Remote contrivance refurbishment apparatus and related methods

Disclosed is a remote contrivance refurbishment apparatus and related methods.

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention is in the field of apparatuses and methods for remote automated contrivance refurbishment.

2. Background of the Invention

Various contrivances (including but not limited to assault rifles) are employed and operated worldwide. Often, it is necessary to refurbish the contrivances at exotic or remote locations wherein refurbishment know-how, repair diagnosis, spare/replacement parts, or cleaning solutions are not readily available. Moreover, frequently a plurality of similar contrivances at the remote locations may simultaneously need refurbishment or repair. Conventional refurbishment under these circumstances has been accomplished in one of three ways: (1) on-site manual refurbishment; or, (2) transmitting the subject contrivances off-site for refurbishment; or, (3) out-right replacement of the subject contrivance.

Conventional refurbishment methods have typically been inadequate. First, on-site personnel may be sparse whereby work-efforts cannot affordably be expended on refurbishment. Second, the delivery of customized replacement packages (including refurbishment parts and cleaning solutions) to the remote site is often expensive. Third, retrieving a subject contrivance from a remote site may entail excessive expenses. Finally, replacing the subject contrivance may be unnecessarily wasteful, as the contrivance would operate sufficiently if merely refurbished.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide an apparatus and the associated methods for remotely and automatedly refurbishing contrivances, including but not limited to assault rifles.

It is an object of the present invention to provide an apparatus and the associated methods for remotely and automatedly refurbishing contrivances wherein refurbishment know-how, repair diagnosis, spare/replacement parts, and cleaning solution are performed by the apparatus.

It is an object of the present invention to provide an apparatus and the associated methods for remotely and automatedly refurbishing contrivances wherein human involvement in the refurbishment process is minimized, and wherein speed is maximized.

It is to be noted, however, that the appended figures illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments that will be appreciated by those reasonably skilled in the relevant arts. Also, figures are not necessarily made to scale but are representative.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Generally, the apparatus of the present application is for remotely and automatedly refurbishing contrivances. In other words, the apparatus may be delivered to remote locations (including outer space) for the automated refurbishment of contrivances, such as weapons. For purposes of this application, “refurbish” and “refurbishment” shall include, but not be limited to, cleaning. The apparatus is preferably transported to the remote location via pick-up truck (whether in the bed or otherwise), truck and trailer, railcar, boat, air-drop, or airplane, or spaceship.

Basic apparatus operation begins with the input of at least one contrivance and ends with the output of a refurbished, or cleaned, contrivance. More specifically, operation of the apparatus is generally as follows. Initially, the apparatus determines (or is told) the identity of a contrivance provided thereto. Identification of the contrivance preferably triggers the apparatus' performance of a contrivance specific disassembly routine. Via a computer means, the apparatus programmatically inventories/examines the parts of the disassembled contrivance and discards any expired parts. The apparatus delivers the disassembled parts (excluding expired parts) to an internally contained solution for ultrasonic cleaning. The apparatus supplements the cleaned contrivance parts, if necessary, with replacement parts from pre-sorted and self-contained bins before the apparatus performs a contrivance specific assembly routine. The apparatus examines the reassembled contrivance for compliance with the contrivance's specifications and tolerances. Noncompliant and intolerant parts are repaired or replaced by the apparatus via either repair specific routines or via contrivance specific disassembly, part replacement, and reassembly routines. After compliance with the contrivance's specifications and tolerances is assured, the refurbished contrivance is output from the apparatus.

FIG. 1depicts a top view of a preferable embodiment of the apparatus1of the present application. As seen in the figure, the apparatus1preferably comprises the following subassemblies: a cache100; paired and opposable robotic arms200; a multi-level, multi-compartment, rotating tool and part bins300; an ultrasonic cleaning tub400; a coordinate-measuring machine500station; and, a reassembly station600. It should be noted that the cache100and the reassembly station600could be the same subassembly, wherein the cache100has been automatedly rotated and moved to the reassembly station600location via a conveyor belt or other conveying means within the apparatus1. The subassemblies are preferably positioned whereby said cache100, rotating bins300, cleaning tub400, coordinate-measuring machine500, and reassembly station600are within the work envelope or range of each robotic arm200.

FIGS. 2 and 3are respectively side and front perspectives of the apparatus1depicted inFIG. 1. In other wordsFIGS. 1 through 3depict the apparatus1from different views and thus together better illustrate the subassemblies composing the same. Viewed in conjunction,FIGS. 1 through 3provide a more complete overview of the apparatus1, which could be a feature of a wheeled carrier, truck, train car, boat, or air drop.

Referring toFIGS. 1 through 3, the cache100is an area for receiving contrivances2. Typically, at least one contrivance is provided to the cache100whereby the cache100systematically provides the input contrivances to the apparatus1for refurbishment. The cache100is composed of a stand101, and a contrivance mounting means. In the most minimal embodiment, the stand101features a single mounting means which, as discussed below in connection with the refurbishment of a rifle, inserts into the clip port of the rifle to support the rifle. In the present embodiment, the mounting means comprises grips102. Input contrivances2are suitably collected in the cache100and systematically presented for refurbishment at the stand101. Although discussed in more detail below, the stand101is sometimes defined by a plurality of radially spaced grips102controllably rotatable around a central axis. Preferably, the stand101simultaneously: (1) gathers contrivances2from the technician, (2) presents a contrivance2for refurbishment, and (3) releases a refurbished contrivance to the output. Each grip102on the stand101performs the stated functions relative to its position during stand101rotation.

AlthoughFIGS. 1 through 3depict the stand101as being defined by a plurality of radial spaced grips102, it is contemplated that other means for securing the contrivance2to the stand101may be employed until, as discussed below, the disassembly of the contrivance2is initiated. For example, if the contrivance is a rifle, the means for presenting the rifle for refurbishment may preferably be a mounting bracket that mimics a standard rifle clip and supports the rifle to the stand via the clip port in the rifle's lower receiver. In a minimal embodiment, the cache100features a plurality of mounting brackets for various types of rifles, said mounting brackets radially extending from an axis. An operator of the apparatus1may communicate the type of rifle to the apparatus and the cache100, via a computer means on the apparatus, will select the appropriate mounting bracket and rotate it into the proper position.

As mentioned above, the cache100may be stationary or move throughout the apparatus1to the reassembly station600location via rotation and transport on a conveyor belt or other conveying means.

Still referring toFIG. 1 through 3, the robotic arms200are preferably for performing refurbishment and repair routines (including disassembly and assembly routines). Preferably, the robotic arms200are six-axis robots for automated control in three spatial dimension plus roll, yaw, and pitch. However, it is contemplated that other preferable designs of the present apparatus1may trade freedoms of motion for cost, speed, and/or accuracy depending on the contrivance2to be refurbished or repaired.

As depicted in theFIGS. 1 and 3, the robotic arms200are generally movably located along the length of the apparatus1. Via movement of the robotic arms200along the apparatus1, the working envelope of each robotic arm200may preferably contain the cache100(including the stand101), the rotating bins300, the cleaning tub400, the coordinate-measuring machine500station, and the reassembly station600. Movement of the respective robotic arms200along the apparatus may be accomplished by motor-plus-chain, motor-plus-track, conveyor belt, and the like.

As discussed below, it is contemplated that the robotic arms200will suitably: (1) work in conjunction with each other for performing refurbishment and repair routines/tasks/routine steps (including disassembly and assembly routines) that require two cooperating appendages; (2) work alone in conjunction with the stand101or other support for performing steps that require a single appendage for performing routines/tasks/routine steps; (3) work in conjunction with the rotating bins300for obtaining tools necessary for performing routines/tasks/routine steps; and (4) work in conjunction with the rotating bins300for obtaining necessary contrivance2replacement parts.

Referring now toFIGS. 1 and 3, the rotating bins300are for systematically organizing and providing tools or replacement parts to the robotic arms200during refurbishment and repair routines/tasks/routine steps (including disassembly and assembly routines). Preferably, the rotating bins300features stacked levels301of radially spaced sub-bins, rotatable around a central pivot. Each level preferably contains a false bin302whereby the robotic arm200may reach, top down (as depicted inFIG. 1), into the bin level immediately below the false bin302. Aligning the false bins302from multiple levels suitably permits the robotic arm to reach into the lowest level of the rotating bins300.

Still referring to the rotating bins300, each sub-bin within the rotating bins300system will preferably be designated by a radial coordinate and level301. Also, each sub-bin will preferably be assigned a particular tool or part depending on the particular function of the apparatus1. If and when a particular tool or part becomes necessary to a routine or routine step performed by the robotic arm200, then the rotating bins300programmatically rotate (under the command of a computer means) for presenting the appropriate sub-bin to the robotic arm200. Ideally, if the appropriate sub-bin occupies a lower level, then all upper levels301correspondingly rotate so as to position the higher false bins302above the appropriate sub-bin. Preferably, and as depicted inFIG. 1, the robotic arm200access is the closest radial coordinate on the associated rotating bins300.

Referring once again toFIGS. 1 through 3, the cleaning tub400is for deeply cleaning and/or cleaning the disassembled parts of the contrivance2. Preferably, the cleaning tub400cleans parts via ultrasound. Suitably, the robotic arms200, under the command of a computing means, orderly and coordinately position the parts of disassembled contrivances2along the basin401of the tub400(with cleaning solution prefilled or filled later). After cleaning, the robotic arms200orderly and coordinately retrieve the contrivance2components according to the coordinate memory of part placement.

Referring again toFIGS. 1 and 2, the coordinate-measuring machine500station is for checking the specifications, gauges, tolerances, and other measurable dimensions of the refurbished contrivance2. Preferably, the coordinate-measuring machine500is a horizontal coordinate-measurement device for touch sensing measurements.

Referring still toFIGS. 1 through 3, the reassembly station600is for reassembling the disassembled contrivance. The reassembly station600interacts with the contrivances2and the robotic arms in a similar manner as the cache100. Before, during, or after the robotic arms200perform the reassembly routines, the refurbished contrivances or sub components are provided to the coordinate measuring machine500as discussed above. If the contrivance2or subparts are determined to be in compliance with the specifications, gauges, tolerances, and other measurable dimensions or criteria, then the contrivance2or subparts are returned to the reassembly routine and provided to the apparatus1output, or else the contrivance2or subparts are returned to the reassembly station600to undergo repair. In the most minimal embodiment, a reassembly station is not necessary because, as discussed above, the cache100may be used to replace the reassembly station.

In one particular mode of operation, the apparatus1is adapted for the refurbishment of a rifle contrivance (e.g., the AR-15, or M4, or AK-47, and the like). In this particular mode of operation a rifle is: provided to the cache100; presented to the robotic arms200for take-down at the stand101; expired rifle parts are discarded; unexpired rifle parts are introduced to the cleaning tub400for cleaning while replacement parts are retrieved by the robotic arms200from the rotating bins300; the rifle is reassembled at the stand601and provided to the coordinate-measuring machine500for checking the rifle's specifications and tolerances; and, finally the refurbished rifle is output from the apparatus1. Below is a more detailed description of the manner by which the apparatus1refurbishes a rifle (e.g., the AR-15 or M4 or AK-47, and the like).

Setup. First, the apparatus1is delivered to a remote location via train, boat, plane, vehicle, or space craft. For example, the apparatus1may occupy a truck bed whereby delivery of the apparatus is accomplished via driving the truck to the remote location. For another example, the apparatus1may occupy a shipping container whereby delivery of the apparatus is accomplished via fly-by parachuted drop-off to the remote location. Next, the apparatus1is provided a power source, whether via gas generator, electrical input, or others. Finally, the apparatus should be powered-on. In the preferable embodiment, the power source preferably provides the energy necessary to operate the hydraulics, pumps and other mechanisms of the apparatus1.

Operation. First, at least one rifle2is input to the apparatus1at the cache100by an operator or technician. In the preferable embodiment, the rifle2is orientedly input to the cache100whereby the stand101may readily grip the rifle stock and rifle muzzle. In an alternate embodiment, the operator or technician provides the rifle2to the apparatus via inserting a weapon mount on the stand101into the clip port of the rifle2. Input rifles2are gripped and presented to the robotic arms200for refurbishment. It is contemplated that many types of rifles2may be refurbished via the apparatus1. To accommodate the diverging dimensions and sizes of the many rifle types, the apparatus1preferably features a manual selection mechanism whereby the operator/technician may indicate to the apparatus1which type of rifle2will be input to the machine whereby a computer means automatedly adjusts the stand to the specific rifle2(i.e., the computer means selects a compatible weapon mount with the rifle2clip port or adjusts the grips to the dimensions of the rifle2). In addition to selecting the appropriate weapon mount, the computer means also commands the robotic arms during the disassembly and reassembly routines based on the manual selection of rifle type.

Normally, an unloaded rifle will be provided to the apparatus1with the clip out, especially if a clip mount is used instead of the grips102. However, it is also contemplated that the apparatus1may unload the rifle2programmatically. A preferable rifle2unloading routine is performed by the robotic arms200after presentment of the rifle2at the stand101. Initially, a first robotic arm200activates the clip release button while the second robotic arm200grips (using a clamping tool head from the rotating bins) the clip and disengages the clip from the clip socket in the lower receiver of the rifle. Next, the first robotic arm200fully extends the charging handle to open the bolt and eject any round from the chamber. The step of ejecting rounds from the chamber may be repeated for the known number of rounds customarily maintained in the chamber during rifle2use.

Preferably, after the rifle has been provided to the cache100, the cache100rotates within the apparatus1and moves to the reassembly station600location via a conveyor means, such as a belt, to a central location in the apparatus1. After the cache100has moved into the reassembly station600position, the refurbishment routines may be performed by the robotic arms200under the command of a computer means.

Typically, the first step of a rifle2disassembly routine is removing the butt stock from the upper and lower receiver assembly. Initially, the first robotic arm200rotates the takedown lever 160 deg. counter-clockwise. Next, the first robotic arm200preferably grasps the rifle butt stock while the second robotic arm200suitably grasps the upper and lower receiver assembly. The components are disengaged by drawing the robotic arms200and associated components in opposite directions along the rifle2plain. Once disengaged, the first robotic arm200preferably places the butt stock in the cleaning tub400or in the appropriate sub-bin in the rotating bins300. Finally, while the upper and lower receiver assembly is still gripped by the second robotic arm200, the first robotic arm200unscrews and disengages the recoil tube1301therefrom. Subsequently, the recoil tube1301is preferably placed in the cleaning tub400or corresponding sub-bin within the rotating bins300.

The second step of a rifle2disassembly routine is separating the upper and lower receivers. First, a double appendaged small diameter drive tool is obtained from the appropriate sub-bin within the rotating bins300by the first robotic arm200. Next, the two appendages of the tool are respectively directed to the first and second takedown pins on the lower receiver, whereby the takedown pins and are simultaneously moved from left to right until attainment of the unlocked position. Thereafter, the first robotic arm200returns the double-appendaged tool to the appropriate sub-bin in the rotating bins300. Next, the first robotic arm200grips the upper receiver1200and the second robotic arm200grips the lower receiver wherein the robotic arms200disengage the upper1200and lower1100receivers via drawing the respectively gripped components in opposite directions within the vertical rifle2plain. Preferably, the lower receiver is coordinately placed in the cleaning tub400by the second robotic arm200.

The third step of a rifle disassembly routine is removing the muzzle compensator. First, with the first robotic arm200still holding the upper receiver, the second robotic arm200grips the locking ring and pulls it forward (i.e., toward the muzzle) for enabling muzzle compensator detachment. Detachment is completed by the second robotic arm200gripping the muzzle compensator and drawing the compensator away from the upper receiver with a concurrent twisting motion relative thereto. Preferably, the muzzle compensator is coordinately placed in the cleaning tub400by the second robotic arm200.

The preferable fourth step of a rifle2disassembly routine is removing the bolt carrier assembly. The bolt carrier assembly is preferably removed by the second robotic arm200pulling the charging handle out of the back of the upper receiver. The charging handle may be thereafter placed in the cleaning tub400.

Preferably the apparatus1need not break down the rifle any further. However, it is contemplated by the inventors that the apparatus is capable of breaking down the subcomponents of the rifle. For example, the robotic arms200may perform disassembly routines for the bolt carrier assembly after its removal from the upper receiver. Initially, while the first robotic arm200holds the carrier assembly, the second robotic arm200pushes the bolt into the locked position. Next, the second robotic arm200removes the firing pin retaining pin from its diametrical position within the assembly by gripping the closed end, preferably using needle pliers (or the equivalent) and drawing the retaining pin from the side of the assembly. Preferably, the needle nose pliers may be retrieved from the rotating bins300as discussed above. The pin1502may be placed in the cleaning tub400after its removal.

Still referring to a breakdown of the bolt carrier assembly, with the firing pin retaining pin removed from the assembly, the first robotic arm200suitably rotates the orientation of the bolt assembly to remove the firing pin. The firing pin is typically coaxially positioned within the bolt and bolt carrier assembly. By orienting the assembly with the bolt end vertically positioned, the firing pin suitably drops out of the assembly. The firing pin may preferably be caught by the second robotic arm200using a cup tool previously retrieved from the rotating bins300as discussed above.

Yet still referring to a breakdown of the bolt carrier assembly, the bolt carrier assembly is further disassembled via removing the bolt cam pin. The bolt cam pin is located on the periphery of the assembly. While the first robotic arm200continues to grip the bolt carrier assembly, the second robotic arm200: (1) grips the cam pin head; (2) rotates the cam pin by one-quarter turn; and, (3) pulls the cam pin from its socket.

Continuing the breakdown of the bolt carrier assembly, with the cam pin removed from the bolt carrier assembly, the bolt may suitably be disengaged from the bolt carrier assembly. The second robotic arm200preferably grips the bolt and coaxially removes the bolt from the bolt carrier assembly. With the bolt thus removed, the bolt carrier assembly may be coordinately placed in the cleaning tub400for cleaning.

The robotic arms200may also perform disassembly routines for the bolt. Initially, a first robotic arm200grips the bolt while the second robotic arm200secantly pushes the extractor pin through the bolt using a punch tool from the rotating bins300. Preferably the extractor pin is discharged from the bolt assembly into a catch or bucket before coordinate placement in the cleaning tub400. After returning the punch tool to the rotating bins300, the second robotic arm grips (whether independently or via pliers from the rotating bins) grips the extractor and spring and disengages the set from the bolt assembly. At this point, the first robotic arm200preferably places the bolt coordinately in the cleaning tub400. Finally, the extractor and spring are preferably separated and coordinately placed in the cleaning tub400.

At any point, expired parts of the disassembled rifle2are discarded instead of placed in the cleaning tub400. For example, the firing pin firing pin may have a firing limit of one-million rounds or useful life of 15 years and, after the limit is exceeded the firing pin is discarded and replaced.

Reassembly routines are preferably the reverse of the above stated disassembly routines. Generally, parts are removed from the cleaning bins400in the order of assembly.

In a minimal embodiment of the apparatus1and the related methods, refurbishment of a rifle requires fewer steps. A method is illustrated by the flowchart ofFIGS. 4A and 4B. First, the apparatus1is preferably powered on as discussed above. Second, a rifle type is communicated to the apparatus1. Automatically, the apparatus1, via a computer means, selects the appropriate weapon-mounting bracket for the cache100and sends the corresponding disassembly and reassembly routines to the robotic arms200. Third, the technician or soldier places the rifle on to the weapon-mounting bracket. Fourth, the cache100, rifle, and mounting bracket move into the work envelope of the robotic arms200via a conveyor belt. Fifth, a first robotic arm200grabs the upper assembly at the barrel with a clamping tool head previously obtained from the rotating bins300. Sixth, a second robotic arm200, with a probe tool head from the bins300, presses out the upper assembly upper release pin. Seventh, the first robotic arm200, pivots the upper assembly downward while the second robotic arm200presses out the upper assembly lower release pin. Eighth, the first robotic arm200then separates the upper assembly from the lower assembly. Ninth, while the lower assembly is still secured to the weapon-mounting bracket and the upper assembly securely held by the first robotic arm200, the second robotic arm200, using a cradled-bottom with two-clawed clamping tool head, removes the charging handle and bolt carrier group and coordinately places them into the cleaning tank400. Tenth, the first robotic arm places the upper carrier assembly into the cleaning tank400. Eleventh, after cleaning is complete, the upper carrier is removed from the cleaning tank by the first robotic arm200and delivered to the coordinate measuring machine500where tolerances are checked. Twelfth, if specifications and tolerances are compliant, the cleaned charging handle plus bolt carrier group are installed and the upper assembly is set to the side. Thirteenth, the lower assembly is released from the weapon mounting bracket by the first robotic arm200clamping onto the lower assembly and lifting the assembly upward while the second robotic arm200presses the clip release button. After its release, the lower assembly is placed in the cleaning tank400by the robotic arm200. Fourteenth, after cleaning is complete, the lower assembly is retrieved from the cleaning tub400by the first robotic arm200and moved to the coordinate measuring machine500for tolerance testing. Fifteenth, if the specifications and tolerances are compliant with the standard, then the lower assembly is returned to the mounting bracket by the first robotic arm200and engaged thereto at the clip port. Next, the tolerance compliant upper receiver is reunited with the lower assembly by the robotic arms200. Finally, the rifle, the cache100and mounting bracket move to the original location where the soldier or technitian removes the rifle from the cache100.

An additional aspect of the present invention is the ability of the robotic arms to cut and weld metals during contrivance repair or refurbishment routines. In such an instance, the robotic arms will retrieve welding and cutting instruments and tools from the rotating bins300. Alternatively, a welding or cutting tool could be manually attached to the robotic arms by a technician. Such a cutting and welding tool could be in the embodiment of an arc welder or other type of welding and cutting tools known to one skilled in the art of welding. In other words, it is contemplated that the robotic arms200may be adapted to spot weld, solder, and cut and grind.

It should be noted that the figures and the associated descriptions are of illustrative importance only. In other words, the depictions and descriptions of the present invention should not be construed as limiting of the subject matter in this application. The apparatuses, assemblies, components, order and inclusion of steps, and methods discussed hereby are susceptible to modification without changing the overall concept of the disclosed invention. Such modifications might become apparent to one skilled in the art after reading this disclosure.

In summary, what is disclosed is an apparatus for remotely cleaning a rifle, comprising: a rifle mounting means; a means for automatedly disassembling a rifle; a means for cleaning rifle components; a means for checking the specifications of a rifle component; a means for refurbishing said rifle and replacing or cleaning components not within said specifications; and, a means for reassembling a rifle.

Also disclosed is a method of cleaning a rifle comprising the steps of: delivering an apparatus for remotely cleaning a rifle, said apparatus comprising a rifle mounting means, a means for automatedly disassembling a rifle, a means for cleaning rifle components, a means for checking the specifications of a rifle component, a means for refurbishing said rifle and replacing or cleaning components not within said specifications, and a means for reassembling a rifle; providing a power source to said apparatus; providing a rifle to a mounting means; disassembling said rifle via said means for automatedly disassembling a rifle into an upper assembly, a charging handle plus bolt carrier group, and a lower assembly; cleaning said upper assembly, said charging handle plus bolt carrier group, and said lower assembly via said means for cleaning rifle components; checking the specifications of said upper and lower assemblies via said means for checking the specifications and tolerances of a rifle component; and, reassembling said upper assembly, said charging handle plus bolt carrier group, and said lower assembly into a rifle, if military specifications are met.