Abstract:
A boom has a cylindrical body with a coupling flange at each end. The body is manufactured from a carbon fiber material. During construction of the carbon fiber body, an electronic feedback mechanism is embedded into the carbon fiber. The electronic feedback mechanism may be a simple electronic strain gauge. Optionally, the feedback mechanism may include a fiber optic cable woven into the carbon fiber weave.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/840,135, filed on Jun. 27, 2013. The entire disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure relates to geometric end effector systems used on a robot and, more particularly, to a boom end effector that has integral sensing technology. 
       BACKGROUND 
       [0003]    End effectors for use in assembly systems have been known in the prior art for many years. Generally, in many automated assembly systems, devices are used for holding and placing components and parts in a specified place so that a manufacturing, finishing or other intermediate step can be performed on the product being assembled or worked upon. These automated assembly systems generally employ many robots that minimize or eliminate the need for manual intervention, thus reducing the cost to the manufacturer of the labor and parts involved. The components used and made in such automated systems are typically made or moved by a robot via an arm or wrist all of which are well known methods in the prior art. Some of these methods may include having an end effector attached to the end of a robot arm and acquires a particular part. The end effector then either releases the part during the work or holds the part steady in a pre-specified position during the actual operation on the part. Other methods include using the robot arm or wrist to hold a tool to actually perform work on a part that is being held by other robots or other components in predetermined positions. 
         [0004]    Also, U.S. Pat. No. 7,609,020, issued Oct. 27, 2009 and U.S. Pat. No. 7,940,023, issued May 10, 2011, both entitled “Geometric End Effector System”, the specification and drawings of which are expressly incorporated by reference, illustrate an improved modular geometric end effector system that proposes a cost effective method of replacing and repairing each component connected to a robotic cell on the end effector of a robotic arm, wrist or the like. While this type of system utilizes a breakaway column system, it is not possible to determine the stress and strain on the particular end effector. Thus, it would be desirable to gain electronic feedback on the status of the jig, fixture or end effector built with the system. Also, it would be desirable to allow the jigs, fixtures or end effectors to become an add on system that, if possible, can determine if the operations are proceeding as normal or are not normal. 
         [0005]    The present disclosure provides the art with such a device. The present disclosure provides electric feedback as to the status of the jig, fixture or end effector built into the system. Also, the boom enables jigs, fixtures or end effectors to become an add-on system capable of processing whether or not the operations are being conducted satisfactorily or if the operation is not normal. 
       SUMMARY 
       [0006]    According to an aspect of the disclosure, a boom comprises a cylindrical body including a coupling flange at each end. The body is manufactured from a carbon fiber material. During construction of the carbon fiber body, an electronic feedback mechanism is embedded into the carbon fiber. The electronic feedback mechanism may be a simple electronic strain gauge. Optionally, the feedback mechanism may include a fiber optic cable woven into the carbon fiber weave. 
         [0007]    Accordingly to a second aspect of the disclosure, a geometric end effector system comprises a platform with a frame secured to the platform. A plurality of bases is arranged at predetermined positions on the frame. An anchor mount is secured to at least one of the bases. A component connects to the anchor mount. The component includes a boom. The boom includes a cylindrical body including a coupling flange at each end. The body is manufactured from a carbon fiber material. During construction of the carbon fiber body, an electronic feedback mechanism is embedded into the carbon fiber. The electronic feedback mechanism may be a simple electronic strain gauge. Optionally, the feedback mechanism may include a fiber optic cable woven into the carbon fiber weave. 
         [0008]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0009]    The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
           [0010]      FIG. 1  is a perspective view of a geometric end effector system. 
           [0011]      FIG. 2  is an exploded perspective view of a connection. 
           [0012]      FIG. 3  is a plan view of a boom. 
           [0013]      FIG. 4  is a cross-section view of  FIG. 3 . 
           [0014]      FIG. 5  is a perspective view of the boom. 
           [0015]      FIG. 6  is a perspective view of the boom of a second embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Example embodiments will now be described more fully with reference to the accompanying drawings. 
