Patent Abstract:
A robotic arm for use with a robotic system and methods for making and using the same are described. The arm can have multiple joints and can have one or more articulating end effectors. The arm and end effectors can have safety releases to prevent over-rotation. The arm can have individual cooling.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority to U.S. Provisional Application 61/438,168 filed 31 Jan. 2011 which is incorporated by reference herein in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates generally to the robotics field, and more specifically to a new and useful robotic arm system. 
       BACKGROUND 
       [0003]    Robot systems can be used in security situations, industrial settings, and for entertainment. The robot systems can provide audio and video information to a remote operator in dangerous situations such as bomb defusing, chemical spills, SWAT missions, and search and rescue operations. However, if an operator of a robot system encounters a situation requiring delicate manipulation of objects, for example examining an object or taking a chemical sample, it is difficult to accomplish. Thus, there is a need in the robotics field to create a new and useful robotic arm system. 
       SUMMARY OF THE INVENTION 
       [0004]    A robot system is disclosed. The system can have a mobile robot and a robotic arm system attached to the mobile robot. The robotic arm system can have an arm base, an arm, a gripper attached to the arm at an end effector attachment location, and a gripper override mechanism. The gripper override mechanism can have a sensor and a clutch. The clutch can have a linear slip interface. 
         [0005]    The system can have a captive fastener attaching the arm base to the mobile robot. The captive fastener can have a thumbscrew attached to the arm base. 
         [0006]    The system can have a motor and a gearbox. The gearbox can have a non-backdriveable, right-angle high-torque gearbox. The gearbox can have two stages of gears. The gearbox can have a first planetary gear attached to a motor, a right angle worm gear attached to the planetary gear at the motor, and a second planetary gear attached to the right angle worm gear. 
         [0007]    The gripper can be detachably attached to the robotic arm system at the end effector attachment location. The system can have a poker configured to be detachably attached to the robotic arm system at the end effector attachment location. The system can have a blower configured to be detachably attached to the robotic arm system at the end effector attachment location. 
         [0008]    The arm can have a payload interface. A camera connector can be attached to the payload interface. The arm can have a payload interface. An arm extension can be attached to the payload interface. 
         [0009]    The arm can have a payload interface. A second gripper can be attached to the payload interface. 
         [0010]    The robot can have a chassis. The arm base can have a base alignment feature. The base alignment feature can mate with a chasses alignment feature in the chassis of the robot. 
         [0011]    The system can have an expandable data bus comprising a node. The system can have at least one motor controller connected to the expandable data bus. The system can have a peripheral connected to the expandable data bus. The peripheral connected to the expandable data bus can be a camera. 
         [0012]    A robot system is disclosed that can have a mobile robot and a robotic arm system attached to the robot. The robotic arm system can have an arm base, an arm, a motor configured to drive motion of the arm, and a gearbox. The gearbox can have a non-backdriveable, right-angle high-torque gearbox. 
         [0013]    A robot system is disclosed that can have a mobile robot, and a robotic arm system attached to the robot. The robotic arm system can have an arm base, a gripper, and a cooling device that can have a fan. 
         [0014]    A robot system is disclosed that can have a mobile robot and a robotic arm system attached to the robot. The robotic arm system can have an arm base, a first arm, a first camera attached to the first arm, a second arm extending from the first arm, and a second camera attached to the second arm. The system can have a first light attached to the first arm and a second light attached to the second arm. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0015]      FIG. 1  is a schematic representation of a variation of the robotic arm system. 
           [0016]      FIGS. 2-4  are perspective drawings of a variation of the robotic arm system. 
           [0017]      FIG. 5  is a top perspective view of a variation of a mobile robot with the robotic arm system.  
           [0018]      FIG. 6  is a perspective view of a variation of the robotic arm system. 
           [0019]      FIG. 7  is a schematic representation of a drive component of a variation of the invention. 
