Educational and laboratory work cell for a robotic device

A robotic cell, or work area, especially useful for education. The cell has a plurality of interchangable work surfaces for mounting objects that the robot manipulates. Students, researchers, or other workers can thus set up separate experiments that need not be torn down each time a different user begins work with the cell. The cell has safety switches that encourage a user, when near the robot, to keep a hand on the robot so as not to be accidentally injured by the robot's motion. There is also a dead man switch effective to disenable the robot entirely, after a short time delay. The cell has a pneumatic control circuit that enables a user to position the robot's gripper arm at positions intermediate of fully up and fully down.

BACKGROUND OF THE INVENTION 
Any but the most simple of today's robotic devices are expensive. 
Unfortunately, the kind of robotic devices commonly used for education in 
technical schools most often are dedicated to one particular use, and 
cannot be used simultaneously for different projects. Worse yet, because 
typically such projects require individual laboratory set-ups before 
employing the robotic device, users cannot minimize the time wasted in 
using a dedicated robot by, at least, setting up their experiments before 
approaching the robot, but must wait until the robot is free, then set up 
their experiment, and then execute their experiment while others wait. 
Similarly, if other work such as research is in progress, this must also 
be torn down so that these laboratory exercises can proceed. This 
necessitates such a technical school losing countless man hours of 
productivity, and can well adversely affect an instructor's morale if it 
is his own research work it must be repeatedly disrupted destroyed in 
mid-course simply to accomodate a student laboratory. 
Moreover, such robotic devices are dangerous. These devices usually have at 
least one articulated cantilevered arm having a gripper device that, 
typically, has a pneumatic drive to move the gripper linearly. As such, a 
robotic arm swings horizontally across a work area, and with the 
considerable inertia carried by such an arm, an unwary worker struck by 
such an arm can experience considerable injury. 
Additionally, the vertically moving gripper arm is, to an extent, unwieldy 
because these pneumatic arms conventionally have only two positions: 
completely up or completely down, and lack fine position control to enable 
a worker or student to manually position the gripper arm intermediate of 
its two extremes. Present robot arms are repeatable, but not accurate. 
That is, if a robot arm would go to one point in space responsive to a 
positioning command, the robot can return to that point responsive to the 
same command with great precision (good repeatability). However, if one 
would attempt to direct the arm to this point by pre-programming the 
point's coordinates, the robot will likely move only to the vicinity of 
the point (poor accuracy). For this reason, robotic routines are 
pre-programmed with position coordinates vacant, and these coordinates 
input by moving the robot by hand to the coordinates. This is called 
"teaching" the robot. If the robot's routine calls for manipulating small 
objects, or performing movements having small tolerances for error, it 
would be a great advantage to have fine control over the arm that must 
manipulate these objects so that the arm may be moved to points 
intermediate of its two extreme positions, thus simplifying the "teaching" 
process. 
SUMMARY OF THE INVENTION 
Accordingly, it is an object of this invention to provide a robot work cell 
especially useful for educating students in the use of robot devices. 
It is a further object of this invention to provide such a work cell that 
enables a plurality of students or other workers to work on plural 
projects simultaneously. 
It is a further object of this invention to provide such a work cell having 
modular, replaceable, work areas to enable different users to work 
simultaneously on assembling several projects. 
It is a further object of this invention to provide such a cell that 
protects users against injury by unexpected motion of the robot. 
It is a further object of this invention to provide a fine control for 
positioning the robot's gripper arm. 
In accordance with these and other objects that shall become apparent 
hereinafter, there is provided a modular cell, or work area, having such a 
conventional cantilevered robotic arm disposed over a work table. A 
portion of the table top is removable, and the frame upon which the table 
top and robotic arm is mounted has a space enclosing a rack for holding a 
plurality of interchangeable table tops. Because these table top sections 
are interchangeable, students, professors, or other users of the robot 
cell can set up their experiments remotely on these table tops, and store 
their experimental setups at the cell until each individual student or 
worker has his turn at the robot cell. Pneumatic feed for the vertical 
control of the gripper arms is provided with a fine, manually operated, 
bleed circuit to allow the user fine control over the arm's vertical 
position. The robot cell is surrounded by a safety mat which serves to 
disenable the robot after a user steps on the mat. A dead man switch is 
disposed on the robot itself, and, when pressed by the user, reenables the 
robot. This combination of switches encourages the user to keep a hand on 
the robot when in the robot's vicinity (e.g. "teaching" the robot) so 
that, if the arm moves in a manner unexpected by the user, the user is 
pushed out of the robot's way, and, if the user is not fully pushed out of 
danger, the user is nonetheless protected from severe injury by releasing 
the dead man switch.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
With particular reference to the drawing figures, especially FIGS. 1 and 3, 
there is shown a work cell, or area, for using robotic arm 1. Robotic arm 
1 is double articulated about axis 2 and 3 so as to be able to sweep 
across table surfaces 4, 5 to manipulate objects disposed atop table tops 
4, 5 by means of pneumatically operated gripper arm 6. Robot arm 1 is 
mounted adjacent table tops 4, 5 on pedestal 7. Pedestal 7 and table tops 
4, 5, as well as other structure are mounted upon a frame structure 8, 
more about which below. 
