Automatic manipulation system and method

• US 4,773,815 A
• Filed: 12/11/1986
• Issued: 09/27/1988
• Est. Priority Date: 01/24/1974
• Status: Expired due to Term

• Current Assignee: Jerome H. Lemelson
• Original Assignee: Jerome H. Lemelson
• Inventors: Lemelson, Jerome H.
• Primary Examiner(s): Valenza, Joseph E.
• Application Number:
  US06/941,554
• Time in Patent Office: 656 Days
• Field of Search: 414/4, 414/730, 414/744 R, 414/744 A, 901/1, 901/9, 901/17, 901/28, 901/29, 901/41, 901/22, 29/26 A, 29/568, 409/218
• US Class Current: 414/744.3
• CPC Class Codes: B25J 15/0491 comprising end-effector racks
• CPC Class Codes: B25J 19/023 including video camera means
• CPC Class Codes: B25J 5/005 mounted on endless tracks or belts
• CPC Class Codes: B25J 9/041 Cylindrical coordinate type
• CPC Class Codes: G05B 19/425 Teaching successive positions by numerical control, i.e. commands being entered to control the positioning servo of the tool head or end effector
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: G05B 2219/33207 Physical means, radio, infra red, ultrasonic, inductive link
• CPC Class Codes: G05B 2219/36395 Load local computer program from host, data transfer ram to rom, BTR
• CPC Class Codes: G05B 2219/36511 Select by a detector
• CPC Class Codes: G05B 2219/36513 Select out of a plurality of programs, patterns
• CPC Class Codes: G05B 2219/37553 Two cameras one for coarse scanning, other for fine scanning
• CPC Class Codes: G05B 2219/37572 Camera, tv, vision
• CPC Class Codes: G05B 2219/40283 Reservoir with additional material on vehicle with manipulator
• CPC Class Codes: G05B 2219/40284 Toolrack on vehicle with manipulator, toolchanger
• CPC Class Codes: G05B 2219/40298 Manipulator on vehicle, wheels, mobile
• CPC Class Codes: G05B 2219/45045 Maintenance, automatic storage and retrieval system
• CPC Class Codes: Y10S 483/901 Robot end effectors
• CPC Class Codes: Y10T 29/5107 Drilling and other

Abstract

An automatic manipulator capable of performing various programs and adaptively controlled operations with respect to work including operations on work. Automatic tool changing means are provided wherein the manipulator changes tools with respect to its tool holding fixture, tool head or heads. In one form, a plurality of tools to be used are supported on a rack adjacent the manipulator and the manipulator is automatically operated to effect the uncoupling of one or more tools from its operating head and the coupling of one or more tools with respect to such operating head. In another form, the tools are supported by the manipulator itself and the manipulator is automatically controlled to effect the transfer of tools between its operating head and a storage location for the tools. In a third form, tool heads themselves are automtically changed and received either from storage on the manipulator or adjacent the manipulator. In a fourth form, the tool head is composed of a turret containing a plurality of different tools and manipulating devices, which turret is automatically operated to bring a selected tool or fixture into an operative location on the manipulator.

Claims

1. An automatic manipulator comprising in combination:

(a) first support means,

(b) a manipulator arm assembly carried by said first support means for multi-axis movement,

(c) an operating head operatively connected to and supported by said arm assembly,

(d) a plurality of power-operated tools for performing different functions with respect to work, each of said tools including means to receive operating power through said arm assembly and coupling means operable to be releasably rotatably connected to said operating head,

(e) first and second motor means located on said first support means for driving said arm assembly in said multiaxis movement to carry said operating head connected to a tool through a multitude of paths adjacent said first support means for performing a multitude of operations with respect to work disposed adjacent said first support means,

(f) means located within the operating range of said arm assembly for positioning a plurality of power-operated tools for use with said operating head, and

(g) master control means including (i) means for automatically controlling the operation of seaid first and second motor means to cause said manipulator arm assembly to position said operating head in operable alignment with a selected tool disposed on said positioning means, (ii) means for controllably moving said head in a path, and (iii) powered means located on the arm assembly to effect the operative rotatable connection between the coupling means of said select tool and the operating head,

(h) said master control means being also operable to control said first and second motor means to drive said arm assembly to cause it to automatically remove said selected tool from said tool positioning means and to predeterminately more thereafter and control the powered operation of said tool so as to cause said selected tool to perform a first predetermined operation with respect to work located adjacent said first support means, and

(i) when it is required to perform another operation with respect to work with another tool, said operation controlling means for the first and second motor means is effective to position said operating head in alignment with a select location of said tool positioning means,

(j) means for rotatably disconnecting the tool coupling means from the operating head at said tool positioning means, and

(k) said operation controlling means being effective to thereafter control said first and second motor means to move said operating head in a manner to effect the positioning of said operating head in alignment with the coupling means of a second select power-operated tool to effect the operable rotatably connecting of said second tool with said operating head and to thereafter move and control the operation of said second tool to cause said second tool to perform a further predetermined operation with respect to work adjacent said first support means and

(l) third motor means disposed on said arm assembly and operable to effect the rotatable securing of selected of said tool coupling means to said tool positioning means and the rotatable uncoupling and release of tools from said tool positioning means,

(m) said third motor means being automatically controlled in its operating by said master control means.

2. An automatic manipulator in accordance with claim 1, wherein

at least certain of said power-operated tools are electrically operable,

said means to receive operating power includes first electrical coupling means supported by said tool operating head,

said first electrical coupling means electrically connects a source of electrical energy to a second electrical coupling means supported by each electrically power-operated tool when said tool is rotatably coupled to said operating head.

3. An automatic manipulator in accordance with claim 2 wherein

said master control means is operable to control the operation of a selected of said electrically power-operated tools in synchronization with its control of said first and second motor means to cause said tools to perform predetermined operations with respect to work adjacent said first support means.

4. An automatic manipulator comprising:

(a) a support carrying an arm assembly including an operating head having rotatably releasable tool holding means

(b) reversible first motor means for driving said arm assembly in multi-axis movement with respect to said support,

(c) means to receive operating power through the arm assembly and reversible second motor means each being located on the arm assembly to respectively power-operate said rotatably releasable tool holding means and operatively rotatably secure and release a power-operated tool with respect to said tool holding means,

(d) means for supporting a plurality of power-operated tools to be individually rotatably secured to said tool holding means within reach of said operating head, and

(e) master control means for controlling the operation of said first and second motor means to operate said arm assembly and said rotatably releasable tool holding means so as to move said arm assembly and predeterminately position said tool holding means in operative alignment with a selected tool on said tool supporting means and to cause power-operable engagement of said operating head with said selected tool and the operation of said second motor means to cause said tool holding means to engage and operatively rotatably secure said selected tool to said tool holding means whereby said manipulator may be operated thereafter for predeterminately operating said selected tool on work disposed adjacent said support.

5. A method of operating an automatic manipulator comprising:

(a) automatically controlling an automatic manipulator assembly including a base and an arm assembly having an operating head defining a holding fixture for rotatably releasing holding and means for coupling power to a first power-operated tool for performing a first select powered operation on work located adjacent said manipulator, said arm assembly carrying means for rotatably connecting said holding fixture, and

(b) when said first operation is completed, automatically controlling the operation of said arm assembly to cause it to move said operating head to an operative location with respect to a storage means for a plurality of power-operated tools and automatically effecting the uncoupling of power from said first tool and the rotatable release and transfer of said first power-operated tool to said storage means,

(c) thereafter automatically controlling the operation of said manipulator to cause a second power-operated tool stored at said storage means to be transferred and operatively rotatably retained by said operating head of said manipulator and to become coupled to recieve power for operating said tool, and

(d) thereafter automatically controlling said manipulator to cause it to carry its operating head and said second power-operated tool into operative relation with respect to work and automatically operating said second power-operated tool thereafter to cause it to predeterminately operate on said work.

6. A method in accordance with claim 5 wherein

said storage means is located on said manipulator, and

said arm assembly is controlled to predeterminately locate said operating head with respect to said manipulator so as to permit a first power-operated tool held by said head to be transferred therefrom to said select storage location and a second power-operated tool held at another storage location of said operating head to be transferred to said operating head, and

automatically transferring said second power-operated tool from said select storage location to said operating head.