           [0020]      FIGS. 8  is a perspective, partial see-through view of a variation of the robotic arm system. 
           [0021]      FIG. 9  is a close-up view of a portion of  FIG. 8 . 
           [0022]      FIGS. 10-16  are exploded views of various components of variations of the robotic arm system. 
           [0023]      FIG. 17  is an electrical schematic diagram of various components of a variation of the robotic arm system. 
           [0024]      FIG. 18  is a close-up, cut-away, partially see-through perspective view of a variation of the robotic arm system. 
           [0025]      FIG. 19  is a close-up, partially see-through view of a portion of  FIG. 18 . 
           [0026]      FIG. 20  illustrates a component of a variation of the robotic arm system. 
           [0027]      FIGS. 21-23  illustrate a variation of the mounting and attaching elements for a variation of the robotic arm system. 
           [0028]      FIG. 24  is a perspective drawing of a variation of the robotic arm system. 
           [0029]      FIG. 25  is a cut away perspective drawing of a variation of the robotic arm system. 
           [0030]      FIG. 26  is an exploded perspective drawing of a component of a variation of the robotic arm system. 
           [0031]      FIG. 27  is a variation of section  300  of  FIG. 24 . 
           [0032]      FIG. 28  is a cut away drawing of an alternative joint structure for elbow joints, shoulder joints and wrist joints on the robotic arm system. 
           [0033]      FIG. 29  is a partial cut-away view of a variation of the gearbox. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    The robotic arm system  90  can be attached to and be a component of a robotic system  10 . As shown in  FIGS. 1-5 , the robotic arm system  90  can include a base  100 , at least one modular arm  200 , and at least one end effector  300 . 
         [0035]    As shown in  FIGS. 2-4 , the robotic arm system  90  can be constructed in a variety of configurations, depending on the characteristics of the robotic system  10 . As shown in  FIG. 2 , the robotic arm system  90  can fold down into a low profile, enabling a robotic system  10  to have a low clearance. As shown in  FIG. 3 , the end effector  300  can be nested behind the base  100 , for example, to enable the end effector  300  to perform additional functionality, for example using a camera to capture images, while the arm is in a stored position. 
         [0036]    As shown in  FIG. 4 , the shoulder joint can be located behind the base  100 . The shoulder joint can narrow the profile of the modular arm  200 , for example to add an additional modular arm extension component to the robotic arm system  90 . The robotic arm system  90  can have multiple motor systems controlling stages of the modular arm  200 . The robotic arm system  90  can be used to press against the ground or a stationary and anchored object to flip the robotic system  10 , such as when the robotic system  10  needs to be righted (i.e., turned right-side up). The robotic arm system  90  when attached to a robotic system  10 , can adjust the weight distribution of a robotic system  10 , by actuating the arm to a specific position, for example to minimize flipping the robotic system  10  over, the robotic arm system  90  may extend the arm to counterbalance a portion of the weight of the combined robotic system  10  and robotic arm system  90 . This can balance the robotic system  10  on a ledge or precipice, stabilizing the robotic system  10  as the robotic system  10  navigates a steep embankment or uneven surfaces. The robotic arm system  90  may push or propel the robotic system  10  up or down an inclined surface, or over an obstacle. 
         [0037]    As shown in  FIG. 2 , a protection device  500  can be used to reduce wear and tear on the robotic arm system  90  as the robotic arm system  90  interacts with the environment. The protection devices  500  can include padding, flexible protection devices resembling kneepads or elbow pads, helmets, plastic domes or shells, hard plastic mushroom caps, foam caps, foam padding tape, rubber bumpers, metal bumpers, thermal shielding, insulation, chemically inert coatings and sleeves, flexible membranes, putty, clay, galvanizations, or combinations thereof. The protection devices  500  can protect the base  100 , modular arm  200 , a modular arm joint, such as an elbow joint  250 , at least one end effector  300 , a camera  229 , any other suitable part of the robotic system  10 . 
         [0038]    As shown in  FIGS. 7 and 9 , a motor system  400  can include a motor controller  410 , a motor  420 , a gearbox  430 , a release device  440 , and a gear interface  450 . The motor controller  410  can be a brushless, brushed or stepper motor controller for a DC motor. The motor system  400  can have first and second motor controllers  411  and  412 . The motor controllers  410 ,  411 ,  412  can have absolute and/or relative sensors, such as potentiometers, optical encoders, magnetic non-contact sensors, or combinations thereof, for example for tracking the position of the motor. 
         [0039]    As shown in  FIG. 9 , a motor controller  115  can include a magnetic non-contact sensor  199  mounted on the PC board of motor controller  115 . A rod  198  can be keyed to the joint spinning magnet  197  at the end near the magnetic non-contact sensor  199 . The rod  198  can be non-ferrous to improve the functionality of the joint spinning magnet  197 . The motor  420  can be a brushless motor, a brushed motor or stepper motor. The gearbox  430  can be optional. 
         [0040]      FIG. 29  illustrates that the gearbox  430  can be a 1 to 4 gearbox, a 1 to 35 gearbox. The gearbox  430  can be have planetary, spur, helical, bevel hypoid gears, or combinations thereof. The gearbox  430  can be non-backdrivable, right-angle high-torque gearbox, which can allow for a smoothly operating control loop that can use three stages of gearboxes (e.g., planetary at motor, right angle worm/hypoid, then final planetary). For example, the high-torque gearbox can deliver a maximum torque from about 10 Nm to about 100 Nm, more narrowly from about 20 Nm to about 60 Nm, for example about 45 Nm. 
         [0041]    The gearbox  430  can have a first gear stage  4301 , connected to the motor and a second gear stage. For example, the first gear stage  4301  can be or have a planetary gear. The second gear stage  4302  can also be connected to a third gear stage  4303 . The second gear stage  4202  can have or be a hypoid or worm gear. The second gear stage can make a right turn from the first gear stage  4301  to the third gear stage  4303 . The third gear stage  4303  can also be connected to an actuator or lever, for example an arm. The third gear stage  4303  can be a planetary gear. The third gear stage  4303  can be obscured by the third gear stage case. The gearbox  430  can deliver power at a perpendicular angle to the direction in which the gearbox  430  received the power. 
         [0042]    The gearbox  430  can be connected to a release device  440 . For example, the release device can connect between the gearbox  430  and the gear interface  450 . The gear interface can connect directly or indirectly to the arms and/or the end effectors  330 . The release device  440  can be a linear slip clutch, a ball detent, a slip clutch, any other mechanical or electromechanical release device, or combinations thereof. The gear interface or gearing interface  450  may include a shaft with a worm pinion interfacing with gears. The shaft can be supported by bearings, spacers, washers, thrustbearings, shaft supports, motor supports, or combinations thereof. The gearing interface  450  can include a hypoid-gearing interface, a spur gear interface (e.g., instead of a pinion-gear interface) and/or a planetary gear interface. 
         [0043]    The robotic system  10  can have one or more motor systems  400 ,  401 ,  402 ,  403 ,  404 ,  405 . Each motor system in the same robotic system  10  can be the same as every other, the same as some of the other, or different than every other motor system throughout the same robotic system  10 . Multiple motor systems for a single robotic system  10  can each be customized for ranges of motion, degree of movement precision, or any other suitable application. The robotic system can have from about one to about ten actuators. 
         [0044]    The base  100  can attach to the robotic system  10 . As shown in  FIGS. 2-6  and  FIG. 8 , the base  100  can attach to at least one payload port on the robotic system  10 . The base  100  can mechanically support the robotic arm system  90 . The base  100  can mechanically attach the robotic arm system  90  to the robotic system  10 . Captive fasteners, such as thumbscrews that are attached to the arm base such that they can remain fixed to the arm base as the arm base is moved, can attach the base  100  to the robotic system  10 . The captive fasteners can be held with the base  100  for quick (e.g., tool-less) attachment and/or detachment. For example, the captive fasteners can be held in place by mechanical features on the base  100 , held in place by springs, locking mechanisms, cables attached to the base, or combinations thereof. 
         [0045]    As shown in  FIG. 20 , the base  100  may contain guiding features at the interface between the robotic system  10  and the base  100  of the robotic arm system  90 , for example grooves  12  mated to rails  11  on the body of the robotic system  10 , to help align the robotic system  10  with the base  100  during assembly. 
         [0046]    As shown in  FIG. 21 , cam follower mounts  22 ,  23  can guide the base  100  onto the chassis of the robotic system  10 . The cam follower mounts  22 ,  23  can be removable by a user, for example, if they are not needed, or if the user would like the arm to possibly detach itself from the robotic system  10 . 
         [0047]    As shown in  FIG. 22 , at least two arm alignment features  13 ,  14  can be keyed to make sure the robotic arm system  90  is located in the correct position on the robotic system  10 , including front-back and left-right positioning. The arm alignment features  13 ,  14  can be as long as possible without digging into the side seal of the robotic system  10 , but alternatively the alignment features  13 ,  14  can dig into the side seal of the robotic system  10 . At least two fasteners  17 ,  18  can hold down the robotic arm system  90  to the robotic system  10 , and can immobilize the ejector as well, such that the ejector cannot be loosened until the fasteners  17 ,  18  are loosened. The fasteners  19 ,  20  can keep the ejector handle  24  sliding with the base  100 . The cam follower slots  15 ,  16  can provide a mechanical advantage for the ejection of the robotic arm system  90  from the robotic system  10 . The cam follower slots  15 ,  16  can include a 20-degree angle inside the cam following path—this can affect the insertion force required to attach the robotic arm system  90  to the robotic system  10 , in that less insertion force can be required due to the weight of the robotic arm system  90  and gravity assisting the user during the attachment process. 
         [0048]    As shown in  FIG. 23 , the base  100  of the robotic arm system  90  can also include a foot  25 , which can protect the connector pins  26 ,  27  from damage or bending if the robotic arm system  90  is set on a surface. 
         [0049]    The base  100  can have a microprocessor controlling the motor controllers for each motor and communicating with the control board of the robotic system  10 . The microprocessors can have and execute control logic software. The motor controllers for each motor can be housed in the base. The motor controls can be connected via wiring to the motors and/or the control board of the robotic system  10 . The motor controllers can be housed right next to the motors. The motor controllers can all (or some) be wired directly to a port in the base  100  where the motor controller wiring will connect to the control board of the robotic system. The base  100  can include control logic connected to a controller board on the robotic system  10 . The base can include the arm control logic that is controlled by the control board, and/or the arm control logic can be integrated onto the control, board. 
         [0050]    The base  100  can interface with the control system in the robotic system  10 . The base  100  may be connected to the robotic system  10  via at least one USB connection, wired and/or wireless connections, Ethernet connections, or combinations thereof. The base  100  can receive control signals from the control board of the robotic system  10 . An operator can operate an operator control unit (OCU) for the robotic system  10 . Control signals generated by the OCU, automatically or in response to the operator&#39;s input, can be processed and controlled at the system level by a main controller of the robotic system  10 , and delivered to the base  100 . The base  100  may communicate directly with an OCU for a robotic system  10  or an entirely independent and separate OCU. The robotic arm  90  may be controlled by an autonomous control program in a microprocessor giving the microprocessor autonomous capability to maneuver or manipulate the robotic arm system  90 . Commands could come from the Internet via wifi, remote computer terminal, GPRS modem, satellite phone, mobile phone, infrared, Ethernet, Firewire, other wireless or wired connection protocols, or combinations thereof. 