Robot arm 1 has a third axis 9 along which gripper arm 6 moves vertically 
to access objects disposed on table tops 4, 5. Gripper arm 6 also can 
rotate about axis 9 so as to better position its caliper arms 10 for 
grasping objects on the table tops. Table tops 4, 5 typically have screw 
holes pre-cut in them so the various objects located on table tops 4, 5 
can be fixed to these table tops with respect to the robot arm 1 for 
repetitive operations executed by robot arm 1. To help position object 
securely on table tops 4, 5, one can use blocks or chocks screwed into 
table tops 4, 5. These blocks or chocks are preferably made of unexpensive 
and relatively frangible material so that, if the robot gripper arm 6 were 
to accidentally crash into such a block or chock, the inexpensive block or 
chock would break rather than the expensive gripper arm 6. Robot arm 1 can 
advantageously be an IBM Model 7535 robot, the robot arm alone 
constituting no part of this invention. The operation and programming of 
this robot, and others of a similar nature, is well known as is readily 
apparent to those skilled in the art 
Located on frame 8 is a control panel 11 housing the pneumatic and solenoid 
valves that control movement of auxiliary devices located on table tops 4, 
5, such as pneumatic vises or pneumatic indexing devices. 
Electrical interface panel 13 serves as an input-output conduit between 
controller 12, and the robot 1 and pneumatic control panel 11. Panel 13 
also serves as the point through which electric power for the cell is 
channelled and controlled. 
Disposed next to frame 8 is a robot controller 12. Controller 12 preferably 
contains a computer unit which directly controls the movements of robot 
arm 1 in accordance with a preprogrammed routine. Preferably, individual 
routines for robot arm 1 are encoded and compiled in computer 20, or an 
off-line equivalent to 20, and loaded into controller 12 where the routine 
is ready to direct arm 1. 
Similar to the robots discussed above, the electrical configuration, 
programming and operation of the computer, the control unit and any 
related ancillary equipment is also well known to those skilled in the 
art. 
Frame 8 is surrounded by safety mat 14, which is a pressure sensitive 
switch effective to disenable operation of the robot arm upon the switch 
being made, and whose function is to stop movement of robot arm 1 if 
anyone approaches near the work cell. This is a safety feature to prevent 
the injury that would occur if someone were inadvertently hit by robot arm 
1 as it swept across table tops 4, 5. Robot arm 1 has an additional safety 
switch 16, which is a dead man's switch. Upon being pressed, switch 16 
re-enables robot arm 1 despite the switch of safety mat 14 being 
connected. This is necessary because programming and teaching of the 
robotic arm frequently necessitates one to be near, or to grab and 
directly move, robot arm 1. Switches 14 and 16 together encourage a user 
to keep a hand on robot 1 so as not to be tken by surprise by an 
unexpected movement of arm 1. If such an unexpected movement were to 
occur, the user would be pushed away, likely without injury, rather than 
struck by arm 1. 
For the convenience of the user, there is programmed into the robot a five 
second delay between the mat switch 14 being made and the robot arm being 
disenabled so that the arm is not repeatedly disenabled during use, or 
disenabled when the user first steps on, or steps off the safety mat. 
Located beneath table tops 4, 5 on frame 8 is a plurality of storage spaces 
17 for housing additional table tops 4', 5'. These additional table tops 
4', 5' are suspended on frame 8 in any conventional shelving manner that 
would allow a user to easily slide and replace the table tops 4', 5' in 
and out easily, an example of which is a simple mounting bracket. 
Additional table tops 4', 5' will be exactly the same size and shape as 
table tops 4, 5, and will have dimensions with tolerances significantly 
smaller than the expected placement error of robot arm 1. The purpose of 
this is to make all table tops 4, 4' and, 5, 5' virtually interchangeable 
so that, after a user of robot arm 1 has finished one experiment, another 
experiment could be quickly set-up merely by interchanging table top 4 and 
a selected one of table tops 4', eliminating the necessity to tear down 
whatever experiment was set-up in order to do the next. This would be 
particularly advantageous in an educational environment, where such a 
robot arm would be used at one time for a professor's research, and at 
another time for a hands-on laboratory in which many different students 
would have to do the same experiment and the teacher would have to 
evaluate these experiments. 
