the same as or slightly lower than the elevation of the inner bottom surface 160 of the second tool arm 22, which is located in the inner portion 174 of the second tool arm 22. Additionally, the depth of the inner portion 174 of the second tool arm 22 and the depth of the outer portion 176 of the second tool arm 22 may be substantially equal.
As shown in
The adjacent position is established when the first tool arm 20 is at a minimum angular spacing from the second tool arm 22. However, the adjacent position may be established at any angular orientation of the first and second tool arms 20, 22 with respect to the carrier plate 16 or other fixed portion of the tool positioning system 10. In the adjacent position, the first tool arm 20 and the second tool arm 22 are in a nested configuration, wherein a portion of the top surface 134 of the first tool arm 20 is directly adjacent to and facing the inner bottom surface 160 of the second tool arm 22, and further wherein one of the side surfaces 138 of the first tool arm 20 is adjacent to and facing the diagonal shoulder 164 of the second tool arm 22. Additionally engagement of one of the side surfaces 138 of the first tool arm 20 with the diagonal shoulder 164 of the second tool arm 22 prevents further movement of the first tool 1 toward the second tool 2, thus preventing a collision of the first and second tools 1, 2.
The spaced position is established when the first tool arm 20 is disposed at any angular spacing with respect to the second tool arm 22 that is substantially greater that the minimum angular spacing as dictated by engagement of one of the side surfaces 138 of the first tool arm 20 with the diagonal shoulder 164 of the second tool arm 22.
In use, an operator may either manually or programmatically utilize the tool positioning system 10 to selectively position the first tool 1 and the second tool 2 along a semi-circular arc. To selectively position the first tool 1, the operator actuates the first drive assembly 34 of the first tool positioner 12 to apply a drive torque to the inner positioning shaft 32, which causes rotation of the inner positioning shaft 32, the first tool arm 20, and the first tool 1. To selectively position the second tool 2, the operator actuates the second drive assembly 84 of the second tool positioner 14 to apply a drive torque to the outer positioning shaft 82, which causes rotation of the outer positioning shaft 82, the second tool arm 22, and the second tool 2.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments, but to the contrary, it is intended to cover various modifications or equivalent arrangements included within the spirit and scope of the appended claims. The scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
