ROBOTIC TOOL CHANGER

FIELD OF THE INVENTION

The present invention relates to robotic tool changers, and more particularly to robotic tool changers having a master unit and a tool unit adapted to be coupled together.

BACKGROUND OF THE INVENTION

Robotic tool changers generally comprise a master unit and a tool unit. Typically the master unit is supported from a robotic arm while the tool unit is coupled to the master unit and supports a tool. In some designs, to couple the master and tool units together, the master unit is provided with a fluid actuated piston that includes a contact area for engaging a series of balls that are normally held in a ball retention area of the master unit. When the master unit and tool unit are engaged for connection, the contact area of the piston engages the ball and positions the balls outwardly where the balls engage a bearing race formed in the tool unit. The geometry of the bearing race and the manner of urging the balls into the bearing race causes the master unit and tool unit to be pulled together into a locked position.

The contact area of the piston, sometimes referred to as a cam, is particularly configured to provide two distinct functions. First the contact surface is provided with a locking surface. When the locking surface engages the balls, the geometry of the locking surface causes the balls to engage the bearing race of the tool unit such that the tool unit is pulled into a locked position within the master unit. Also disposed on the contact area is what is typically referred to as a failsafe

surface. The function of the failsafe surface is to engage the balls and aid in maintaining a coupled relationship between the master unit and tool unit when there has been a failure of the fluid supply system to the piston, or when the supply of fluid has been temporarily shut off or otherwise interrupted. In other words, the failsafe surface, on a temporary basis, prevents the piston and its contact surface from moving directly from a locked position to an unlocked position. However, failsafe surfaces found on pistons are cylindrical and extend generally parallel to the longitudinal axis of the piston. Thus, when such a failsafe surface engages the balls, there is no opposing force to be overcome in order for the piston to move from the locked position to the unlocked position. In some situations it may be possible for the piston to accidentally move past the failsafe position. For example, it is conceivable that because of vibrations or shocks or other external forces that the piston can accidentally move past the failsafe position to the unlocked position.

SUMMARY OF THE INVENTION

The present invention entails a robotic tool changer having first and second units adapted to be coupled together. Mounted in one unit is a fluid actuated piston that moves between locked and unlocked positions. In the locked position the piston engages a series of rolling members and urges the rolling members into engagement with the other unit to lock the two units together. To prevent the piston from inadvertently or accidentally moving from the locked position to the unlocked position, the piston includes a failsafe or retarding surface that is shaped or configured to retard the movement of the piston as the piston moves from the locked position to the unlocked position.

In addition, the present invention entails a robotic tool changer having a first unit, a second unit, and a plurality of rolling members disposed in one of the units. A piston is movably mounted in one of the units of the robotic tool changer and movable between locked and unlocked positions. The piston includes a stem movable back and forth through an opening in the robotic tool changer. The stem of the piston and the opening are configured so as to at least slightly restrain the movement of the piston during at least a portion of the piston's movement as the piston moves from the locked position to the unlocked position. This restraint is intended to prevent the piston from inadvertently or accidentally assuming the unlocked position.

Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a cross-sectional view of the robotic tool changer of the present invention showing the piston of the tool changer in a locked position.

Figure 2 is an enlarged view of the portion of the tool changer encircled in Figure 1 and indicated by II.

Figure 3 is a view similar to Figure 1 , but showing the piston in a failsafe position.

Figure 4 is an enlarged view of the encircled portion of Figure 3 indicated by IV.

Figure 5 is a view similar to Figure 1 , but showing the piston in an unlocked position.

Figure 6 is an enlarged view of the encircled portion indicated by Vl in Figure 5.

Figure 7A is a schematic illustration showing the relationship between a portion of the piston and a rolling member as the piston moves between locked, failsafe, and unlocked positions.

Figure 7B is a schematic illustration similar to Figure 7A, but illustrating the contact area of the piston with respect to the longitudinal axis of the piston.

Figure 8 is an enlarged view of a portion of the tool changer showing an alternate design for the piston and with the piston being shown in the locked position.

Figure 9 is a view similar to Figure 8, but wherein the piston is disposed in the failsafe position.

Figure 10 is a view similar to Figure 8 wherein the piston is disposed in the unlocked position.