In use, a typical sequence of events would be as follows: Before class, all 
students would set up their experiments on individual table tops 4', 5' 
and encode and compile their laboratory routines for robotic arm 1 on an 
off-line computer 20, typically recording this on a diskette. A fist 
student would then proceed to input his program, and load it into robot 
controller 12. The first student would then proceed to input location 
coordinates ito his program by hand manipulation of robot arm 1, and 
subsequent students would then repeat this procedure sequentially. After 
each student has thus perfected his program at computers 12 and 20, each 
student's experimental apparatus attached to individual table tops 4', 5', 
can be placed under frame 8 in space 17 for later evaluation by the 
professor. The professor could, at his leisure, place each of his 
students' experimental set-ups 4', 5', atop frame 8, run each students' 
program stored in robot controller 12's memory, and critique each 
students' work. When this is done, the professor can then replace his own 
table tops 4, 5, having his own experimental set-up, and continue his 
research work. It is submitted that the time and effort that can be saved 
by this work cell arrangement, obviating as it does the necessity of 
tearing down an experimental set-up each time the work cell is used for 
another purpose, and further obviating the need for each student in a 
laboratory class to do his work sequentially, rather than simultaneously, 
is great. 
With special reference to FIG. 4, there is shown the pneumatic air supply 
for gripper arm 6. The portion of the air supply that moves caliper arms 
10 is not shown. Caliper 6 is moved vertically along axis 9 by air piston 
30 disposed in piston cylinder 31 having pressure sides 32 and 33. By 
inspection of FIG. 4, it is seen that if side 32 is at higher pressure 
than side 33 piston 30 moves downwards, and if side 33 has greater 
pressure, piston 33 moves upwards. This corresponds to downward and upward 
movement respectively of gripper arm 6. 
Air pressure enters the supply system at 34. Pressure can come ultimately 
from any conventional source, such as air reservoir 18, (illustrated in 
FIG. 1). The air supply circuit is shown in FIGS. 4a to 4d, and has in it 
two pneumatic control valves 36 and 38. Valve 38 has two input and two 
output ports, and can be switched between two positions, one of which is 
shown in FIGS. 4a and 4c, the other of which is shown in FIGS. 4b and 4d. 
The function of valve 38 is to switch lines 37 and 41 between pneumatic 
connection with portions 32 and 33 of cylinder 31. If one of lines 37 and 
41 were at high pressure, and the other at exhaust, switching of valve 38 
between the positions shown in FIGS. 4a, 4c, and FIGS. 4b, 4d, reverses 
the pressure in cylinder 31, causing piston 31 and gripper arm 6 to 
reverse position between fully up and fully down. Switching of valve 38 is 
ultimately controlled by controller 12, and whatever computer routine is 
being run by controller 12. 
Valve 36 is a five port pneumatic valve that also switches between two 
positions, one of which is shown in FIGS. 4a and 4b, the other of which is 
shown in FIGS. 4c and 4d. In the position of FIGS. 4a, 4b, high pressure 
is delivered to valve 38 by connection of lines 35 and 37, and exhaust by 
lines 41 and 42. In this position, valve 36 constitutes an air conduit for 
valve 38, and switching of valve 38 operates merely to switch gripper arm 
6 between its completely up and down position. 
In valve 36's position of FIGS. 4c, 4d, the high pressure and exhaust 
connections are reversed, with line 41 connected to high pressure line 35 
via port 46, and line 37 connected to exhaust line 43. Mere switching of 
valve 36 would not, of itself, alter the position of gripper arm 6, 
because exhaust line 43 is blocked by normally closed bleed-off valve 44. 
By hand operating bleed-off valve 44 (which preferably has a toggle arm 
for this purpose), one can exert fine control over the position of gripper 
arm 6 along axis 9. The four operating states represented by FIGS. 4a to 
4d are as follows: 
FIGURE 
4a: Gripper arm 6 up, with no ability to finely position arm 6. 
4b: Gripper arm 6 down, with no ability to finely position arm 6. 
4c: Gripper arm 6 down, with ability to finely position arm 6. 
4d: Gripper arm 6 up, with ability to finely position arm 6. 
The foregoing description deals entirely with one kind of robot. There are 
others, examples of which are known as cylindrical, spherical, cartesian, 
and jointed robots, as workers in this art know. The first three locate 
gripper arms in space by motions along directional axes from familiar 
cylindrical, sphrical, and rectangular coordinates respectively. The last 
is a variation of the spherical type, but with extra joints for additional 
rotation in additional planes. But the feature common to all such robot 
arms is that a manipulative arm is located to preselected points in 
three-space above a work surface. As such, practice of the invention 
disclosed herein is not limited to the use of the particular robot 
disclosed herein, but is useable with any robot that can manipulate 
objects resting on any surface. Indeed, the instant invention is disclosed 
herein in what is thought to be the most practical and prefered 
embodiment; it is understood, however, that the instant invention is 
capable of application beyond the particulars set forth in the Detailed 
Description, and that obvious modifications will occur to those skilled in 
this art. Accordingly, the scope of the instant invention is to be 
discerned by reference to the appended claims, wherein: