Robotic system for carrying out an operation

A robotic system for carrying out an operation is provided. The robotic system is lightweight. The principle application of the robotic system is in manufacturing industry typically to hold a tool that can perform various operations. The robotic system includes a first carriage, an arm, an arm swiveling mechanism, a second carriage, a first displacement mechanism, and a controller. The first carriage is configured to be linearly displaced. The arm is coupled to the first carriage. The second carriage is connected to a free end of the arm, and is configured to securely hold the tool. The first displacement mechanism is configured to displace the second carriage.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Section 371 of International Application No. PCT/IB2017/052297, filed Apr. 21, 2017, which was published in the English language on Oct. 26, 2017, under International Publication No. WO 2017/182990 A1, which claims priority under 35 U.S.C. § 119(b) to Indian Patent Application No. 201621013990, filed on Apr. 21, 2016, the disclosures of which are incorporated herein by reference in their entireties.

FIELD

The present disclosure relates to the field of robotic systems.

BACKGROUND

Conventionally, a gantry and rail system is used in the manufacturing industry to hold and displace objects. Typically, tools are held in a carriage assembly connected to the gantry to perform various operations. The gantry system is controlled by a computerized numerical control. For example, in a plasma cutting systems, a plasma torch is coupled to the carriage assembly which is connected to the gantry to make a hole in a workpiece. However, the aforementioned system is bulky. Further, the moving mass of the aforementioned system is excessive, thereby resulting in higher inertia. Furthermore, the conventional system requires more number of mechanical and electrical components. Thus, the conventional system is costly. Due to use of large number of motors, the operational speed of the conventional system is low, thereby increasing the cycle time. The conventional system is expensive, requires frequent maintenance, requires more installation time, have slow operating speed, and have high cycle time.

Further, the conventional system employs at least one rail along the side of the system, thereby limiting the coverage area for performing an operation. Typically, the conventional system is able to operate only in 180° work zone, thereby restricting the access to remaining 180° work zone.

Typically, conventional bridge type gantry systems are bulky in nature, and have higher moving mass. Further, in conventional bridge type gantry systems, the synchronization of two motors employed is an essential part, which adds to the manufacturing cost. The conventional bridge type gantry systems require heavy structure to connect the two motors. Further, in the conventional bridge type gantry systems, a work zone can be created only between two rails. Additionally, aligning the two rails in the gantry systems is a cumbersome task, and increases the installation time.

Typically, in a conventional cantilever system, an arm experiences vibrations. Further, increasing the reach of the arm in the conventional cantilever beam increases the vibrations and reduces the accuracy of the system. Furthermore, in the cantilever systems, a work zone can be formed only at one side of the system.

Typically, in a conventional articulated arm robotic system, to increase the reach of an arm, size of the system needs to be increased, thereby adding to the manufacturing cost. Further, to increase the payload bearing capacity, size of the robotic system needs to be increased.

Furthermore, the robotic system requires a large number of motors for performing an operation, thereby increasing the cost of the electrical components.

A SCARA (Selective Compliance Articulated Robot Arm) robotic system has a complicated mechanical structure, and requires large number of motors to perform an operation. Further, the SCARA system faces accuracy issues due to restricted movement of an arm thereof. To increase the reach of the arm of the SCARA system, the size of the system needs to be increased which adds to the manufacturing cost.

Therefore, there is felt a need for a robotic system that alleviates the above mentioned drawbacks of the conventional systems.

OBJECTS

An object of the present disclosure is to provide a robotic system that operates in multiple work zones covering 360 degrees.

Another object of the present disclosure is to provide a robotic system that has lower inertia.

Yet another object of the present disclosure is to provide a robotic system that is easy to transport.

Still another object of the present disclosure is to provide a robotic system that facilities enhanced reach for a tool.

Yet another object of the present disclosure is to provide a robotic system that is lightweight.

Another object of the present disclosure is to provide a robotic system that is less expensive.

Another object of the present disclosure is to provide a robotic system that is easy to install.

Another object of the present disclosure is to provide a robotic system that has pre-aligned internal components.

Yet another object of the present disclosure is to provide a robotic system that has a low operating cycle time.

Yet another object of the present disclosure is to provide a robotic system that occupies less space, thereby saving valuable space on the shop floor.

SUMMARY

The present disclosure envisages a robotic system for carrying out an operation. The robotic system comprises a first carriage, an arm, an arm swiveling mechanism, a second carriage, a first displacement mechanism, and a controller. The first carriage is configured to be linearly displaced. The arm is coupled to the first carriage. The arm swiveling mechanism is coupled to the first carriage and the arm, and is configured to angularly displace the arm when the first carriage is linearly displaced. The second carriage is coupled to a free end of the arm. The first displacement mechanism is coupled to the second carriage and the arm, and is configured to displace the second carriage about the free end of the arm. The controller is adapted for synchronizing the movement of the arm, the first carriage, and the second carriage to perform an operation.

The arm swiveling mechanism includes a first motor configured to rotate the arm about the first carriage.

In an embodiment, the system comprises a supporting structure configured to facilitate linear displacement of the first carriage thereon. In an embodiment, at least one rail is configured on the supporting structure to facilitate linear movement of the first carriage thereon.

In another embodiment, the system comprises a second displacement mechanism coupled to the first carriage and configured to facilitate linear displacement of the first carriage along the supporting structure. The second displacement mechanism includes a second motor configured to facilitate sliding movement of the first carriage along the supporting structure.

In an embodiment, the first displacement mechanism includes a third motor, and is configured to linearly move the second carriage in an operative upward and an operative downward direction.

In an embodiment, the system further comprises a tool swiveling mechanism coupled with the second carriage, and configured to rotate the tool about the free end of the arm. The tool swiveling mechanism includes at least one motor configured to facilitate swiveling movement of the tool.

In another embodiment, the tool is coupled with the second carriage via an articulated robotic arm, a robotic wrist, or any combination thereof to rotate the tool.

In an embodiment, the system comprises a trolley configured to linearly displace the first carriage.

In an embodiment, the operation is selected from the group consisting of welding, cutting, grasping an object, moving an object from one place to another, and lifting an object.

In an embodiment, the second carriage is configured to hold a tool for performing the operation.

In an embodiment, the arm swiveling mechanism is configured to move the arm about the first carriage along the rotary C-axis.

In an embodiment, the system comprises an arm sliding mechanism connected to the first carriage and the arm, and configured to linearly displace the arm about the first carriage. The arm sliding mechanism includes a rack, a pinion, and a fifth motor. The rack is connected to the arm. The pinion abuts the rack, and is connected to the first carriage. The fifth motor is coupled to the pinion, and configured to rotate the pinion.

In an embodiment, the system further comprises a rotating member disposed at each operative end of the rail, and configured to facilitate rotational movement of the rail, thereby rotating the first carriage.

In an embodiment, the system comprises a first carriage swiveling mechanism coupled with the first carriage, and configured to rotate the first carriage.

In an embodiment, the supporting structure is securely suspended at a predetermined height from the ground level, and the first carriage is securely connected to an operative bottom portion of the supporting structure.

In an embodiment, the system further comprises an arm rotation mechanism configured to facilitate rotational movement of the arm about the longitudinal axis of the arm.

LIST OF REFERENCE NUMERALS

100—Conventional bridge gantry system

202a—Operative end of the arm

202b—free end of the arm

DETAILED DESCRIPTION

Conventionally, a gantry and rail system is used in the manufacturing industry to hold and displace objects or carrying out an operation using various tools. Typically, tools are held in a carriage assembly connected to the gantry to perform various operations. The bridge gantry system is controlled by a computerized numerical control machines.

FIG. 1illustrates an isometric view of a conventional bridge gantry system100.

The conventional bridge gantry system100comprises a tool102, a tool carriage assembly104, a gantry106, a rail system108, a controller (not shown in figure), a power supply (not shown in figure) and a cutting table112. A workpiece110to be cut is disposed on the cutting table112. The tool102, which is a plasma torch, is mounted on the tool carriage assembly104. The tool carriage assembly104is coupled to the gantry106. The gantry106facilitates movement of the tool carriage assembly104along the X-axis. The rail system108comprises at least one rail. The rail is disposed on one side of the cutting table112. The rail system108facilitates the movement of the gantry106and the tool carriage assembly104along Y-axis.

The conventional bridge gantry system100facilitates the movement of the tool102along the X-axis and the Y-axis using two pairs of motors and the controller. The first pair of motors facilitates the movement of the gantry106along the Y-axis, thereby moving the tool carriage assembly104along the Y-axis. The second pair of motor facilitates the movement of the tool carriage assembly104along the X-axis.

However, the conventional bridge gantry system requires synchronizing of two motors for X-axis movement. Further, as the conventional bridge gantry system100requires more number of electrical components, the conventional bridge gantry system100is expensive, and requires frequent maintenance. Further, the conventional bridge gantry system100requires more installation time, and is difficult to transport from one place to another.

The present disclosure envisages a robotic system that operates in multiple work zones, has lower inertia, is easy to transport, facilities enhanced reach for a tool, is lightweight, is less expensive, is easy to install, and has a low operating cycle time.

The robotic system, of the present disclosure, is now described with reference toFIG. 2throughFIG. 7.

FIG. 2illustrates an isometric view of a robotic system200, in accordance with an embodiment of the present disclosure.FIG. 3illustrates a side view of the robotic system200, in accordance with an embodiment of the present disclosure.FIG. 4illustrates a front view of the robotic system200, in accordance with an embodiment of the present disclosure.FIG. 5,FIG. 6, andFIG. 7illustrate isometric views of the robotic system200depicting different positions of the robotic system200during performing an operation, in accordance with an embodiment of the present disclosure. More specifically,FIG. 5depicts the robotic system's200positioning of the tool in a first work zone.FIG. 6depicts the robotic system's200positioning of the tool in the center.FIG. 7depicts the robotic system's200positioning of the tool in a second work zone at 180 degrees to the first work zone.

The robotic system200comprises a first carriage206, an arm202, an arm swiveling mechanism210, a second carriage208, a first displacement mechanism203, and a controller (not exclusively shown in figures).

The first carriage206is configured to be linearly displaced. In an embodiment, the system200comprises a supporting structure204configured to facilitate linear displacement of the first carriage206thereon. In another embodiment, the supporting structure204comprises at least one rail configured on the operative top surface of the supporting structure204. The rail205is configured to facilitate the linear movement of the first carriage206thereon. In another embodiment, the supporting structure204comprises two rails configured on an operative top surface of the supporting structure204. In yet another embodiment, the supporting structure204comprises multiple rails configured on an operative top surface of the supporting structure204. In still another embodiment, the rail205is configured on an operative side surface of the supporting structure204, and the first carriage206is mounted on the operative side surface of the supporting structure204abutting the rail205.

In an embodiment, the system200comprises a trolley (not shown in figures). The first carriage206is mounted on the trolley. The trolley is configured to linearly displace the first carriage206.

The arm202is coupled to the first carriage206. More specifically, one operative end202aof the arm202is coupled to the first carriage206. The arm202is angularly displaceable along the first carriage206. In an embodiment, the arm202is a robotic arm, and is of a light weight material. In another embodiment, the arm202is made of a material selected from the group consisting of carbon fiber, graphite fiber, carbon nanotube, fiberglass, and any other known lightweight material. In yet another embodiment, the arm202is made of a combination of pipes, corrugated sheets of metal and fiberglass. In an embodiment, the vibrations in the arm202are reduced by active damping or passive damping methods.

As the arm202is of light weight material, the overall weight of the system200is reduced. Further, the lightweight arm202facilitates reduction in the moving mass of the system200. The reduction in moving mass reduces the inertia of the system200, and enables the system200to precisely move the arm202to effectively perform any operation. Further, reduction in weight of the arm202reduces the vibrations experienced by the arm202during movement.

The configuration of the arm202is in accordance with an application for which the system200is to be used. In an embodiment, the length of the arm202is in the range of 100 millimeters to 3 meters.

The arm swiveling mechanism210is coupled to the first carriage206and the arm202. The arm swiveling mechanism210is configured to angularly displace the arm202about the first carriage206when the first carriage206is displaced. The arm swiveling mechanism210includes a first motor (not shown in figures) configured to rotate the arm202about the first carriage206.

In another embodiment, the system200comprises a second displacement mechanism coupled to the first carriage206, and is configured to facilitate linear displacement of the first carriage206along the rail205. In an embodiment, the second displacement mechanism includes a second motor (not shown in figures). The second motor is configured to facilitate linear movement of the first carriage206along the supporting structure204.

The second carriage208is coupled to a free end202bof the arm202. The second carriage208is configured to securely hold a tool209therein. The tool209is any tool required for carrying out the operations. In an embodiment, the tool209is a plasma torch. In another embodiment, the tool209is a gripper configured to securely grasp objects. In yet another embodiment, the tool209is a vision camera. In still another embodiment, the tool209is a laser tool used for measurement purposes or any other purposes.

The first displacement mechanism203is coupled to the second carriage208and the arm202. The first displacement mechanism203is configured to displace the second carriage208about the free end202bof the arm202.

In an embodiment, the first displacement mechanism203includes a third motor configured to linearly move the second carriage in an operative upward direction and an operative downward direction. In an embodiment, the first displacement mechanism203comprises a rail mounted on the free end202bof the arm202. The third motor is configured to linearly move the second carriage208on the rail mounted on the free end202b.

In an embodiment, the system further comprises a tool swiveling mechanism coupled with the tool209and the second carriage208, and configured to rotate the tool209about the free end202bof the arm202. The tool swiveling mechanism includes at least one motor, referred as fourth motor, to facilitate swiveling movement of the tool209.

In an embodiment, the system200comprises an arm sliding mechanism (not exclusively shown in figures). The arm sliding mechanism is configured to linearly displace the arm202along the first carriage206. The arm sliding mechanism is connected to the arm202and the first carriage206. The arm sliding mechanism comprises a rack212and pinion arrangement (not shown in figures). The rack212is connected to the arm202. The pinion abuts the rack212, and is connected to the first carriage206. More specifically, the pinion is in abutting relationship with the rack212. The arm sliding mechanism further comprises a fifth motor (not shown in figures) coupled to the pinion. The fifth motor rotates the pinion, thereby sliding the rack212and the arm202along the first carriage206. The arm sliding mechanism facilitates alteration in the length and reach of the arm202whenever required.

In an embodiment, each of the first motor, the second motor, the third motor, the fourth motor, and the fifth motor is selected from the group consisting of linear motors, servo motors, variable speed motors, and any combination thereof.

The controller (not shown in figures) is adapted to synchronize the movement of the first carriage206, the arm202, and the second carriage208to perform an operation. More specifically, the controller cooperates with the first motor, the second motor, the third motor, the fourth motor, and the fifth motor to concurrently control the movement of the first carriage206, the arm202, and the second carriage208to carry out an operation.

In an embodiment, the controller is coupled to a power unit (not shown in figures). The power unit is configured to provide voltage to the controller.

The operation carried out by using the robotic system200includes, but not limited to, welding, cutting, grasping an object, moving an object from one place to another, lifting an object, inspecting objects using a vision camera, and checking dimensions of an object using laser systems.

The system200further comprises a rotating member (not shown in figures) disposed at each operative end of the rail205of the supporting structure204. The rotating member is configured to facilitate rotational movement of the rails205, thereby rotating the first carriage206. In another embodiment, the rotating member is a gear mechanism (not shown in figure) disposed at the operative ends of the rail205. In yet another embodiment, the gear mechanism is disposed at an operative middle portion of the rail205.

The system comprises an arm rotation mechanism (not shown in figures) configured to facilitate rotational movement of the arm202about the longitudinal axis of the arm202. The arm rotation mechanism includes a sixth motor configured to facilitate rotational movement of the arm202about the longitudinal axis of the arm202.

The rotational and translational movements of the system200are now described in detail. The first carriage206is linearly displaceable along X-axis (as shown inFIG. 2). The second displacement mechanism facilitates linear displacement of the first carriage206along the X-axis. The arm202is movable along the rotary C-axis (as shown inFIG. 2). Further, the arm202is also linearly displaceable along the first carriage206in the Y-axis (as shown inFIG. 2). The arm swiveling mechanism210facilitates the rotational movement of the arm202along the rotary C-axis.

In an embodiment, the first carriage206and the arm202are simultaneously displaced. More specifically, the arm202is angularly displaced about the first carriage206when the first carriage206is linearly displaced along the rail205.

Further, the arm sliding mechanism facilitates the sliding movement of the arm202along the first carriage206. Furthermore, the second carriage208is linearly displaceable in an operative upward and downward direction about the free end202bof the arm202. In an embodiment, the second carriage208is linearly displaceable along Z-axis (as shown inFIG. 2). The first displacement mechanism facilitates the sliding movement of the second carriage208along the free end202b. The rail205is rotatable along X-axis. The rotating member facilitates rotation of the rail205along the X-axis. In yet another embodiment, the first carriage206is rotatable along the X-axis. A first carriage swiveling mechanism (not shown in figures) is configured to rotate the first carriage206about the supporting structure204along the X-axis. The first carriage swiveling mechanism includes a seventh motor mounted on the first carriage206, and configured to rotate the first carriage206about the supporting structure204.

Further, the tool209is also rotatable along the free end202bof the arm202. The tool swiveling mechanism facilitates the rotation of the tool209. In an embodiment, the tool209is coupled with the second carriage208via an articulated arm configured to facilitate the movement of the tool209. In yet another embodiment, the tool209is coupled to the second carriage208via a swinging and rotary arrangement. In yet another embodiment, the tool209is coupled with the second carriage208via a robotic wrist mechanism to facilitate wrist movement of the tool209.

In an embodiment, the combined movement of the first carriage206, the arm202, and the second carriage208facilitate precise operation of the tool209. More specifically, the controller is adapted for synchronizing the linear movement of the first carriage along the X-axis, the rotary movement of the arm202along the rotary C-axis, and the linear movement of the second carriage208along the Z-axis to effectively perform the operation.

In an embodiment, the rotary movement of the arm202along the rotary C-axis increases the reach of the tool209as the tool209can reach closer to the rail205.

In an embodiment, the arm202is rotatable about the longitudinal axis thereof. The arm rotation mechanism facilitates the rotational movement of the arm202about the longitudinal axis of the arm202.

In yet another embodiment, the system200comprises a moving structure, such as a trolley.

The first carriage206is mounted on the trolley. The linear displacement of the first carriage206is achieved by moving the trolley.

In an embodiment of the present disclosure, the supporting structure204is disposed on the ground. In another embodiment, the supporting structure204is mounted overhead. More specifically, the supporting structure204is securely suspended at a predetermined height from the ground level. The first carriage206is then securely connected to an operative bottom portion of the supporting structure204, and is displaceable along the supporting structure204. The rail205is configured on the operative bottom surface of the supporting structure204. The overhead mounting of the supporting structure204increases the reach of the tool209as the tool209can perform the operation in the space formed operatively below the supporting structure204.

Therefore, by combining the aforementioned movements, the arm202, and hence the tool209, can reach and perform operations in X-axis, Y-axis, and rotary C-axis. In an embodiment, the tool209has six degrees of freedom which can be achieved by combining the aforementioned movements.

The rotatable movement of the arm202along the rotary C-axis facilitates enhanced reach of the tool209. Further, the robotic system200can perform operations in multiple work zones due to the movement of the arm202along the rotary C-axis. More specifically, in case of picking objects, the tool209can pick object from one side of the supporting structure204, and can place the object on the other side of the supporting structure204. The placed object can be further operated when the system200is picking next object. Thus, various operations can be performed on the objects simultaneously. In an embodiment, the arm202is movable in 360° along the rotary C-axis enabling the system200to perform operations in at least four work zones.

In the robotic system200, the reach of the tool209can be increased by increasing the length of the arm202, which is cost effective, and does not require more number of motors.

In the robotic system200, the load bearing capacity of the arm202can be increased by increasing the dimensions of the arm202.

As compared to conventional robotic systems, cable management is easier in the system200due to its compact and less complicated structure.

In an embodiment, all the aforementioned motors, are mounted on the first carriage206, which makes the system200compact. Due to the aforementioned arrangement, the arm202bears only the payload of tool209. Reduction in payload on the arm202reduces the vibrations in the arm202. Further, the compact structure of the system200saves valuable space on the shop floor as the system200has smaller footprint on the shop floor.

The robotic system200is particularly useful in a manufacturing industry where heavy objects are required to be displaced or handled. Further, in one application, the system200is useful to handle welding tools for welding applications. The system200is useful in performing cutting operations using methods such as plasma cutting, flame cutting, or water jet cutting. Further, the system200is also useful in carrying out painting operations on a workpiece. The system200can also be used for engraving and marking an object typically made of glass or wood. The system200is useful in handling laser tools, and drilling operations.

Further, the system200performs the operations using the tool209with high accuracy. The arm swiveling mechanism210is configured such that it displaces the tool209with high accuracy, thereby achieving accurate positioning of the tool209and reducing the errors.

Due to use of lightweight material in the manufacturing of the arm202, the system200is light in weight, and can be easily transferred from one place to another. Further, as compared to the conventional gantry system, the system200is versatile is nature, and can perform operations in multiple work zones. Further, the configuration of the system200is not as complex as a six axis robot, also known as an articulated arm robot. Thus, the system200is less bulky, and requires less installation time.

TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a robotic system that:operates in multiple work zones;has lower inertia;is easy to transport;can operate in proximal vicinity thereof as compared to a gantry system and conventional robotic systems;eliminates the issue of singularity wherein multiple axis gets locked;is lightweight;is suitable for a plurality of applications;is less expensive;is easy to install;has a low operating cycle time;is easily transportable and can work at multiple locations on the shop floor; andoccupies less space, thereby saving valuable space on the shop floor.

The disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.