Figure 11A is a schematic illustration of the piston of the alternative embodiment illustrating the movement of the piston with respect to a rolling member between locked, failsafe and unlocked positions.

Figure 11 B is a schematic illustration similar to Figure 11A, but showing the contact area of the piston with respect to the longitudinal axis of the piston.

Figure 11 C is a schematic illustration of the force components that result as a rolling member moves from the locked position to the unlocked position with respect to the embodiment shown in Figures 8-11 B.

Figure 12 is a schematic illustration showing another alternate design for the contact area of the piston.

Figure 13 is an enlarged view of the encircled area shown in Figure 1 and denoted XII.

DESCRIPTION OF EXEMPLARY EMBODIMENT With further reference to the drawings, the robotic tool changer of the present invention is shown therein and indicated generally by the numeral 10. Tool changer 10 basically comprises a first unit and a second unit that are adapted to be coupled together. The first unit is indicated generally by the numeral 12 and is sometimes referred to as a master unit. The second unit is indicated generally by the numeral 14 and sometimes referred to as the tool unit. In use, the first or master unit 12 is typically connected to a robotic arm (not shown) while the second or tool unit 14 is typically connected to a particular tool. Furthermore, in use there may be provided a series of tool units 14 with each tool unit carrying or supporting a particular tool. Hence, during use, the respective tool units 14 are coupled and decoupled to the first and master unit 12. The robotic tool changer 10 disclosed herein is similar in many respects to that disclosed in U.S. Patent No. 5,211 ,501 , which is expressly incorporated herein by reference.

Since most robotic systems typically include a robotic arm, a master unit 12 and a plurality of tool units 14, each coupled to a different tool, it is common to locate active components of the tool changer 10 within the master unit 12. However, it is appreciated that the distribution of active and passive components within the master unit 12 and the tool unit 14 can be reversed. Although the master unit 12 is typically connected to a robotic arm and the tool unit 14 is connected to a robotic tool, this particular orientation may be reversed in any given application.

As discussed below, one of the principal functions of the robotic tool changer 10 is to provide a system for quickly and efficiently coupling and decoupling tool units 14 to the master unit 12. However, the robotic tool changer 10 includes additional facilities for the provision of various services and utilities to the attached tool. For example, it is common to provide a master electrical contact with the master unit 12. This permits electrical service to be channeled through the master unit 12, through the tool unit 14 and ultimately to the tool. For example, relatively large electrical currents such as those utilized by a welding tool can be passed from an electrical source through the robotic system to the tool unit 14. In like fashion, fluids such as pneumatics can be transferred through the master unit 12 to the tool unit 14 for use by a particular tool connected thereto. Other such services and utilities, which are typically provided by robotic tool changers include hydraulic fluid, cooling fluid, oil, and data transfer. Details of these services and utilities are not dealt with here in detail because such is not per se material to the present invention and because robotic tool changers of the general type shown herein are commercially known and available.

Turning now to a discussion of the first or master unit 12, the same is provided with a fluid chamber 14. See Figure 1. In the design illustrated the fluid chamber 14 is cylindrical and includes a cylindrical wall 16. Adjacent to the fluid chamber 14 is a structure that includes a horizontal member 18 that includes an annular ring 20 projecting therefrom. Horizontal member 18 forms one end of the fluid chamber 14. Additionally, horizontal member 18 includes a central opening 18A having an O-ring 18B secured in an annular groove formed in the central opening. Formed in the annular ring 20 is a series of apertures or openings 22. A rolling member 24 is generally held or disposed in each of the apertures or

openings 22. The area in and around the apertures 22 is sometimes referred to as a retention area because this area tends to at least partially retain the rolling members 24 that, as will be discussed subsequently herein, are utilized to lock the master unit 12 with the tool unit 14.

