Non-contact optical distance and tactile sensing system and method

• US 9,120,233 B2
• Filed: 05/31/2012
• Issued: 09/01/2015
• Est. Priority Date: 05/31/2012
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Moore, Douglas A.
• Primary Examiner(s): Nguyen, Bao Long T
• Application Number:
  US13/485,691
• Publication Number:
  US 20130325181A1
• Time in Patent Office: 1,188 Days
• US Class Current: 1/1
• CPC Class Codes: B25J 13/08 by means of sensing devices, e.g. viewing or touching devices
• CPC Class Codes: B25J 13/084 Tactile sensors in general G01L5/16, G01L5/22
• CPC Class Codes: B25J 13/086 Proximity sensors
• CPC Class Codes: B25J 15/10 with three or more finger members B25J15/0009 takes precedence
• CPC Class Codes: Y10S 901/31 Gripping jaw
• CPC Class Codes: Y10S 901/33 Tactile sensor
• CPC Class Codes: Y10S 901/35 Proximity
• CPC Class Codes: Y10S 901/46 Sensing device

Abstract

The systems and methods are directed to mechanical arms and manipulators, and more particularly, to optical distance sensors in use for approach, grasping and manipulation. The system may include a manipulator having an arm and a multi fingered end-effector coupled to the distal end of the arm. The end-effector may include an optical proximity sensor configured to detect the distance to an object prior to contact with the object. The end-effector may include an optical proximity sensor configured detect a measurement of force applied to the object by the manipulator post contact with the object. The measurement of force may be a range of force measurements including a minimum, a maximum and a measurement between or within the minimum and the maximum.

Claims

1. A system comprising:

a manipulator including an arm having a distal end and a proximal end and an end-effector coupled to the distal end of the arm, the end-effector having at least two fingers and a contact surface defining a channel, the contact surface being configured to compress as force is applied to an object by the end-effector;

an optical proximity sensor positioned on the end-effector and in the channel such that the optical proximity sensor senses a distance to the object through the channel in response to the object entering a predetermined range of the optical proximity sensor; and

a processor configured to determine an amount of force applied to the object by the end-effector based on the sensed distance from the optical proximity sensor to the object when the contact surface is compressed.

2. The system of claim 1, wherein the arm further comprises proximity sensors configured to aid in movement of the manipulator.

3. The system of claim 1, wherein the arm further comprises an arm segment configured to flex and rotate.

4. The system of claim 1, further comprising a tactile sensor coupled to the end-effector.

5. The system of claim 1, wherein the optical proximity sensor is further configured to sense surface features of the object and the at least two fingers may be configured to mirror a portion of the sensed surface features of the object at a dynamically adjusted range.

6. The system of claim 1, wherein a single light source generator of the optical proximity sensor may comprise a plurality of receivers.

7. The system of claim 1, wherein the optical proximity sensor is further configured to sense surface features of the object and the end-effector and the at least two fingers may be configured to be positioned in a desired shape and orientation based on the sensed surface features of the object.

8. The system of claim 1, wherein the processor is further configured to determine the optimal position of the end-effector for making contact with the object based on data sensed by the optical proximity sensor.

9. The system of claim 1, wherein the manipulator is coupled to a vehicle.

10. The system of claim 1, wherein a direction of sensing of the optical proximity sensor is configured to sweep in a desired range of angles from a surface of the manipulator.

11. The system of claim 1, wherein a range of the optical proximity sensor is dynamically adjusted to a dynamically scalable range.

12. The system of claim 1, wherein a direction of sensing of the optical proximity sensor is configured to be held steady independent of motion of the manipulator.

13. The system of claim 1, further comprising a second optical proximity sensor positioned on at least one of a palm, a wrist, a backhand, a fingertip or one of the at least two fingers of the end-effector.

14. A method comprising:

providing a manipulator including an end effector having a contact surface that defines a channel;

sensing, by an optical proximity sensor positioned within the channel, a distance to an object;

applying pressure to the contact surface in order to compress the contact surface; and

determining, by a processor, an amount of force applied to the object by the manipulator in response to contact with the object based on the sensed distance from the optical proximity sensor to the object when the contact surface is compressed.

15. A system comprising:

an end-effector having an optical proximity sensor positioned in a channel defined by a contact surface of the end-effector that is configured to compress as force is applied to the object, the optical proximity sensor being configured to sense a distance to an object through the channel; and

a processor configured to determine a scaled range of force measurements of force applied to the object subsequent to contact with the object based on the sensed distance to the object when the contact surface is compressed.

16. A system comprising:

a manipulator including an arm having a distal end and a proximal end and an end-effector coupled to the distal end of the arm and having at least two fingers and an optical proximity sensor configured to sense in a dynamically positioned direction independent from the movement of the manipulator and to sense the distance to an object in response to the object entering a predetermined range of the optical proximity sensor; and

a processor configured to determine an amount of force applied to the object by the end-effector in response to contact with the object.