Abstract:
A multi-head robotic system capable of delivering numerous robotic devices to a task site is disclosed. A number of robotic devices perform tasks simultaneously, thus tasks can be completed quickly. Each individual robot does not need to move at an extremely fast speed. The sequence in which the robotic devices arrive at or leave a task site is unlimited. The robotic delivery system is capable of “leapfrogging” robotic devices, or placing them randomly, at locations where they are most needed.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Technical Field  
           [0002]    The present invention relates generally to the field of robotics. In particular, this invention relates to a multi-head robot device, system and method, which include a number of robotic devices, each of which is able to operate independently at any of a number of discrete destinations.  
           [0003]    2. Related Art  
           [0004]    The field of robotics is a rapidly developing area of technology. Robotic systems are continually being adapted to operate in new market niches, and to operate at higher speeds in existing product areas. Robotics will continue to play an increasingly important role in the economic viability of existing, as well as emerging, technologies. For example, manufacture of miniature assemblies incorporating MEMS (Micro-Electro-Mechanics) devices is tedious and extremely difficult to perform efficiently for even a skilled person. Similarly repetitive and labor intensive tasks are present in many other industries, including photonics, laboratory automation, electronics assembly, food processing, material handling, and pouch singulation. Inherent in each of these processes is the need for a high speed transfer system which can repeatedly target variable locations, acquire an object, and then deposit that object at a specific location.  
           [0005]    In general, the related art has provided a variety of robotic devices with which to address these tasks. For instance, in the field of material handling there is the task of singulation, or the separating of items one from another. Attempts have been made to increase the speed of singulation using a large number of tilted conveyors. However, this approach introduces the problem of the amount of space required to accommodate the numerous conveyors. A second approach involves computer vision systems to direct a single robot arm to pick a single package and transfer it. This approach requires a complex robot gripper, one which is capable of grasping any shape or size package.  
           [0006]    Another example of an industry having a need for high speed transfer systems is the food processing industry. Food processing lines, such as cookie process lines, typically require that individual cookies be picked from a conveyor and either placed in a package, or prepared for further processing. Current automation takes one of two forms. The first is a series of industrial robot arms that transfer one or two cookies at a time. Many of these, typically SCARA (Selectively Compliant Articulated Robot Arm) robot arms and attendant vision systems must be employed on a single cookie conveyor to handle the volume of product. The second form of automation utilizes a spider-like device which descends to pick a cookie and then transfer it. Here again, a vision system is required, and range of motion is limited.  
           [0007]    Finally, a governmental requirement to enhance worker safety calls for retrofitting of assembly lines to curtail ergonomic injuries caused by repetitive motions. This requirement provides further incentive for manufacturers to address the long felt need for high speed, high throughput robotic systems involving variable tasks.  
           [0008]    However, known robotic machines are limited to the speed at which a single robotic device can be manipulated. That is, the industry is confronted by physical limitations that curb the development of machinery capable of the increases in speed necessary to meet the challenges confronting industry.  
           [0009]    Therefore, a novel apparatus which is less complex and costly than presently available robotic systems, but which provides for increases in speed, throughput, and tasks is believed clearly desirable.  
         SUMMARY OF THE INVENTION  
         [0010]    As noted initially and more fully described herein, the the present invention solves these problems in the related art by providing a multi-head robot system capable of delivering numerous robotic devices to a task site. Since a number of robotic devices are performing tasks simultaneously, the tasks can be completed quickly, and each individual robotic device need not move at an extremely fast speed. The sequence in which robotic devices arrive at or leave a task site is unlimited. That is, the robotic delivery system is capable of “leapfrogging” robotic devices, or placing them in random order, where ever they are most needed. The robotic devices typically function as material handling instruments, although other embodiments are readily available.  
           [0011]    In a first general aspect, the present invention presents a material handling system comprising: at least one material handling device; at least one track for transporting said material handling device; a plurality of workstations located along the track; and wherein each material handling device is removably coupled to the track.  