Disposed within the fluid chamber is a double acting piston indicated generally by the numeral 30. Piston 30 is actuated back and forth in the fluid chamber 14 by a pressurized fluid source. In one embodiment, the piston 30 is pneumatically moved back and forth. Piston 30 includes a longitudinal axis indicated by the numeral 32. Further, piston 30 includes a base 34 that is slidably contained within the fluid chamber 14 and forms a fluid tight seal with the chamber to prevent air or other fluid from bypassing the base. More particularly, the base 34 is provided with an O-ring 36 that seals against the cylindrical wall 16 of the fluid chamber 14. Centered with respect to the base 34 is a stem 38. Preferably the longitudinal axis 32 extends centrally through the stem 38. As seen in Figure 1 stem 38 extends through the opening 18A formed in the horizontal member 18. Secured to the stem is a generally cylindrical head indicated generally by the numeral 40. A screw 42 extends through a portion of the head 40 and into a threaded cavity formed in the stem 18. By tightening the screw 42 the head 40 of the piston 30 is coupled or connected to the base 34 of the piston.

The outer perimeter of the head 40 is configured to engage the rolling members 24 to effectuate locking the master unit 12 to the tool unit 14. The outer perimeter of the head is particularly configured to cooperate with the locking members 24 to achieve both a locking and an unlocking function. Accordingly, the outer perimeter or outer area of the head 40 includes a contact area for contacting

the rolling members 24 and for urging the rolling members 24 into a locked relationship with a portion of the tool unit 14 to be described subsequently herein.

Viewing the contact area of the head 40, it is seen that as viewed in Figures 1-7B that the head includes a locking surface 50. Locking surface 50 is disposed at a taper or an angle with respect to the longitudinal axis 32. Note as viewed in Figures 7A and 7B, the locking surface 50 tapers generally upwardly and inwardly with respect to the longitudinal axis 32. As will be discussed subsequently herein, when the piston 30 assumes the locked position, locking surface 50 will engage the respective rolling members 24 and cause the rolling members 24 to engage a portion of the tool unit 14 and lock the master unit 12 and the tool unit 14 together.

Also formed on the contact area of the piston head 40 is a contact surface 56 that is sometimes referred to as an unlocking surface. As seen in Figures 2, 4 and 6, the contact surface 56 is tapered upwardly and inwardly towards the longitudinal axis 32. Contact surface 56 provides two functions. As the piston 30 moves from the unlocked position to the locked position, the contact surface 56 surrounding the head 40 of the piston will contact the rolling members 24 and urge the same outwardly through the openings or apertures 22 formed in the annular ring 20. Thus, surface 56 can be referred to as a contact surface. In addition, when the piston 30 assumes the unlocked position, the contact surface 56 will lie adjacent the rolling members 24 as shown in Figure 6. Because of the shape of the apertures 22 and the position and shape of the contact surface 56, the rolling members 24 are permitted to move to one side of the apertures 22 as shown in Figure 6. The contact surface 56 of the piston 30 will prevent the rolling members 24 from falling from the apertures 22. At the same time, the position of the rolling members 24 will permit the tool unit 14 to be decoupled from the master unit 12

without interference from the rolling members 24. Thus, the surface 56 is sometimes referred to as an unlocking surface.

Disposed adjacent the locking surface 50 is a failsafe surface 52. In this embodiment, a portion of the failsafe surface 52 includes a generally cylindrical surface that extends generally parallel to the longitudinal axis 32 of the piston 30. The failsafe surface 52 also includes another portion which is referred to as a retarding surface 52A. As seen in the drawings, the failsafe surface 52 extends generally between the locking surface 50 and the unlocking surface 56. The cylindrical portion of the failsafe surface 52 is disposed adjacent the locking surface 50. The retarding portion 52A of the locking surface is disposed adjacent the unlocking surface 56. The purpose of the failsafe surface 52 is to prevent the piston 30 from inadvertently or accidentally moving from the locked position shown in Figure 1 to the unlocked position shown in Figures 5 and 6. More particularly, in the locked position shown in Figure 1 , the rolling members 24 will cause a force to be directed against the piston head 40 that will tend to drive the piston to the unlocked position in the event of an interruption in the actuating force that urges the piston to the locked position. If there is an inadvertent interruption in the actuating force acting on the piston 30, then the piston will tend to move from the locked position in Figure 1 to the failsafe position shown in Figures 3 and 4. The cylindrical portion of the failsafe surface 52 will, in many cases, aid in maintaining a coupled relationship between the master unit 12 and the tool unit 14. However, the normal force directed against the rolling members 24 by the cylindrical portion of the failsafe surface 52 will produce no significant force component in the axial direction. However, the retarding surface 52A that forms a part of the failsafe surface 52 projects at least slightly outwardly from the cylindrical portion of the

failsafe surface. The engagement of the retarding surface 52A with the rolling members 24 will give rise to at least a slight resistance to further movement of the piston towards the unlocked position.

In the case of the embodiment illustrated in Figures 1-7B, the retarding surface 52A assumes the form of a ridge. Note that the ridge that forms the retarding surface 52A is disposed generally between the cylindrical portion of the failsafe surface 52 and the contact or unlocking surface 56. Although the dimensions of the ridge may vary, it is contemplated that the ridge may project outwardly approximately 0.010 to 0.040 inches past the cylindrical portion of the failsafe surface. Note the relationship of the retarding surface 52A in Figures 7A and 7B. Here the ridge forming the retarding surface 52A lies generally between the unlocking surface 56 and the cylindrical portion of the failsafe surface 52. In this design there appears a slight concave in the contact area of the head just above the cylindrical portion of the failsafe surface 52. Hence, the rolling members 24 will be at least slightly compressed between the ridge and the locking surface 62 of the locking race 60 as the piston 30 moves past the ridge to the unlocked position of Figure 6 as the rolling members 24 are required to clear the ridge in the process.

Turning to the tool unit 14, as discussed above, the master unit 12 is adapted to be coupled to the tool unit. In order to lock with the master unit 12, the tool unit 14 is provided with a locking race 60. The locking race 60, which forms a part of the tool unit 14, is designed to be inserted into the master unit 12 and to assume a position outwardly of and adjacent the rolling members 24. See Figures 1-6. Locking race 60 includes a locking surface 62. To lock the tool unit 14 with the master unit 12, the piston 30 is actuated and driven upwardly as viewed in

Figure 1. Eventually the locking surface 50 of the piston 30 will engage the rolling members 24 urging them outwardly through the apertures 22 of the annular ring 20. The rolling members 24 will engage the locking surface 62 that forms a part of the tool unit 14 and will urge the locking race 60 downwardly as viewed in Figure 1 into the locked position shown therein.

In the failsafe position shown in Figures 4 and 7A, the failsafe surface 52 still engages the rolling members 24. When the cylindrical portion of the failsafe surface 52 engages the rolling members 24, the failsafe surface aids in maintaining the coupled relationship between the master unit 12 and the tool unit 14 even though there is no significant opposing axial force created. However, when the piston 30 attempts to move past the ridge or retarding surface 52A there will be an opposing axial force created by the engagement of the ridge with the rolling members 24. This will provide at least a slight and positive resistance that must be overcome in order for the piston 30 to move to the unlocked position. That is, as the rolling members attempt to clear the ridge, there will be at least a slight opposing axial force created.

When the piston 30 assumes the unlocked position, the locking race 60 is free to move from the coupled position. More particularly, the unlocking surface 56 permits the rolling members 24 to assume the position shown in Figure 6, which in turn frees the locking race 60, which of course means that the tool unit 14 can be decoupled from the master unit 12.

In Figures 8-11 C, a second embodiment is shown for the contact area of the head 40 of the piston 30. In the embodiment shown in Figure 1 , the failsafe surface 52 comprised a ridge disposed between the locking surface 50 and the contact or unlocking surface 56. In this embodiment the failsafe surface 52 forms a generally

conical shape surface between the locking surface 50 and the contact or unlocking surface 56. That is, as viewed in Figures 11 A and 11 B, the failsafe surface 52 extends upwardly and slightly outwardly to a point where the failsafe surface joins the contact or unlocking surface 56. If the failsafe surface 52 is projected downwardly around the piston 30, the projecting lines would form a cone. As seen in Figure 11 A, as the piston moves from the locked position shown in Figure 8 to the unlocked position shown in Figure 10, it is seen that the conical surface 52 retards the movement of the piston and gives rise to at least a slight resistance to the movement of the piston. Effectively, the rolling members 24 are slightly compressed between the conical surface 52 and the locking surface 62 of the locking race 60.

