Reconfigurable robotic system and methods

• US 10,265,863 B2
• Filed: 09/09/2016
• Issued: 04/23/2019
• Est. Priority Date: 09/09/2015
• Status: Active Grant

• Current Assignee: Carbon Robotics, Inc.
• Original Assignee: Carbon Robotics, Inc.
• Inventors: Corkum, Daniel, Myers, Rosanna
• Primary Examiner(s): Sample, Jonathan L
• Application Number:
  US15/260,407
• Publication Number:
  US 20170066139A1
• Time in Patent Office: 956 Days
• Field of Search: 700245-264
• CPC Class Codes: B25J 15/04 with provision for the remote detachment or exchange of the head or parts thereof
• CPC Class Codes: B25J 15/0408 Connections means
• CPC Class Codes: B25J 19/0033 with axial connectors in end effector flange

Abstract

One variation of a reconfigurable robotic system includes: a base; an arm extending from the base, including a set of articulable axes, and terminating at a head interface board defining a set of interface pins; a component interconnect arranged within the base, including a set of interconnect pins electrically coupled to the set of interface pins, and including a set of logic pins; a control card configured to transiently engage the component interconnect and including: a set of interconnect pads configured to contact the set of interconnect pins, a set of logic pads configured to contact the set of logic pins, and a control circuit interposed between the set of interconnect pads and the set of logic pads and including a set of independently selectable function circuits between each interconnect pad in a subset of the set of interconnect pads and corresponding logic pads in the set of logic pads.

Claims

1. A system comprising:

a base;

an arm extending from the base, comprising a set of articulable axes, and terminating in a head, the head comprising a head interface board defining a set of interface pins;

a component interconnect arranged within the base, comprising a set of interconnect pins electrically coupled to the set of interface pins via a set of hookup wires, and comprising a set of logic pins;

a first control card configured to transiently engage the component interconnect and comprising;

a first set of interconnect pads configured to contact the set of interconnect pins,

a first set of logic pads configured to contact the set of logic pins, and

a first control circuit interposed between the first set of interconnect pads and the first set of logic pads and comprising a first set of independently-selectable function circuits between each interconnect pad in a subset of the first set of interconnect pads and corresponding logic pads in the first set of logic pads;

a second control card configured to transiently engage the component interconnect in replacement of the first control card and comprising;

a second set of interconnect pads configured to contact the set of interconnect pins,

a second set of logic pads configured to contact the set of logic pins, and

a first control circuit interposed between the second set of interconnect pads and the second set of logic pads and comprising a second set of independently-selectable function circuits between each interconnect pad in a subset of the second set of interconnect pads and corresponding logic pads in the second set of logic pads;

a first end effector configured to transiently install on the head, comprising a first end effector interface board configured to electrically couple to the head interface board, configured to execute a first function, and comprising a first actuator and a first sensor electrically coupled to the first end effector interface board;

a second end effector configured to transiently install on the head in replacement of the first end effector, comprising a second end effector interface board configured to electrically couple to the head interface board, configured to execute a second function different from the first function, and comprising a second actuator electrically coupled to the second end effector interface board;

a processor arranged within the base, comprising a set of input/output ports, configured to identify a type of a control card loaded into the component interconnect and a type of an end effector installed on the head, and configured to retrieve a logic configuration based on the type of the control card and the type of the end effector; and

a digital logic arranged within the base, comprising a set of logic-side ports electrically coupled to the logic pins in the component interconnect, comprising a set of processor-side ports connected to the input/output ports in the processor, and configured to electrically couple select logic-side ports in the set of logic-side ports to select processor-side ports in the set of processor-side ports based on the logic configuration received from the processor.

2. The system of claim 1:

further comprising a third end effector configured to transiently install on the head in replacement of the first end effector, comprising a third end effector interface board configured to electrically couple to the head interface board, configured to execute a third function different from the first function and the second function, and comprising a third actuator electrically coupled to the third end effector interface board;

wherein the processor is further configured to;

navigate the arm through a first motion path and to trigger the first end effector to execute the first function via the first control card when the first end effector is installed on the head and the first processor is loaded into the component interconnect;

navigate the arm through a second motion path and to trigger the second end effector to execute the second function via the first control card when the second end effector is installed on the head and the first processor is loaded into the component interconnect; and

navigate the arm through a third motion path and to trigger the third end effector to execute the third function via the second control card when the third end effector is installed on the head and the second processor is loaded into the component interconnect.

3. The system of claim 2:

wherein the first end effector comprises a screw driver actuated and positioned by the first actuator;

wherein the second end effector comprises a pick-and-place interface actuated by the second actuator;

wherein the third end effector comprises a gripper actuated by the third actuator;

wherein the first control card is configured to control actuation of the screw driver in the first end effector and the pick-and-place interface in the second end effector responsive to commands from the processor; and

wherein the second control card is configured to control actuation of the gripper in the third end effector responsive to commands from the processor.