7. A method in accordance with claim 6 wherein

said storage location contains a rotatable power-operated movable rack having a plurality of storage locations for holding respective of a plurality of power-operated tools for use by said manipulator, and

controlling the operation of said movable rack to bring selected storage locations thereof into operable relation with respect to the operating head of said manipulator.

8. A method in accordance with claim 6 wherein

said storage location is defined by a rotatable rotary rack containing means for holding a plurality of different power-operated tools,

automatically selectively rotating said rotary rack a first time to bring the selected empty storage location thereof into operable location with respect to said arm assembly and the holding fixture to permit transfer of the power-operated tool held by said fixture to said empty storage location, and thereafter

automatically selectively rotating said rotary rack a second time after the automatic transfer of the power-operated tool held by said fixture to said selected empty storage location of said rack to bring the second storage location thereof containing a second selected power-operated tool into operative location with respect to said fixture for automatically transferring said second tool to said fixture.

9. A method in accordance with claim 5 wherein

said storage means comprises a movable storage fixture,

moving such storage fixture while said arm assembly is in movement and stopping both said arm assembly and said fixture with said arm assembly fixture aligned with a selected location of said movable storage location fixture.

10. A method in accordance with claim 9 wherein

said storage location fixture is movably supported on said manipulator,

said method including power driving said storage location fixture on said manipulator to bring selected storage locations thereof into operable alignment with respect to said fixture of said arm assembly.

11. A method in accordance with claim 9 wherein

said storage fixture is rotatably supported on said manipulator,

said method including power rotating said storage fixture on said manipulator to bring selected storage locations thereof into operable alignment with respect to said fixture of said arm assembly.

12. A method in accordance with claim 9 wherein

said storage fixture is movably supported on said base of said manipulator,

said method including power moving said storage fixture on said manipulator to bring selected storage locations thereof into operable alignment with respect to said fixture of said arm assembly.

13. A method in accordance with claim 5 wherein

said power-operated tool is operable to seize and release work permitting such work to be handled by said manipulator,

said method including controlling the operation of said manipulator, when a first power-operated tool is held by said head to seize, manipulate and release a first unit of work, and

thereafter transferring said first power-operated tool to a first storage location of said storage means and replacing said first power-operated tool, with a second power-operated tool,

thereafter operating said manipulator and said second power-operated tool to operate on a second unit of work,

said second power-operated tool is a work handling means,

said method including operating said work handling means to seize, manipulate and release a second unit of work.

said first power-operated tool is operable to perform programmed operations on work disposed adjacent said manipulator,

said method comprising controlling said manipulator and said first power-operated tool to perform a predetermined operation on work adjacent said manipulator.

14. A method in accordance with claim 13 wherein

said second power-operated tool is operable to perform variable operations on work,

said method including program controlling the operation of said manipulator and said second power-operated tool to perform a programmed operation on work located adjacent said manipulator.

15. An automatic manipulation apparatus comprising:

(a) power supply means,

(b) an automatic manipulator for performing programmed operations with respect to work and including a first support and a manipulator arm assembly supported for multiple axis movement of said first support,

(c) an operating head disposed on said arm assembly and including a tool holding fixture and powered means for removably rotatably coupling power-operated tools to said fixture,

(d) said fixture being supported at the end of said arm assembly and including power supply coupling means, tool holding means and tool release means for releasing power-operated tool rotatably secured to said head,

(e) each of said power-operated tools having a power coupling means operable, when coupled to said power supply coupling means of said tool holding fixture to permit its tool to be power-operated while supported by said manipulator in performing different operations with respect to work located adjacent said first support,

(f) master control means for automatically controlling the operation of said manipulator arm assembly and power-operated tools which are operatively supported thereby to cause said power-operated tools to perform different programmed operations on work,

(g) tool prepositioning means located within operating range of said first support and containing a plurality of different power-operated tools for use by said manipulator in operating on work,

(h) said master control means being also operable to automatically control the movement of said manipulator arm assembly on said first support to bring said operating head into alignment with a selected power-operated tool held by said prepositioning means and to cause said operating head fixture to receive and operatively retain said selected power-operated tool for use thereafter in performing a programmed operation on work.

16. Manipulation apparatus in accordance with claim 15 including

means supported by said manipulator for sensing a surface adjacent said manipulator and generating sensing signals for use by said master control means in controlling said manipulator during the operation of charging power-operated tools.

17. An automatic manipulator comprising in combination:

(a) first support means,

(b) a manipulator arm assembly carried by said first support means for multi-axis movement,

(c) an operating head operatively connected to and supported by said arm assembly,

(d) a plurality of power-operated tools for performing different functions with respect to work, each of said tools including means to receive operating power through said arm assembly and powered coupling means operable to be releasably rotatably connected to said operating head,

(e) first and second motor means located on said first support means for driving said arm assembly in said multi-axis movement to carry said operating head connected to a tool through a multitude of paths adjacent said first support means for performing a multitude of operations with respect to work disposed adjacent said first support means,

(f) means located within the operating range of said arm assembly for positioning a plurality of power-operated tools for use with said operating head, and

(g) master control means including (i) means for automatically controlling the operation of said first and second motor means to cause said manipulator arm assembly to position said operating head in operable alignment with a selected tool disposed on said positioning means, (ii) means for controllably moving said head in a path, and (iii) powered means located on the arm assembly to effect the operative rotatable connection between the coupling means of said select tool and the operating head,

(h) said master control means being also operable to control said first and second motor means to drive said arm assembly to cause it to automatically remove said selected tool from said tool positioning means and to predeterminately move thereafter and control the powered operation of said tool so as to cause said selected tool to perform a first predetermined operation with respect to work located adjacent said first support means, and

(i) when it is required to perform another operation with respect to work with another tool, said operation controlling means for the first and second motor means is effective to position said operating head in alignment with a select location of said tool positioning means,

(j) means for rotatably disconnecting the tool coupling means from the operating head at said tool positioning means, and

(k) said operation controlling means being effective to thereafter control said first and second motor means to move said operating head in a manner to effect the positioning of said operating head in alignment with the coupling means of a second select power-operated tool to effect the operable rotatably connecting of said second tool with said operating head and to thereafter move and control the operation of said second tool to cause said second tool to perform a further predetermined operation with respect to work adjacent said first support means and

(l) said first support means includes an upstanding column with said arm assembly movably supported thereon,

(m) said tool positioning means being supported for rotation about the longitudinal axis of said column and having a plurality of tool holding locations,

(n) third motor means disposed on said arm assembly for rotating said tool positioning means about said rotational axis,

(o) said master control means being operable to control the operation of said rotating means simultaneously as it controls the operation of said first motor means to selectively align a selected tool holding location of said tool positioning means and said operating head of said arm assembly.

18. A tool manipulation apparatus comprising:

(a) releasable tool holding means for storing a plurality of power-operated tools for performing different functions with respect to work,

(b) supporting means for moving a tool operating head between the releasable tool holding means and work disposed adjacent said supporting means which includes an arm assembly having said operated head disposed at a outer end portion thereof,

(c) powered coupling means adapted to operatively rotatably connect and disconnect said operating head with respect to a power-operated tool disposed at a location of said releasable tool holding means,

(d) power supply means located on said arm assembly for supplying power to said powered coupling means and to a power-operated tool which is connected to the generating head with said coupling means, and

(e) master control means for (i) automatically controlling said supporting means to effect programmed movement of the tool operating head between the releasable tool holding means and said work, and (ii) automatically controlling said coupling means to effect programmed connecting and disconnecting of said operating head with respect to said power-operated tool, and (iii) automatically controlling power to effect programmed operation of said power-operated tool to perform a tool function with respect to said work.

19. A machine tool apparatus comprising:

(a) releasable tool holding means for positioning a plurality of power-operated tools for performing different functions with respect to work,

(b) supporting means for moving a tool operating head between the releasable tool holding means and work disposed adjacent said supporting means,

(c) said supporting means including an arm assembly having said operating head disposed at an outer end portion thereof,

(d) said operating head including powered coupling means for operatively rotatably connecting and disconnecting the tool operating head with respect to a power-operated tool disposed at a position on the releasable tool holding means, and

(e) power supply means located on said arm assembly for supplying power to said powered coupling means and to a power-operated tool which is connected to the operating head with said coupling means.