           [0012]    In a second general aspect, the present invention presents a system comprising: a conveyor track; at least one robot removably attached to said conveyor track; a drive system for movement of the conveyor track; at least one workstation adapted to operationally receive said robot; and a coupling mechanism to disengage or engage the robot to the conveyor track.  
           [0013]    In a third general aspect, the present invention presents a delivery system for a robotic device comprising: a first track guide element for routing the robotic device; a conveyor track for transporting the robotic device, said conveyor track operably positioned with said fixed track guide element; at least one robotic device removably attached to said conveyor track and said guide element; a drive system for maintaining the speed of the conveyor track; at least one workstation adapted to operationally receive said robotic device from said conveyor track and said guide element; and a coupling mechanism operationally attached to the robotic device which allows the robotic device to disengage or engage the conveyor track and the guide element.  
           [0014]    In a fourth general aspect, the present invention presents a material handling system comprising: a plurality of independent material handling devices; at least one continuously moving track for transporting said material handling devices; a drive system for maintaining said track at a constant speed; a plurality of workstations located along the route traversed by the track; and wherein each material handling device further comprises means for removably attaching itself to the track.  
           [0015]    In a fifth general aspect, the present invention presents a delivery system for a robotic device comprising: a track guide element for routing the robotic device; at least one robotic device removably attached to said guide element, said robotic device capable of propelling itself along said guide element; at least one workstation adapted to operationally receive said robotic device from said guide element; and a coupling mechanism operationally attached to the robotic device which allows the robotic device to disengage or engage the guide element.  
           [0016]    In a sixth general aspect, the present invention presents a material handling system comprising: a plurality of independent material handling devices; at least one continuously moving track for transporting said material handling devices; a drive system for maintaining said track at a constant speed; a plurality of workstations located along the route traversed by the track; and wherein each material handling device further comprises a device for removably attaching the material handling device to the track.  
           [0017]    In a seventh general aspect, the present invention presents a transport system for a docking end effector comprising: a first track; a plurality of end effectors removably coupled to said track; at least one docking station adapted to receive at least one of said end effectors; a vision system adapted to control operation of said transport system; a position sensor system adapted to control operation of said transport system; a drive system operationally connected to said track; at least one second track adapted to receive at least one end effector, said second track further adapted to provide access to the first track; a system for supplying control signals to the said end effector; a system for supplying power to said end effector; and a coupling device, said coupling device adapted to couple and decouple said end effector to the first track and the second track.  
           [0018]    In a eighth general aspect, the present invention presents a method of distributing at least one robotic device, said method comprising: providing at least one robotic device; providing at least one track for transporting said robotic device; providing at least one workstation along the track; providing a system for removably attaching each robotic device to the track; and providing a device to mate each robotic device to a workstation.  