4. The system of claim 1:

wherein the first end effector excludes control circuitry; and

wherein the first actuator in the first end effector is controlled by a control circuit in the first control card, loaded into the component interconnect, responsive to commands received from the processor when the first end effector is installed on the head.

5. The system of claim 1:

wherein the first end effector further comprises a first identification chip electrically coupled to the first end effector interface board; and

wherein the processor is configured to;

identify a first end effector type of the first end effector based on a first end effector identifier read from the first identification chip via the head interface board when the first end effector is installed on the head;

identify a first control card type of the first control card based on a first control card identifier read from the first control card via the component interconnect when the first control card is installed in the component interconnect;

load a first logic configuration for a combination of the first end effector and the first control card based on the first end effector type and the first control card type;

configure the digital logic according to the first logic configuration when the first end effector is installed on the head and when the first control card is installed in the component interconnect; and

control the set of articulable axes in the arm and the first end effector through the drive logic.

6. The system of claim 5, wherein the processor is configured to retrieve the first logic configuration for a combination of the first end effector and the first control card from a remote server, via a computer network, based on the first end effector type and the first control card type.

7. The system of claim 1:

wherein the first end effector comprises a polymer extruder;

wherein the first control card is configured to interface with the first end effector to heat and dispense polymer responsive to commands from the processor; and

wherein the processor is configured to;

access a first logic configuration for the first end effector and the first control card when the first end effector is installed on the head and when the first control card is installed in the component interconnect;

configure the digital logic according to the first logic configuration when the first end effector is installed on the head and when the first control card is installed in the component interconnect; and

control the set of articulable axes in the arm and the first end effector through the drive logic to print a second housing of the second end effector.

8. The system of claim 7:

wherein the processor is configured to control the set of articulable axes in the arm and control the first end effector through the drive logic to print the second housing of the second end effector in response to selection of the second end effector by a user at a virtual marketplace associated with the system;

wherein the second actuator of the second end effector is supplied to the user for assembly in the second housing in response to selection of the second end effector at the virtual marketplace; and

wherein the second control card is supplied to the user in response to selection of the second end effector at the virtual marketplace.

9. The system of claim 8:

wherein the second end effector interface board of the second end effector comprises a second identification chip electrically coupled to the first end effector interface board and is supplied to the user for assembly in the second housing in response to selection of the second end effector at the virtual marketplace;

wherein the processor is configured to;

identify a second end effector type of the second end effector based on a second end effector identifier read from the second identification chip via the head interface board when the second end effector is installed on the head;

identify a second control card type of the second control card based on a second control card identifier read from the second control card via the component interconnect when the second control card is installed in the component interconnect;

load a second logic configuration for a combination of the second end effector and the second control card from a remote database based on the second end effector type and the second control card type;

configure the digital logic according to the second logic configuration when the second end effector is installed on the head and when the second control card is installed in the component interconnect; and

control the set of articulable axes in the arm and the second end effector through the drive logic.

10. The system of claim 1:

further comprising;

a first application associated with the first end effector and stored in an application database;

a second application associated with the second end effector and stored in the application database;

wherein the processor is configured

access the first application when the first end effector is installed on the head;

control the set of articulable axes in the arm and the first actuator in the first end effector based on the first application when the first end effector is installed on the head;

access the second application when the second end effector is installed on the head; and

control the set of articulable axes in the arm and the second actuator in the second end effector based on the second application when the second end effector is installed on the head.

11. The system of claim 10:

wherein the first end effector further comprises a first identification chip electrically coupled to the first end effector interface board; and

wherein the processor is configured to;

identify a first end effector type of the first end effector based on a first end effector identifier read from the first identification chip via the head interface board when the first end effector is installed on the head; and

download the first application from the application database via a computer network in response to identifying the first end effector type.

12. The system of claim 1:

wherein the first control card is configured to supply a high-current power signal to the first actuator in the first end effector through a first subset of hookup wires in the set of hookup wires when the first end effector is installed on the head; and

wherein the second control card is configured to communicate with the second end effector via low-current data signals through the first subset of hookup wires in the set of hookup wires when the second end effector is installed on the head.