         [0017]      FIGS. 1 through 5  show one contemplated embodiment of the geometric end effector system  10  according to the present invention. The end effector system  10  includes a platform  12  that is preferably made of steel, however it should be noted that any other type of metal, plastic, ceramic, or composite may be used for the platform  12 . The platform  12  will have a variety of orifices therethrough to mate with any of the known robotic arms, robotic wrists or the like. The platform  12  may be of any known shape, such as a plate with the orifices therethrough, a circular, square, triangular, or any other shaped plate or any other type of platform known to connect to the end of a robot. The platform  12  is attached by any known fastening technique, i.e., chemical, mechanical or the like to a frame  14  which is preferably made of a steel material. However, it should be noted that the frame  14  may be made of any other known material such as any other known metal, plastic, ceramic, composite, natural material or the like. The frame  14  may have any known shape. The shape will depend on the environment in which the robotic cell will be used. The frame  14  will allow for a plurality of components to be connected thereto such that one robot arm may perform several functions or hold complex geometric parts for operations thereon or movement between stations in a manufacturing environment. 
         [0018]    Each frame  14  will have a plurality of base members  16  secured thereto. The base members  16  are secured to the frame  14  by any known mechanical or chemical bonding technique such as welding, fastening or the like. Each of the base members  16  will have a plurality of orifices  18  arranged at predetermined positions thereon. In the embodiment shown the orifices  18  are arranged along near or at each end thereof. Some of the orifices  18  may be threaded while some of the orifices may not be threaded. However, in some embodiments all orifices  18  may be threaded and in some other embodiments none of the orifices  18  are threaded. The base  16  generally has a rectangular shape with a predetermined thickness. In the embodiment shown three orifices  18  are arranged at or near each end of the base  16 . It should be noted that any known shape can be used for the base members  16  depending on the design requirements and space available for the base members  16  on the frame  14 . The base members  16  are generally made of a steel material, however it should be noted that any other metal, plastic, ceramic, composite or the like may be used for the base members  16  depending on the robotic cell and the environment such robot will be used in. 
         [0019]    Secured to the base member  16  is an anchor mount  20 . It should be noted that the anchor mount  20  may be secured to all base members  16  on a robot end effector system frame  14  or on just selected base members  16  depending on the components to be connected to the frame  14  of the robot end effector system  10 . The anchor mount  20  generally has a base  22  that mimics the shape of the base member  16 . The anchor mount base  22  in the present embodiment generally has a rectangular shape with a predetermined thickness. A plurality of orifices  24  are arranged through the thickness of the anchor mount base  22  to align with and mate with the orifices  18  in the frame base member  16 . 
         [0020]    Extending from generally a midpoint of the anchor mount base  22  on one side thereof is a cylindrically shaped member  26  extending therefrom. The cylindrical member  26  is fastened to the face of the anchor mount base  22  via any known fastening technique, such as welding or the like, or it is also contemplated to have cylindrical member  26  cast with the base  22  as one member, or made as an extrusion or machined. Arranged at an end of the cylindrical member  26  is a circumferential coupling flange  28 . The flange  28  has a predetermined diameter with a predetermined sized bore or orifice through a midpoint thereof. A plurality of slots  30  are arranged on the end face of the coupling flange  28 . The slots  30  extend a predetermined distance into the face of the flange  28 . The slots  30  are arranged on the face such that any number of degrees are located between the slots  30 . In the embodiment shown four slots  30  are positioned within the face of the flange  28 . The slots  30  are arranged at 90° intervals around the ring like face of the flange  28 . 
         [0021]    The anchor mount  20  is designed such that a breakaway point  32  occurs generally to where the flange  28  and cylindrical member  26  intersect. This intersectional point  32  between the flange  28  and cylindrical member  26  may be designed by either increasing or decreasing the thickness of the material used at the breakaway point  32  for the anchor mount  20 . The reduction of material will create a breakaway point  32  that will fail at a lower force than that of a breakaway point  32  that has a thicker material cross section therethrough. Other methods of creating a breakaway point  32  are also contemplated such as scoring the intersection between the flange  28  and cylindrical member  26 , pre-stressing, placing a plurality of notches there along, arranging a plurality of orifices therearound, using a different material, or any other contemplated and known method of creating a breakaway point  32  that will fail at a particular lower force in comparison to other components connected to the anchor mount  20  and within the end effector system  10 . The breakaway point  32  will create a specific point at which a predetermined force will break the anchor mount  20  in relation to all other components connected to the anchor mount  20  between the robot and the components being held by the end effector system  10 . 
