Free-traveling manipulator with optical feedback control and methods

• US 5,570,992 A
• Filed: 06/07/1995
• Issued: 11/05/1996
• Est. Priority Date: 07/28/1954
• 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:
  US08/480,114
• Time in Patent Office: 517 Days
• Field of Search: 414/4, 414/730, 414/244.3, 414/244.6, 414/244.8, 901/1, 901/9, 901/17, 901/22, 901/28, 901/29, 901/32, 901/41
• US Class Current: 414/744.3
• CPC Class Codes: B23Q 11/10 Arrangements for cooling or lubricating tools or work incorporated in tools, see the relevant subclass for the tool , e.g. B23B27/10, B23B51/06, B23C5/28, B23D77/006; for circular saw blades B23D59/02, for cooling grinding surfaces B24B55/02
• CPC Class Codes: B23Q 41/00 Combinations or associations of metal-working machines not directed to a particular result according to classes B21, B23, or B24 B23Q37/00, B23Q39/00 take precedence; features relating to operations performed, if the different metal-working operations are of the same kind, see the subclass for the kind of operation, e.g. punching B21D, welding B23K, grinding B24B; features relating to technically specified combinations of different metal-working operations B23P23/00
• CPC Class Codes: B25J 15/0491 comprising end-effector racks
• CPC Class Codes: B25J 19/021 Optical sensing devices
• 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 9/0084 comprising a plurality of manipulators
• CPC Class Codes: B25J 9/0093 co-operating with conveyor means
• CPC Class Codes: B25J 9/041 Cylindrical coordinate type
• CPC Class Codes: B25J 9/1015 using additional, e.g. microadjustment of the end effector
• CPC Class Codes: B25J 9/161 Hardware, e.g. neural networks, fuzzy logic, interfaces, processor
• CPC Class Codes: G05B 19/14 using punched cards or tapes G05B19/128 takes precedence
• CPC Class Codes: G05B 19/41815 characterised by the cooperation between machine tools, manipulators and conveyor or other workpiece supply system, workcell
• 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 2219/41249 : Several slides along one axis
• CPC Class Codes: G05B 2219/45045 : Maintenance, automatic storage and retrieval system
• CPC Class Codes: G05B 2219/45051 : Transfer line
• CPC Class Codes: G05B 2219/45083 : Manipulators, robot
• CPC Class Codes: G05B 2219/45213 : Integrated manufacturing system ims, transfer line, machining center
• CPC Class Codes: G05B 2219/49395 : Repeating same operations for other coordinates
• CPC Class Codes: G06K 13/26 : Winding-up or unwinding of record carriers; Driving of record carriers
• CPC Class Codes: G06K 7/04 : by mechanical means, e.g. by pins operating electric contacts
• CPC Class Codes: G11B 15/1883 : for record carriers inside containers
• CPC Class Codes: G11B 15/58 : with vacuum column
• CPC Class Codes: G11B 27/102 : Programmed access in sequence to addressed parts of tracks of operating record carriers access by moving the head G11B3/08, G11B5/54, G11B7/085, G11B21/022; by moving the record carrier G11B15/005, G11B17/005, by driving of both record carrier and head G11B15/1816
• CPC Class Codes: G11B 27/28 : by using information signals recorded by the same method as the main recording G11B27/22 takes precedence
• CPC Class Codes: H03D 13/005 : in which one of the oscillations is, or is converted into, a signal having a special waveform, e.g. triangular
• CPC Class Codes: H04L 27/16 : Frequency regulation arrangements
• CPC Class Codes: Y02P 90/02 : Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An automatic, controlled manipulator includes a moveable tool head on an arm and a tool supported at the end of the arm. The manipulator may be moveable in multiple or all directions. A storage for remotely generated control signals can be accessed to control motors causing 3D motion of the tool head, attachment of the tool, and (if applicable) motion of the manipulator, and also to control power to operate the tool. Video signals generated at the manipulator are used to identify the workpiece, to select one of a plurality of stored control programs, and to select the tool operations applied.

Claims

1. An automatic, moveable manipulator comprising:

(a) a carriage;

(b) a power drive coupled to the carriage and positioned to move the carriage in a multitude of directions, comprising two moving members oriented parallel to each other, which may be driven simultaneously and independently in the same or different directions;

(c) at least one manipulator arm supported at a first end by the carriage and having a tool holder at a second end with an engagement-release mechanism adapted to support one of a plurality of different tools;

(d) a motor drive coupled to the arm so as to move the arm;

(e) a scanner supported by the manipulator and positioned to scan the external environment of the manipulator and structured to generate a varying scanning signal;

(f) a wireless receiver supported by the carriage;

(g) an electronic storage device supported by the carriage and structured to store signals received from a remote location by the receiver; and

(h) a controller coupled to reproduce the stored signals from the storage and structured to process the reproduced signals to generate command control signals and to apply the command control signals to control the operation of the manipulator; and

(i) a computer structured to analyze the generated scanning signal to determine a characteristic of a workpiece in the vicinity of the manipulator, which computer is coupled to the manipulator arm so that the results of the analysis is applied to control the selection of one of the plurality of different tools, the supporting of the selected tool by the tool holder, and the operation of the selected tool.