         [0051]    The base  100  may include a rotary joint  96  to provide axial rotation for the robotic arm system  90 . The rotary joint  96  can be underneath the robotic arm system  90 , for example between the interface (i.e., the connection between the body of the robotic system  10  and the base  100 , as shown in  FIG. 20  and mentioned above in paragraph 0016) with the robotic system  10  and the robotic arm system  90 . The rotary joint  96  can be in the base  100 , the lower shoulder gearbox output housing  201 , or in the lower arm  225 . 
         [0052]    As shown in  FIGS. 10-11 , the base  100  of a robotic arm system  90  can have cable glands  111 ,  112  that can connect the robotic arm system  90 , for example through cables (not shown) or direct connections through the cable glands  111  and  112 , to the control and power source of the robotic system  10 . The cable glands  111 ,  112  can deliver power and/or control signals to the motors, gearboxes, and other end effectors  300 , cameras, and other devices on the robotic arm system  90 , or combinations thereof. 
         [0053]    The shoulder housing  117  can protect and seal the components of the base  100 , including the robotic arm control board  116 . The shoulder housing  117  can provide a mounting or fastening interface to the frame or structure of the robotic system  10 . The shoulder housing electronics cover gasket  114  can seal the shoulder housing electronics cover  113  and can protect and seal the motor controller  115  and the robotic arm control board  116  from the environment. The motor controller  115  can be a brushless motor controller, for a DC motor or a stepper motor. 
         [0054]    The gear  118  can be attached to a first side of the joint while interfacing with a small gear on a second side of the joint, opposite to the first side of the joint, that turns a potentiometer. This creates angular feedback between the two housings (i.e., first housing  117 , and second housing is not shown in the figures) of the joint, regardless of the clutch status (e.g., whether the clutch is open or closed), motor position, motor speed, or combinations thereof. The gear  118  can interface with a gear-connected motor in the lower shoulder gearbox output housing  201 . The shoulder o-ring  119  can seal the interface between the shoulder housing  117  and lower shoulder gearbox output housing  201 , around the lip of the shoulder housing  120 . The lip of the shoulder housing  120  can be mated to the lower shoulder gearbox output housing  201 . 
         [0055]    The sungear  135  can rotate around the shoulder shaft  121  on the sungear bearing  136 . The sungear  135  can interface with at least one planetary gear,  133 ,  134 . The planetary gears  133 ,  134  can be attached to a carrier plate (not shown in perspective) rotating with a bearing  131  between the carrier plate and the shoulder shaft  121 . The planetary gear  133 ,  134  can interface with a single stage ring gear  132 . The bearing  131  can be held in place with a snap ring  130 . 
         [0056]    The ring gear  132  can interface (e.g., the clutch disk/pack interfacing with the housing piece, which acts as pressure plate) with a clutch such that an external torque (e.g., about 100 N-m) on the robotic arm system  90  can be applied without damaging the motor  151 . The clutch can slip, for example protecting the gear train and motor. The clutch plates  123 ,  129  protect the internal portions of the clutch and can interface with other rotary parts. The clutch plate  129  can interface with the shoulder shaft  121 , and can enable rotary power from the planetary gearset to be transferred through the clutch friction disk clutch packs  124  to the shoulder gearbox output housing  201 . The spacers  125 ,  128  can hold a bearing  126  inside of the shoulder clutch packs  124 ,  127 . For example, when the clutch packs  124 ,  127  are pressed together, rotary power can be transferred from the two clutch packs  124 ,  127  to the shoulder gearbox output housing  201 . The shoulder clutch bellevue  122  can compress the clutch packs  124  and  127  together. The shoulder clutch bellevue  122  can be made of steel, titanium, aluminum, plastic, or combinations thereof. A gear  137  can interface with a gearbox  152  and a gear  138 . An additional gear  138  can interface with a gear  137  and the shoulder worm shaft  149 . 