         [0022]    A boom  36  and/or junction member  38  may be secured to the anchor mount  20  via a collar assembly  40 . The boom  36  which generally has a cylindrical shape with a bore through an entire longitudinal length thereof. The boom  36  will include a generally circular coupling flange  42  on both ends thereof. The boom  36  can be of any length or incremental length needed within the end effector system  10 . The boom  36  will also include a plurality of orifices  44  prearranged at predetermined positions such that accessories may be mounted to the boom  36  or the booms  36  may be connected to components connected thereto or to an anchor mount  20  via a safety harness or the like. The orifices  44  are predetermined size and arranged at predetermined intervals along the boom  36  depending on the design requirements and the components being held. The coupling flange  42  located at each end of the boom  36  have a plurality of slots  46  therein to align with the slots  30  on the anchor mount  20 , other junction members  38  or any other components. The slots  46  will have the same positioning around the end of the flange  42  and will have the same predetermined depth as that of the anchor mount flange  28 . The boom  36  may have a predetermined thickness thus creating a part that will be able to absorb forces greater than that at the breakaway point  32  of the anchor mount  20 . 
         [0023]    The junction members  38  generally will have at least one circumferential coupling flange  42  thereon but may have any number of coupling flanges  42  and faces thereon such as two face junction members, three face, four face, five face, or the like. These junction members  38  may allow for a connection to the anchor mount  20  at various angles, or with other various components connected thereto. Each of the faces of the junction members  38  will include a generally circumferential coupling flange  42  having slots  46  that are arranged in the same manner as those discussed for the anchor mount flange  28 . Other edge accessory members  48  may also be connected to or used as an end member which connects to a clamp or other component being held by the end effector system  10 . Generally, the edge accessory members  48  will have one circumferential coupling flange  42  arranged thereon but more than one may also be used. The flange  42  will include the same slots  46  arranged at the same intervals as those for the anchor mount flange  28 . The edge accessory components  48  will be capable of holding parts at predetermined angles and/or straight as shown in  FIG. 1 . 
         [0024]    The boom  36 , junction members  38 , edge accessory members  48 , other components and anchor mounts  20  are all interconnected with each other and fastened to one another in a multitude of combinations. The connections are created via a collar assembly  40 . The collar assembly  40  includes a first and second collar member  50  and a cross key  52 . The cross key  52  generally has an X-shape with a predetermined thickness. The predetermined thickness will be such that approximately half of the cross key  52  will extend into a slot  30 ,  46  on any of the coupling flanges  28 ,  42  while the other half of the cross key  52  will extend into an adjacent coupling flange  28 ,  42  of the other component being connected thereto The cross key  52  is arranged within all four of the slots  30 ,  46  and thus will secure the components being connected to one another such that no rotation can occur between the components after they are secured to one another with the collar assembly  40 . 
         [0025]    The body  60  of the boom  36  is manufactured from a carbon fiber material  62 . Additionally, any type of fiber reinforced material may be utilized. A feedback sensing element  70  is molded into the fiber reinforced material  62 . The sensing element  70  may be an electric strain gauge, fiber optic cable  74  or the like. The sensing feedback device  70  provides accurate real time information of what is occurring at the jig  76 , fixture  78 , or end effector  80 . This sensing feedback device  70  provides stress and strain of the boom  36  that indicates the deflection and force on the jig, fixture or end effector. This real time determination helps to improve the control of the system  10 . Thus, the fiber reinforced boom  36  enables the jigs, fixtures or end effectors to become add-on systems that determine the process and whether or not the operation are functioning satisfactory or if they are out of control. A plurality of wires  72  are connected with the sensing feedback device  70 . The wires  72  are coupled with the controller (not shown). 
         [0026]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.