19. The apparatus of claim 1 wherein the scanner comprises a television camera having an output for video signals generated thereby.

21. The apparatus of claim 1 further comprising (a) an electrical coupling through the arm and the tool holder including a power line extending to the selected, supported one of the tools;

and (b) a tool rack supported by the carriage and containing a plurality of power-operated tools configured to be electrically and physically connected to the tool holder.

23. The apparatus of claim 1 wherein the power drive comprises a pair of moving belt members oriented parallel to each other and a reversible-gear motor coupled to and separately driving each of the belt members.

24. The apparatus of claim 23 wherein the two belt members are cleated.

25. The apparatus of claim 1 further comprising a column supported on the carriage, wherein the arm is supported on and moveable along the column, and wherein the motor drive includes a first motor positioned to drive the arm along the column, a second motor positioned to rotate the arm around the column, and a third motor positioned to extend the arm orthogonal to the column.

26. The apparatus of claim 21 further comprising a column supported on the carriage, wherein the arm is supported on and moveable along the column, wherein the arm is hinged, wherein the tool rack is supported on top of the column, and wherein the motor drive includes a first motor positioned to drive the arm along the column, a second motor positioned to rotate the arm around the column, and a third motor positioned to bend the arm at the hinge.

27. The apparatus of claim 21 wherein the engagement-release mechanism comprises a rotatable, threaded sleeve at the end of the arm and a reversible motor coupled to rotate the sleeve.

28. The apparatus of claim 1 further comprising a stabilizer positioned to counterbalance a load supported by the arm, including a retractable extension positioned to stabilize the manipulator by bracing the manipulator against a stable surface.

2. An automatic manipulator and control system therefor comprising:

(a) at least one manipulator, including;

i) a carriage;

ii) drive means for moving the carriage in a multitude of directions along a surface, comprising two moving members oriented parallel to each other, which may be driven simultaneously and independently in the same or different directions;

iii) a manipulator arm assembly supported by the carriage;

iv) a tool rack containing a plurality of power-operated tools;

v) means for removing a selected one of the tools from the tool rack, for electrically and physically connecting the selected tool to the arm assembly, for supporting the selected tool with the arm assembly, for power operating the selected tool while it is supported by the arm assembly, and for controllably releasing tools from the arm assembly;

vi) motor means for moving the arm assembly through three-dimensional space;

vii) means on the manipulator for receiving command signals;

viii) means on the manipulator for storing a plurality of command control signals;

ix) means for reproducing a selected group of signals from the storage means, for generating the reproduced signals as a sequence of commands, and for applying the commands to control the movement and operation of the manipulator; and

x) means for electro-optically sensing a field of view adjacent to the manipulator and for generating output signals that vary in accordance with optical variations in the sensed field of view;

xi) signal processing means for digitizing the output signal from the sensing means, for computer analyzing the digitized signals, and for using the results of the analysis to modify the operation of the tool selection and operation means by selecting one of a plurality of control programs; and

(b) a remote computer, including;

i) means for storing a plurality of control programs as signals controlling the manipulator to cause it to perform a preselected sequence of operations involving the programmed operation of the drive means, the motor means, and the coupling means;

ii) means for selectively reproducing the control programs from the storage means; and

iii) means for transmitting trains of signals defining the selected control programs to the receiving means of the manipulator.

3. A moveable manipulator comprising:

(a) a carriage;

(b) a power drive coupled to the carriage and positioned to move the carriage in a multitude of directions, comprising two moving members oriented parallel to each other, which may be driven simultaneously and independently in the same or different directions;

(c) at least one arm assembly supported by the carriage, which arm assembly supports one of a plurality of tools;

(d) a motor drive coupled to and driving the arm assembly;

(e) an electronic storage device containing a plurality of control programs, each comprising a sequence of command signals;

(f) a reproduction transducer coupled to the storage device and structured to reproduce a selected one of the control programs from the storage device as command control signals and coupled to apply the sequence of command signals to control the operation of the manipulator and to select one of the tools;

(g) a video scanner supported by the manipulator and having an output for video signals that vary in accordance with a visual characteristic of the external environment of the manipulator; and

(h) a signal processor coupled to the output of the video scanner and the reproduction transducer and structured to identify a workpiece adjacent to the manipulator from the video signals on the scanner output and to use the results of the identification to select one of the plurality of control programs to cause the manipulator to perform a tooling operation on the identified workpiece using the selected tool.

4. An apparatus in accordance with claim 3 wherein the reproduction transducer is coupled to apply the selected program to cause the arm assembly to swap among a plurality of the tools to perform a predetermined operation on the workpiece.

5. An apparatus in accordance with claim 3 wherein the signal processor is structured to identify the type of workpiece adjacent to the manipulator and to use the results of the identification to select one of the programs to control the manipulator.

