INCORPORATION BY REFERENCE

[0001] The following documents are incorporated herein by reference as if fully set forth: U.S. Nonprovisional Patent Application No. 15/185,660, filed June 17, 2016.

FIELD OF INVENTION

[0002] The present invention relates to a robotic system, and, more particularly, to a modular articulating assembly of a robotic system having extruded connector arms.

BACKGROUND

[0003] Robots and robotic systems are often used to automate manufacturing processes. A typical robotic system may include an articulating arm configured to move through a predetermined path to perform a selected operation, such as moving or rotating an object. The articulating arm, much like a human arm, may include joints and connectors. The joints may extend, rotate, pivot, actuate, or otherwise move the connectors or a tool in order to perform the selected operation.

[0004] Current robotic systems suffer from some drawbacks because they are lacking in an ability to be customized. For example, components are typically formed through expensive casting and/or machining processes, thereby incentivizing the continued use of a component, despite any limitations it may have. Further, components of current robotic systems may be heavy and/or bulky, further inhibiting system variation and customization. The present disclosure is directed to overcoming one or more problems of the prior art through providing robotic system components that are modular, lightweight-yet-strong, and compact. SUMMARY

[0005] In one aspect, the present disclosure is directed to an articulating assembly of a robotic system. The articulating assembly includes a connector arm including an extruded body portion. The extruded body portion includes an axial base member, a perimeter wall, a plurality of webs extending radially from the base member to the perimeter wall, and a connection portion. The articulating assembly further includes an actuatable joint secured to the connection portion and configured to rotate the connector arm.

BRIEF DESCRIPTION OF THE DRAWING(S)

[0006] The foregoing Summary and the following detailed description will be better understood when read in conjunction with the appended drawings, which illustrate a preferred embodiment of the invention. In the drawings:

[0007] Fig. 1 is a perspective view of an exemplary robotic system;

[0008] Fig. 2 is an exploded view of an exemplary articulating portion that may be used in conjunction with the robotic system of Fig. 2;

[0009] Fig. 3 is a plan view of an exemplary connector arm of the articulating portion of Fig. 2;

[0010] Fig. 4 is a plan view of an exemplary joint of the articulating portion of Fig. 2; and

[0011] Fig. 5 is a cross-sectional view of the joint of Fig. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) [0012] Fig. 1 illustrates an exemplary robotic system 10. The robotic system 10 may be an automated machine configured to perform a task, such as a task in a manufacturing process. In an exemplary embodiment, the robotic system 10 includes a base portion 12 and an articulating assembly 14. The base portion 12 may be stationary, in that it may be immovably mounted or it may be stationary relative to the articulating assembly 14. For example, the base portion 12 may include a base bracket 16 secured to an underlying surface.

[0013] The articulating assembly 14 includes operable components of the robotic system 10 for completing a selected task (e.g., move or rotate an object, position a tool, etc.). For example, the articulating assembly 14 may include components configured to move through a predetermined path in order to perform the task (e.g., move or rotate an object, position a tool, etc.). Consistent with disclosed embodiments, the components of the articulating assembly 14 may be modular such that the robotic system 10 is customizable for completing a variety of different tasks (e.g., moving through any selected path).

[0014] In an exemplary embodiment, the articulating assembly 14 includes a plurality of actuatable joints 18, a plurality of connector arms 20, and a plurality of brackets 22. The joints 18 are actuatable in that they include relatively movable parts. For example, one or more of the joints 18 may be configured to rotate about an axis. In some embodiments, other joints 18 may be configured to extend, pivot, or otherwise cause relative movement. The connector arms 20 are secured between pairs of joints 18, such as to position different axes of rotation relative to each other and increase the degrees of freedom of the robotic system 10. The brackets 22 are configured as connectors, such as to allow a rotational axis of a joint 18 to be angled relative to a longitudinal axis of a connector arm 20 extending therefrom.

[0015] Fig. 2 further illustrates an exploded view of a possible configuration of the articulating assembly 14. The illustrated articulating assembly 14 includes a first joint 18 rotatable about a horizontal axis 24 and a connector arm 20 connectable to the first joint 18 and extending along the horizontal axis 24. The articulating assembly 14 further includes a bracket 22 configured to allow additional components of the articulating assembly 14 to extend along a vertical axis 26. For example, the bracket 22 is also connected to a second joint 18, rotatable about the vertical axis 26. An additional bracket 22 is secured to the second joint 18, thereby allowing for additional components to be secured and additional degrees of freedom for an associated robotic system 10.

[0016] The illustrated joints 18 include relatively movable components that provide the above-described rotation. In an exemplary embodiment, each joint 18 includes a body 28 which houses internal components for rotating a connection plate 30. The joints 18 may include an additional connection plate 32 which may or may not be rotatable by the internal components of the body 28. In any case, the connection plate 30 is rotatable with respect to the other connection plate 32 such that a components secured to the connection plates 30, 32 are relatively movable to each other by the joint 18.

[0017] The connector arm 20 and brackets 22 are modular components configured to position the joints 18 and any other actuatable elements (not shown) relative to each other. The connector arm 20 includes a body portion 34 which extends longitudinally between a first end 35 and a second end 36 through a length 38, each end 35, 36 being connectable to a joint 18, a bracket 22, or another component. The bracket 22 includes a first attachment surface 40 and a second attachment surface 42, each secured to different components. The first attachment surface 40 is angled relative to the second attachment surface 42 such that the articulating assembly 14 can extend through different planes, along relatively oriented axes, such as horizontal and vertical axes 34, 36.

[0018] Regarding the connector arm 20, a value for the length 38 depends on a particular application of the articulating assembly 14 (i.e., the degrees of freedom, a movement path, a range, etc.). In order to accommodate these variable applications, the connector arm 20 is configured to be replaceable and customizable in a cost-effective manner. In an exemplary embodiment, the body portion 34 is formed from an extruded material, such as extruded aluminum, other metals (e.g., steel), a plastic material, or a ceramic material. In this way, the connector arm 20 may be cut-to-size to accommodate a particular robotic system configuration. Moreover, the extruded body portion 34 includes a geometrical configuration that allows the connector arm 20 to be lightweight-yet-strong and rigid.

[0019] Fig. 3 further illustrates a cross -sectional view of the connector arm 20. In an exemplary embodiment, the connector arm 20 includes an axial base member 44, a perimeter wall 46 preferably having a toothed configuration, a plurality of webs 48, and a connection portion 50. The axial base member 42 extends on or along a corresponding longitudinal axis of the connector arm 20. The axial base member 44 may include any shape, including circular, square, rectangular, hexagonal, etc.

[0020] The perimeter wall 46 defines a perimeter shape of the connector arm 20. In an exemplary embodiment, the perimeter shape defined by the perimeter wall 46 includes a plurality of concave sections 52 alternating with a plurality of convex sections 54 to define the toothed configuration. The plurality of webs 48 extend radially from the base member 44 to the perimeter wall 46. In an exemplary embodiment, the plurality of webs are connected to inner walls of the concave sections 52.

[0021] In an exemplary embodiment, the connection portion 50 includes a plurality of attachment members 56. The plurality of attachment members 56 are preferably formed as radially-extending flanges or protrusions which define an opening for receiving a fastener. In an exemplary embodiment, the plurality of attachment members 56 are attached to inner walls of the plurality of convex sections 54. The attachment members 56 may extend only at an end portion of the connector arm 20 or may extend an entire length of the connector arm 20 such that the attachment members 56 are present at the end portions even if the connector arm 20 is cut to length.

[0022] For example, the attachment members may include axially- extending beads formed on inner walls of the convex sections 54. The beads may include pre-formed holes for receiving a fastener or may be solid such that a connection hole may be formed therein when needed.

[0023] The above-described configuration provides a lightweight but rigid construction for the connector arm 20, and which allows the body portion 34 to be formed from an extruded material. It should be understood, however, that the perimeter wall 46 and corresponding perimeter shape is not limited to the illustrated embodiment but could have alternative shapes and configurations. For example, the perimeter wall 46 may be triangular, rectangular, hexagonal, octagonal, etc.

[0024] As shown in Fig. 3, a plurality of channels 58 are defined between adjacent webs 48. The channels 58 contribute to the lightweight structure of the connector arm 20 while also providing a space for additional components of the robotic system 10. For example, at least one cable 60 connected to the actuatable joint 18 (e.g., a power cable) extends through at least one of the plurality of channels 58. This routing capability allows components, such as cable 60, to extend throughout the robotic system 10 internally.

[0025] Fig. 4 illustrates a plan view of the joint 18 from a perspective axially above the connection plate 30. The connection plate 30 is connected to a rotatable internal component of the body 28 (as will be described below) by one or more fasteners 62. In an exemplary embodiment, the connection plate 30 is configured to be secured to the connection portion 50 of the connector arm 20. The connection plate 30 may include a perimeter shape that matches the perimeter shape of the connector arm 30. For example, the connection plate 30 may include a plurality of concave sections 64 alternating with a plurality of convex sections 66. The plurality of convex sections 66 include openings 68 for being aligned with openings in the attachment members 56 and receiving a fastener therethrough. During operation, the joint 18 is actuatable to rotate the connection plate 30, thereby rotating the connected arm portion 20.

[0026] Fig. 5 is a cross-sectional view of an exemplary actuatable joint

18 depicting the internal components thereof. In an exemplary embodiment, the joint 18 includes a motor 70, a gearbox 73, an output shaft 74, and a bearing assembly 76. The motor 70 may be, for example, a compact frameless motor integrated into the housing 28. In other embodiments, the motor 70 may be a housed motor, such as a brushed DC motor, a brushless DC motor, a stepper motor, or an induction motor. In an exemplary embodiment, the motor 70 includes a stator 71 and a rotor 72. The rotor 72 is operatively connected to the gearbox 73.

[0027] The motor 70 may produce rotational motion to rotate one or more components of the inhne gearbox 73, which, in turn, causes rotation of the output shaft 74. The output shaft 74 is secured to the connection plate 30 by the one or more fasteners 62 to thereby rotate the connection plate 30 (and the connector arm 20, if connected).

[0028] In an exemplary embodiment, the output shaft 74 includes a generally frusto-conical section 75 which defines a pair of frusto-conical support surfaces 77. The bearing assembly 76 supports the output shaft 74 and gearbox 73 in order to allow for reliable rotation of the connection plate 30 by the motor 70. Consistent with disclosed embodiments, the bearing assembly 76 includes a pair of axial angular contact roller bearings 76A, 76B.

[0029] As shown in Fig. 5, each bearing 76A, 76B includes a pair of bearing rings 78, a bearing cage 80, and a plurality of rollers 82. The bearing rings 78 of each bearing 76 A, 76B are thin and frusto-conical, and form a pair of parallel races which are angled to also be parallel to a respective one of the frusto-conical support surfaces 77. In this way, a corresponding bearing ring 78 of each bearing 76A, 76B may be positioned on one of the two opposing support surfaces 77 of the output shaft 74. Moreover, the bearing rings 78 form races that are angled with respect to a plane perpendicular to an axis of rotation of the output shaft 74 . In comparing the two bearings 76 A, 76B to each other, the corresponding pairs of races are angled toward each other in a radially inward direction, corresponding to the shape of the frusto-conical section 75.

[0030] The bearing cage 80 may be formed from an injection-molded material (e.g., plastic) and be shaped to fit within an angled space defined by the bearing rings 78. In other embodiments, the bearing cage 80 may be formed from another type of material, such as brass, sheet steel, or fiber glass. The bearing cage 80 includes a plurality of openings for receiving the rollers 82. The rollers 82 are depicted as cylindrical bearing rollers, but may include a different shape (e.g., spherical or tapered needles).

[0031] The above axial angular contact roller bearings provide high load carrying capacity with taking up only a small cross-sectional area. This allows the envelope size and weight of each joint to remain relatively small without sacrificing carrying capacity. This further contributes to the modular, replaceable, and customizable aspects of the disclosed articulating assembly 14 and robotic system 10.

[0032] Having thus described the presently preferred embodiments in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the invention, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The present embodiments and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.

[0033] Parts List

10. Robotic System

12. Base Portion

14. Articulating Assembly

16. Base Bracket

18. Actuatable Joint

20. Connector Arm

22. Bracket 4. Horizontal Axis

6. Vertical Axis

8. Body

0. Connection Plate

32. Connection Plate

34. Body Portion

35. First End

36. Second End

38. Length

0. First Attachment Surface

42. Second Attachment Surface

44. Axial Base Member

46. Perimeter Wall

48. Web

50. Connection Portion

52. Concave Section

54. Convex Section

56. Attachment Member

58. Channel

60. Cable

62. Fastener

64. Concave Section

66. Convex Section

68. Opening

70. Motor

71. Stator

72. Rotor

73. Gearbox

74. Output Shaft

75. Frusto-conical Section

76. Bearing Assembly 76A. Axial Angular Contact Roller Bearing

76B. Axial Angular Contact Roller Bearing

77. Frusto-conical Support Surface

78. Bearing Ring

80. Bearing Cage

82. Roller

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