Preferably, the angle of the conical surface 52 is slight. As illustrated in Figure 11 B, the angle of the conical surface 52 with respect to a reference line RF, which is parallel to the longitudinal axis 32 of the piston, is preferably about 2° but may range from approximately 1° to 5°. Note that the angle of the conical surface 52 is represented by angle A (Figure 11 B) which is formed by reference line RF and construction line CL which is an extension of the conical or retarding surface 52.

Briefly reviewing the second embodiment shown in Figures 8-11 B, in Figure 8 the piston 30 assumes the locked position. Here the locking surface 50 engages the rolling members 24 and urges the rolling members outwardly to where the rolling members engage the locking surface 62 of the locking race 60 of the tool unit 14. This pulls the locking race 60 downwardly into a locked position.

If there is a failure in the activating force for the piston 30, the piston 30 will tend, as viewed in Figure 9, to move downwardly to where the rolling members 24 engage the failsafe surface 52. Since the failsafe surface 52 is conical or angled

with respect to the longitudinal axis 32 of the piston, the rolling members 24 will be urged at least slightly outwardly as the piston 30 moves from the locked position to the unlocked position. That is, the conical or angled failsafe surface 52 generally prevents the piston from inadvertently moving from the locked position to the unlocked position. This is because the conical shape of the surface 52 forms a retarding surface which effectively retards the movement of the piston downwardly as viewed in Figure 9 without an active unlocking force being applied to the piston.

With reference to Figure 11C, there is a schematic illustration of the opposing axial force that is created or which results when the piston 30 moves from the locked position to the unlocked position. Note that as the rolling members 24 engage the conical surface 52 that a normal force Fi is created. This force acts perpendicular to conical surface 52 and is directed generally horizontally and slightly upwardly as viewed in Figure 11C. Force Fi includes a horizontal force component F ₂ and a vertical or upwardly axial force component F ₃ . It is the axial force component F ₃ that must be overcome in order for the piston 30 to move from the locked position to the unlocked position.

Figure 12 illustrates a third embodiment of the contact area of the piston head 40. In this case, the failsafe surface 52 includes two portions. First there is a generally cylindrical portion 52B and a second conical portion 52A. This design is similar to the embodiment shown in Figures 1-7B with the exception that the conical surface 52B assumes the position of the ridge in the embodiment of Figures 1-7B. In any event, in this embodiment, as the piston 30 moves from the locked position to the unlocked position, the rolling members will first engage the cylindrical portion 52B of the failsafe surface, and thereafter will engage the conical or angled surface 52B. Again, the conical or angled surface 52B will retard the movement of the

piston 30 and prevent the piston 30 from inadvertently or accidentally moving past the conical or angled surface 52B to the unlocked position.

There are other ways to retard the movement of the piston from the failsafe position to the unlocked position. In Figure 13 a portion of the stem 38 of the piston 30 is shown adjacent the horizontal member 18. Stem 38 is provided with a step 38A. The dimension of the step can vary. In one embodiment it is contemplated that the step 38A will project outwardly from the stem 38 approximately 0.005 to 0.010 inches. As the stem 38 moves downwardly, as viewed in Figure 12, the step 38A will pass through the opening 18A and the horizontal member 18. In passing through the opening 18A, the step 38A will engage the O-ring 18B. The engagement of the step 38A with the O-ring 18B will at least slightly retard the further downward movement of the stem 38. The engagement of the step 38A with the O-ring 18B will tend to compress or slightly deform the O-ring 18B as the step 38A passes the same.

Step 38A is strategically placed on the stem 38 in order to protect against the inadvertent or accidental movement of the piston from the failsafe position to the unlocked position. Hence, when the piston 30 assumes the failsafe position, the step 38A would lie immediately above the O-ring 18B. If due to vibration or other external forces there was a tendency for the piston 30 to move to the unlocked position, step 38A would engage the O-ring 18B and at least slightly retard the further downward movement of the stem 38. This would effectively hold the piston in the failsafe position. However, because the step 38A is relatively small, its presence on a stem 38 would not inhibit or interfere with the normal up and down operation of the stem 38 as it and the piston moves between locked and unlocked positions.

The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the scope and the essential characteristics of the invention. The present embodiments are therefore to be construed in all aspects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.