6. An apparatus in accordance with claim 5 including a sensor positioned to detect the presence of a workpiece adjacent to the manipulator, which sensor is coupled to cause the selected control program to operate the manipulator in a predetermined manner upon activation of the sensor.

7. An apparatus in accordance with claim 5 wherein the signal processor further comprises a sensor positioned to detect a workpiece at a predetermined location relative to the manipulator, which sensor is coupled to cause reproduction and application of the selected control program to cause the manipulator to operate on the workpiece.

8. An apparatus in accordance with claim 3 wherein the signal processor includes an identification subsystem structured to analyze digitized video signals from the output to identify a select object and to generate select control signals, and coupled to the power drive to cause it to move the carriage in a predetermined manner with respect to the object based on the identification.

9. An apparatus in accordance with claim 8 wherein the identification subsystem is further coupled to controllably pick up and move the object in a predetermined manner based on the identification.

10. An apparatus in accordance with claim 3 wherein the signal processor includes an identification subsystem structured to analyze digitized video signals from the output to identify a select object and to generate select control signals, and coupled to the arm assembly to cause it to operate on the object in a predetermined manner based on the identification.

20. The apparatus of claim 3 wherein the video scanner comprises a television camera.

22. The apparatus of claim 3:

(a) wherein the arm assembly includes a tool holder having an engagement-release mechanism configured to support a single one of a plurality of tools on the arm assembly and an electrical coupling through the arm including a power line extending to the selected, supported one of the tools;

(b) wherein the manipulator further comprises a tool rack containing a plurality of power-operated tools configured to be electrically and physically connected to the tool holder; and

(c) further comprising a wireless receiver supported by the carriage and coupled to the storage device.

29. The apparatus of claim 3 wherein the power drive comprises a pair of moving belt members oriented parallel to each other and a reversible-gear motor coupled to and separately driving each of the belt members.

30. The apparatus of claim 29 wherein the two belt members are cleated.

31. The apparatus of claim 3 wherein the arm assembly comprises a column supported on the carriage and an extendable shaft supported on and moveable along the column, and wherein the motor drive includes a first motor positioned to drive the shaft along the column, a second motor positioned to rotate the shaft around the column, and a third motor positioned to extend the shaft orthogonal to the column.

32. The apparatus of claim 22 wherein the arm assembly comprises a column supported on the carriage and a hinged shaft supported on and moveable along the column, wherein the tool rack is supported on top of the column, and wherein the motor drive includes a first motor positioned to drive the shaft along the column, a second motor positioned to rotate the shaft around the column, and a third motor positioned to bend the shaft at the hinge.

33. The apparatus of claim 22 wherein the engagement-release mechanism comprises a rotatable, threaded sleeve at the end of the arm assembly and a reversible motor coupled to rotate the sleeve.

34. The apparatus of claim 3 further comprising a stabilizer positioned to counterbalance a load supported by the arm assembly, including a retractable extension positioned to stabilize the manipulator by bracing the manipulator against a stable surface.

11. A process of controlling an moveable manipulator having a moveable base, at least one multi-part arm assembly supported by the base and capable of holding a tool, and motors coupled to move the arm in 3D space comprising:

(a) storing at the manipulator a plurality of control programs, each comprising a sequence of command signals;

(b) reproducing a selected one of the control programs as command control signals and applying the command signals to control the movement of the arm, the selection of one of a plurality of interchangeable tools, and the operation of the selected tool;

(c) generating at the manipulator video signals that vary in accordance with a visual characteristic of the external environment of the manipulator;

(d) digitizing the video signals;

(e) computer analyzing the digitized signals to identify a workpiece sensed adjacent to the manipulator;

(f) using the results of the identification to select one of a plurality of the control programs;

(g) applying the selected program to cause the base to move in any direction in two dimensions by simultaneously and independently driving two moving members oriented parallel to each other in the same or different directions; and

(h) applying the selected program to cause the manipulator to perform a tooling operation on the identified workpiece using the selected tool.

12. The process of claim 11 further comprising applying the selected program to cause the arm assembly to select and operate several of a plurality of tools to perform a predetermined operation on the workpiece.

13. The process of claim 12 further comprising applying the selected program to cause the arm assembly to sequentially support and release each of the selected tools to perform sequential operations on the workpiece.

14. The process of claim 11 further comprising identifying the type of workpiece adjacent to the manipulator and using the results of the identification to select one of the programs to control the manipulator.

15. The process of claim 14 including detecting the presence of a workpiece adjacent to the manipulator and applying the selected control program to operate the manipulator upon the detection to cause the manipulator to handle the workpiece in a predetermined manner.

16. The process of claim 14 wherein further comprising detecting a workpiece at a predetermined location relative to the manipulator and thereupon reproducing and using the selected program to cause the manipulator to operate on the workpiece.

17. The process of claim 11 further comprising identifying a select object by analyzing the digitized scanning signals, generating select control signals based on the identification, and applying the select control signals to move the carriage in a predetermined manner with respect to the object based on the identification.

18. The process of claim 17 including controllably picking up and moving the object in a predetermined manner based on the identification.