           [0019]    The foregoing and other objects, features and advantages of the invention will be apparent in the following and more particular description of the preferred embodiments of the invention as illustrated in the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    The preferred embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like elements, and wherein:  
         [0021]    [0021]FIG. 1 is an overall perspective view of a multi-head tracked robot system capable of delivering numerous robotic devices to a task site in one embodiment of the present invention;  
         [0022]    [0022]FIG. 2 is a perspective view showing a portion of FIG. 1 in greater detail;  
         [0023]    [0023]FIG. 3 is a perspective view of another embodiment of the multi-head tracked robot system capable of delivering numerous robotic devices to a task site of the present invention;  
         [0024]    [0024]FIG. 4A is a side elevational view of a portion of an embodiment of the robotic device rigid track delivery system of the present invention;  
         [0025]    [0025]FIG. 4B is a side elevational view of a portion of another embodiment of the robotic device moving-chain delivery system of the present invention;  
         [0026]    [0026]FIG. 4C is a side elevational view of a portion of a further embodiment of the robotic device dual-moving-chain delivery system of the present invention;  
         [0027]    [0027]FIG. 5 is an overhead view of a portion of an embodiment of the robotic device double-wide-chain delivery system of the present invention;  
         [0028]    [0028]FIG. 6 is a side elevational view of a portion of a further embodiment of the robotic device drop/pinch cable delivery system of the present invention;  
         [0029]    [0029]FIG. 7 is a plan view of a portion of another embodiment of the robotic device delivery system of the present invention adapted for trailer unloading;  
         [0030]    [0030]FIG. 8 is a plan view of a portion of yet another embodiment of the robotic device delivery system of the present invention adapted for trailer unloading;  
         [0031]    [0031]FIG. 9A is a plan view of a portion of another embodiment of the robotic device delivery system of the present invention adapted for trailer unloading;  
         [0032]    [0032]FIG. 9B is a detail view of a portion of FIG. 9A;  
         [0033]    [0033]FIG. 9C is another detail view of a portion of FIG. 9A;  
         [0034]    [0034]FIG. 9D is still another detail view of a portion of FIG. 9A;  
         [0035]    [0035]FIG. 10A is a plan view of a portion of another embodiment of the robotic device switchable-track delivery system of the present invention;  
         [0036]    [0036]FIG. 10B is a detail view of a portion of FIG. 10;  
         [0037]    [0037]FIG. 11A is a plan view of a portion of another embodiment of the robotic device delivery system of the present invention employing multiple cable/chain loops;  
         [0038]    [0038]FIG. 11B is a detail view of a portion of FIG. 11A;  
         [0039]    [0039]FIG. 12 is a perspective view of another embodiment of the multi-head tracked robot system capable of delivering numerous robotic devices, equipped with a spatula end effector, to a task site;  
         [0040]    [0040]FIG. 13 is a perspective view of another embodiment of the multi-head tracked robot system capable of delivering numerous robotic devices to more than one task site;  
         [0041]    [0041]FIG. 14 is a perspective view of another embodiment of the multi-head tracked robot system capable of delivering numerous robotic devices in a recirculation scheme; and  
         [0042]    [0042]FIG. 15 is a perspective view of another embodiment of the multi-head tracked robot system capable of delivering numerous robotic devices in a laboratory automation environment. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0043]    Referring to the drawings, FIG. 1 illustrates a first form of the present invention, that is, a multi-head robot system  100  capable of delivering numerous robotic devices  130  to a task site or first workstation  150 . In the embodiment depicted in FIG. 1, a series of robotic devices  130  are shown removably attached to a drive belt  120 . The drive belt  120  may be a chain, belt, cable or other suitable means for moving the robotic devices  130  along a track  110 . A machine vision control system  180  monitors the location and movement of the robotic devices  130 . The robotic devices rest upon the track  110 , and are propelled or carried along the track by the drive belt  120 . The track  110  is supported by frame members  160 . Similarly, the drive belt  120  is supported by structural members  170 . Finally, a plurality of work pieces  140  are located on a first workstation  150 .  
         [0044]    In a typical processing routine, robotic devices  130  are removably attached to the drive belt  120 . The robotic devices  130  are also attached to the track  110  in such a manner that they may glide along track  110  when they are propelled by drive belt  120 . A drive system (not shown) controls the speed and direction of drive belt  120 , through driven, rotating spindles  190 .  
         [0045]    During operation, the drive belt  120  is maintained at a desired speed. The robotic devices  130  travel around the route defined by the track  110  until machine vision control system  180  or some other sensing means determines that a particular robotic device  130  is in an appropriate position to perform process steps on a particular workpiece  140 . At this time, the robotic device  130  is optionally decoupled from the drive belt  120 , and its end effector  210  (FIG. 2) will commence operations on the workpiece  140 .  
         [0046]    In the embodiment depicted in FIG. 2, the end effector  210  includes a vacuum head which picks up a workpiece  140 . The robotic device  130  subsequently reacquires the drive belt  120 , so that the robotic device  130  and the workpiece  140  are moved along the track  120 .  