13. A system comprising:

a base;

an arm extending from the base, comprising a set of articulable axes, and terminating in a head comprising a head interface;

a first end effector configured to execute a first function, configured to transiently install on the head, comprising a first end effector interface configured to transiently couple to the head interface, and comprising a first identification package;

a second end effector configured to execute a second function different from the first function, configured to transiently install on the head in replacement of the first end effector, comprising a second end effector interface configured to transiently couple to the head interface, and comprising a second identification package;

control electronics arranged within the base, configured to distribute command signals to the set of articulable axes and the head interface, and configured to receive sensor signals from the set of articulable axes and the head interface; and

a processor;

arranged within the base;

configured to read a first identifier from the first identification package, to access a first logic configuration and a first application for controlling the set of articulable axes and the first end effector based on the first identifier, to configure the control electronics according to the first logic configuration, and to serve commands to the set of articulable axes and the first end effector via the control electronics according to the first application when the first end effector is installed on the head; and

configured to read a second identifier from the second identification package, to access a second logic configuration and a second application for controlling the set of articulable axes and the second end effector based on the second identifier, to reconfigure the control electronics according to the second logic configuration, and to serve commands to the set of articulable axes and the second end effector via the control electronics according to the second application when the second end effector is installed on the head.

14. The method of claim 13, wherein the processor:

retrieves the first logic configuration and the first application from a remote database via a computer network in response to installation of the first end effector on the head;

retrieves the second logic configuration and the second application from the remote database via the computer network in response to installation of the second end effector on the head.

15. The method of claim 13:

wherein the head interface defines a set of interface pins;

wherein the control electronics comprises a component interconnect arranged within the base, comprising a set of interconnect pins electrically coupled to the set of interface pins via a set of hookup wires, and comprising a set of logic pins;

further comprising;

a first control card configured to transiently engage the component interconnect and comprising;

a first set of interconnect pads configured to contact the set of interconnect pins,

a first set of logic pads configured to contact the set of logic pins, and

a first control circuit interposed between the first set of interconnect pads and the first set of logic pads and comprising a first set of independently-selectable function circuits between each interconnect pad in a subset of the first set of interconnect pads and corresponding logic pads in the first set of logic pads;

a second control card configured to transiently engage the component interconnect in replacement of the first control card and comprising;

a second set of interconnect pads configured to contact the set of interconnect pins,

a second set of logic pads configured to contact the set of logic pins, and

a first control circuit interposed between the second set of interconnect pads and the second set of logic pads and comprising a second set of independently-selectable function circuits between each interconnect pad in a subset of the second set of interconnect pads and corresponding logic pads in the second set of logic pads;

wherein the processor is configured to;

access the first logic configuration based on the first identifier of the first end effector and a first card identifier of the first control card when the first end effector is installed on the head and the first control card is installed in the component interconnect; and

access the second logic configuration based on the second identifier of the second end effector and a second card identifier of the second control card when the second end effector is installed on the head and the second control card is installed in the component interconnect.

16. The method of claim 15:

wherein the processor further comprises a set of input/output ports;

wherein the control electronics further comprises a digital logic;

arranged within the base,

comprising a set of logic-side ports electrically coupled to the logic pins in the component interconnect, and

comprising a set of processor-side ports connected to the input/output ports in the processor; and

wherein the processor;

loads the first logic configuration onto the digital logic to trigger the digital logic to electrically couple a first subset of logic-side ports in the set of logic-side ports to a first subset of processor-side ports in the set of processor-side ports when the first end effector is installed on the head and the first control card is installed in the component interconnect; and

loads the second logic configuration onto the digital logic to trigger the digital logic to electrically couple a second subset of logic-side ports in the set of logic-side ports to a second subset of processor-side ports in the set of processor-side ports when the second end effector is installed on the head and the second control card is installed in the component interconnect.

17. The method of claim 15:

wherein the first end effector comprises a pick-and-place interface actuated by a first actuator;

wherein the second end effector comprises a gripper actuated by a second actuator;

wherein the first control card is configured to control actuation of the pick-and-place interface by the first actuator in the first end effector responsive to commands from the processor; and

wherein the second control card is configured to control actuation of the gripper by the second actuator in the second end effector responsive to commands from the processor.

18. The system of claim 13, wherein the first end effector:

excludes control circuitry; and

comprises a first actuator controlled by the control electronics according to the first logic configuration responsive to commands received from the processor according to the first application when the first end effector is installed on the head.

19. The method of claim 13, wherein the processor is further configured to:

navigate the arm through a first motion path and to trigger the first end effector to execute the first function when the first end effector is installed on the head by;

generating a first set of commands based on the first application; and

serving the first set of commands to the control logic for distribution to the set of articulable axes and the first end effector according to the first logic configuration; and

navigate the arm through a second motion path and to trigger the second end effector to execute the second function when the second end effector is installed on the head by;

generating a second set of commands based on the second application; and

serving the second set of commands to the control logic for distribution to the set of articulable axes and the second end effector according to the second logic configuration.

20. The system of claim 13:

further comprising a set of hookup wires extending through the arm between the control electronics in the base and the head interface;

wherein the control electronics is configured to supply a high-current power signal to a first actuator in the first end effector through a first subset of hookup wires in the set of hookup wires when the first end effector is installed on the head; and

wherein the control electronics is configured to communicate with the second end effector via low-current data signals through the first subset of hookup wires in the set of hookup wires when the second end effector is installed on the head.