         [0047]    As shown in FIG. 1, at a designated point in the route, for example, at a second designated workstation  155 , the robotic device  130  again optionally decouples from the drive belt  120 , and its end effector  210  (FIG. 2) will again perform operations on the workpiece  140 .  
         [0048]    In the embodiment depicted in FIGS. 1 and 2, the end effector  210  vacuum head now places the workpiece  140  at an appropriate location on the second workstation  155 , and the vacuum head of the end effector  210  releases the workpiece  140 . The robotic device  130  subsequently reacquires the drive belt  120 , and the robotic device  130  is transported further along the track  120 . In this manner, the robotic device  130  is once more ready to repeat the pick and place operation described supra, or any other operation suitable for a robotic device.  
         [0049]    It should be noted that the drive belt  120  can maintain a high speed throughout the pick and place operation. This is possible because the robotic device  130  engages and disengages from the drive belt  120  when at an appropriate location, or when commanded to do so by a machine vision control system  180  or the like. This allows a plurality of robotic devices  130  to be in operation simultaneously. The net result is a dramatic increase in throughput for the process line, especially when compared to existing robotic systems.  
         [0050]    Referring now to FIG. 3, a second embodiment is illustrated, wherein each of the numerous robotic devices  130  includes an end effector docking/locking device  310  capable of independently performing complex operations or manipulations on a workpiece  340 . The docking/locking device is further disclosed in U.S. patent application Ser. No.60/195,064, filed concurrently, which patent application is hereby incorporated by reference. Each docking/locking device  310  is capable of stand alone operation when it is properly docked and locked to a workpiece  340 , and the docking/locking device  310  may either receive command signals and power from the workstation, or from internal sources.  
         [0051]    The embodiment shown in FIG. 3 is a novel automation device characterized by three important features, namely, high throughput, high precision, and a relatively long process setting time. In FIG. 3, individual docking/locking devices  310  are shuttled around a track  110  by a drive belt  120 . The docking/locking devices  310  are able to pick objects (not shown) from trays  340  at a first workstation  370  and subsequently place them in openings  360  of component tray  350  at a second workstation  380 . The docking/locking devices  310  are able to disengage from and reacquire the drive belt  120  at either workstation  370 ,  380 . The docking/locking devices  310  are further able to temporarily dock to portions of the workstations  370 ,  380 , by mating docking pins  395  to docking holes  390 . Once docked at the workstation  370 ,  380  and locked into place, the docking/locking devices  310  are able to perform any robotic manipulation necessary to further complete production of the device under assembly.  
         [0052]    Several alternative drive systems contemplated by the inventor will now be discussed. Referring to FIG. 4A, a first embodiment  400  is illustrated. This embodiment  400  incorporates a track  490  (e.g., railroad track, I-beam, etc.), and riding on the track  490  is a truck  415  from which is suspended a robotic device  130 , docking/locking device  310 , or the like. The truck  415  also includes at least one first wheeled carriage  410  to facilitate movement of the truck  415  along the track  490 . A second wheeled carriage  420  can be attached to ride along the opposite side of the track  415  from the first wheeled carriage  410 . This configuration yields improved balance, and smoother operation, when the truck  415  moves along the track  490 .  
         [0053]    The embodiment  401  of the present invention illustrated in FIG. 4B builds on the concept of FIG. 4A. The embodiment  401  includes a drive chain  440  which engages the truck  415  via a drive gear or cog  450  which contains a clutch mechanism (not shown). Controlled movement of the drive chain  440  thus propels the truck  415 . The truck  415  is thus equipped with a disconnect means (i.e., the drive gear or cog  450  containing a clutch mechanism) which allows the truck  415  to release or reacquire the drive chain  440  as necessary.  
         [0054]    [0054]FIG. 4C depicts another embellishment of the embodiment  401  of FIG. 4B. In this embodiment  402 , a fixed chain  440  is added to the system. The fixed chain  440  is operatively connected to the truck  415  via a geared braking mechanism  480 . The geared braking mechanism  480  permits the truck  415  to more positively stop when it approaches some desired position where it is to detach from the drive chain  440 . In an alternative model, the fixed chain  440  can be geared to rotate an encoder shaft (not shown) to give positional feedback to the robotic system. Yet another embodiment  500  is shown in FIG. 5 wherein a double-linked drive chain  510  is used to provide two functions. First, one side of the double-linked drive chain  510  passes over support gears  530  which support the double-linked drive chain  510 . Second, the robot drive gear  520  is used to propel a robot-laden truck  415 .  
         [0055]    Referring now to FIG. 6, a drop/pinch cable drive system  600  for transporting robotic devices is shown. In this drive system  600 , a moving cable  640 , maintained in motion, is used to carry the robotic device carriers  630  in place of a drive chain or drive belt. In operation, a plurality of robotic device carriers  630  are positioned as ready spares in a wait zone  610 . The robotic device carriers  630  are positioned above the cable  640 . A pusher mechanism  620  is used to push a robotic device carrier  630  away from the wait zone  610  and onto the moving cable  640 . Once on the moving cable  640 , the robotic device carrier  630  operates as explained supra regarding the multi-head tracked robot system  100 . At such time as it becomes desirable to remove a robotic device carrier  630  from the moving cable  640  (e.g., for maintenance, no further use, etc.) the robotic device carrier  630  is guided to an unload zone  650 . The unload zone  650  includes a ramp or other means for removing the robotic device carrier  630  from the moving cable  640 . In an alternative embodiment (not shown) of this model, a track is used to support the weight of the robotic device carrier  630 , and the robotic device carrier  630  includes a pinching mechanism to grip the moving cable  640 . Another alternative embodiment (not shown) utilizes a plurality of parallel cables to provide additional structural support and/or room for additional robotic device carriers  630 .  
         [0056]    The illustrations of FIG. 7, 8,  9 A,  9 B,  9 C, and  9 D represent versions of the invention adapted for the unloading of the contents of a cargo trailer  720 . In FIG. 7, a multi-head tracked robot system  700 , of the present invention, is shown which is capable of delivering numerous robotic devices  730  to the interior of cargo trailer  720  via a track, moving cable, or the like  710 . As described, supra, each of the robotic devices  730  is capable of picking a single package  725  and placing it on a conveyor or workstation  740 . For instance, the robotic devices  130  may have grippers or suction cups that are faced externally to the track loop. A vision system may be used to guide the robotic devices  130  to the proper package to pick. Gripper types can be assigned to ensure the best match between gripper type and package to be picked.  
         [0057]    Also in this embodiment is the capability to move the entire multi-head tracked robot system  700  in three (X, Y, Z) dimensions, namely horizontally, from side to side within, and into and out of, the interior of the cargo trailer  720 , and vertically within the interior. This allows the multi-head tracked robot system  700  to clear packages  725  from anywhere within the cargo trailer. The entire robot system  700  can be placed on rollers or wheels to facilitate this movement.  
         [0058]    A modification to the apparatus of FIG. 7 is shown in FIG. 8. The apparatus  800  is similar to that discussed regarding FIG. 7, except that FIG. 8 includes moveable spindles  820 ,  840  which are moved forward and backwards, enabling the picking end  860  of the multi-head tracked robot system  800  to move into and out of the cargo trailer  720 .  
         [0059]    Another alternate embodiment of FIG. 7 is presented in FIGS. 9A, 9B,  9 C, and  9 D. Rotating spindle  960  has a relatively fixed location, while rotating spindles  920 ,  940 , and  950  do not have a fixed location, i.e., they can move forward and backward, thereby allowing the multi-head tracked robot system  910  to move into (e.g. FIG. 9B) and out of (e.g. FIG. 9C) the cargo trailer  720 . Rotating spindles  920  and  960  act in combination to provide a method of taking up slack in the drive belt or chain  915 .  
         [0060]    [0060]FIG. 9D represents a method of bypassing spindle  960  by using a jumper  925  from spindle  920  to belt portion. The jumper  925  is useful to avoid having the drive belt or chain  915  jog in one direction and immediately jog in the other direction while the drive belt or chain  915  reverses direction.  
         [0061]    Still another alternative embodiment is shown in FIGS. 10A, 10B, and  10 C. This embodiment  1000  includes a guide track  1010  upon which the robotic devices  130  (FIG. 1) move. At least one area  1020  of guide track  1010  includes a portion  1030  that is hingedly movable so as to allow branching of the guide track  1010 , which permits rerouting of robotic devices  130  onto a second guide track  1040 .  
         [0062]    Referring now to FIG. 11, there is shown an embodiment  1100  utilizing a first guide track  1110  with a first drive chain (not shown) operating below it. A drive gear  1130 , mounted on the robotic device, operatively and simultaneously connects this first guide track  1110  and first drive chain to a second guide track  1120  and a second drive chain (not shown). The gear teeth and the speed of the drive gear  1130  ensure that the first and second drive chains operate at the same speed.  
         [0063]    This embodiment  1100  (FIG. 11) also includes two track supporting guides  1140 ,  1160  mounted on the robotic device (not shown) which enable gear  1150  to catch and release either of the first or second guide tracks  1110 ,  1120 , respectively, as shown in FIG. 11B. Thus, the robotic device (not shown) can use each parallel track for support, and can switch from moving along the first guide track  1110  to moving along the second guide track  1120 .  
         [0064]    The embodiment  1200  of FIG. 12 is similar to that of FIG. 2, except that FIG. 12 illustrates a spatula-type gripper  210 . When used as an end effector, the spatula-type gripper  210  is useful for lifting up fragile items (e.g., cookies or candies) which may otherwise be damaged, particularly when the end effector does not come to a complete stop while picking the item.  
         [0065]    The embodiment  1300  depicted in FIG. 13 is that of a multi-head tracked robot system  1310  which utilizes both sides  1314 ,  1316  of the track. In a typical operating mode, incoming items  1340  to be singulated are scanned by a machine vision system (e.g., a line scan camera). Next, the items  1340  are conveyed, by incoming conveyors  1350 , under the robotic devices  1330 , which pick some or all of the items  1340  and place them on the outgoing conveyors  1360 .  
         [0066]    Under certain circumstances, it is necessary to use a processing technique called “recirculation” to deal with a plurality of items which are piled too deeply for the initial vision system scan to determine where all of the items are located. FIG. 14 illustrates one example of this. In the embodiment  1400 , a conveyor  1450  is configured to recirculate the items  1440  back to the initial scanning location  1480 . The recirculation model may include a second vision system (not shown) as well as the picking of items  1440  from the recirculation side  1445  of the conveyor  1450 , for higher overall efficiency.  
         [0067]    Two laboratory automation schemes are represented by FIG. 15. In FIG. 15, the feet  1535  of the robotic device  1530  are docked to a tray  1520  of a plurality of wells  1525 . The tray  1520  be one of a plurality of trays situated in a pallet (not shown). The robotic devices  1530  will dock to the tray  1520  or pallet by mating docking pins  1545  to docking holes  1540 . Once the robotic device  1530  or devices have docked to the tray  1520  or pallet, the robotic devices  1530  can dispense simultaneously into the wells  1525 . The robotic devices  1530  are then refilled on the opposite side of the multi-head tracked robotic system  1500 .  
         [0068]    In a second, similar, laboratory automation scheme, newly filled robotic devices  1530  are cycled in to the filling station, while empty robotic devices  1530  are cycled to the opposite side of the multi-head tracked robotic system  1500  where they are refilled.  
         [0069]    While preferred and particular embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. Accordingly, the appended claims are intended to encompass all such modifications and changes as fall within the true spirit and scope of this invention.