         [0057]    The shoulder worm gear  140  can be aligned and supported by the worm gear bearing support  141 . The worm gear bearing support  141  can rotationally support a ball bearing  142  around the sungear inner bearings  136  and  143 . The sungear inner bearing  143  can be held in place with a snap ring  144 . An internal washer  139  can be used to hold the shoulder worm gear  140  in place. 
         [0058]    The shoulder housing cover  145  and the shoulder housing gasket  146  can seal the shoulder housing and protect the components housed inside from moisture, particles, temperature and other elements, and can enable easy access for repairs, replacements or modifications. 
         [0059]    The shoulder motor mount  147  can attach, support and align the motor  151  within the shoulder housing  117 . The motor  151  can be a brushless, brushed, or stepper motor. The motor  151  can be connected to a 4-to-1 gearbox  152 . The 4-to-1 gearbox  152  can enable various speeds and precisions of articulation of the shoulder. The gearbox  152  can interface with a shoulder worm shaft  149 . The shoulder worm shaft  149  can be aligned and supported with bearings  155 ,  156  and thrustbearings  153 ,  154  located around the shaft and between the shoulder worm shaft  149 , the shoulder motor mount  147 , and the shoulder worm bearing support  150 . The elbow worm pinion  148  is also adapted to turn with the shoulder worm shaft  149 , and interfaces with the shoulder worm gear  140 . 
         [0060]    The thrustbearings  153 ,  154  and the bearings  155 ,  156  can protect the rotation of the shoulder worm shaft  149 . The thrustbearings  153 ,  154  can be about 8 mm in diameter. The bearings  155 ,  156  can be about 14×8×4 mm bearings. The bearing  142  can be or have about 30×42×7 mm ball bearing The bearing  131  can be a ball bearing about 32×20∴7 mm. 
         [0061]    As shown in  FIGS. 2-6 , the modular arm  200  can have a lower arm  225  and an upper arm  275 . A lower elbow joint or shoulder joint can connect the lower arm  225  to the base  100 . An upper elbow joint  250  or shoulder joint can connect the lower arm  225  to the upper arm  275 . The upper arm  275  can be connected to at least one end effector  300 . The joint  250  can be an elbow joint, a wrist joint a shoulder joint, or combinations thereof. At least one end effector  300  may be connected to additional joints or modular arms. The modular arm components and/or joints may include payload interfaces to expand functionality of the robotic arm system  90 . The modular arm  200  may include telescoping sections, and electronic or mechanical interfaces for additional modular arm connections, components, and/or devices. 
         [0062]    As shown in  FIGS. 2-6  and  FIGS. 12-14 , the lower arm  225  can be connected to the shoulder joint of the base  100  using the lower shoulder gearbox output housing  201 . The lower arm  225  can be connected to the upper arm  275 . The upper arm  275  near the elbow joint  250 , the elbow joint  250 , the lower arm  225  near the elbow joint, or combinations thereof, can be sealed and protected by the elbow gearbox input housing  251 . The upper arm  275  can be connected to the lower arm  225  at the elbow joint. The upper arm  275  near the elbow joint  250 , the elbow joint  250 , the lower arm  225  near the elbow joint, or combinations thereof, can be sealed and protected with the elbow gearbox output housing  252 . 
         [0063]    The internal sungear  257  can interface with the elbow worm gear  255 . The interface between the internal sungear  257  and the elbow worm gear  255  can be keyed. The elbow ring gear bearing support  256  can hold a bearing  258  around the interface between the internal sungear  257  and the elbow worm gear  255 . The bearing  258  can be held in place with a snap ring  259 . A washer  260  can provide a thrust bearing surface for the planetary gears  262 . 
         [0064]    The internal sungear  257  can interface with at least one planetary gear  262  attached to a carrier plate  264 . The planetary gear  262  attached to the carrier plate  264  can interface with a ring gear  261 . An elbow ring gear bearing support  265  can align the bearings  263 ,  266  around the carrier plate shaft  264 . 
         [0065]    The elbow clutch pressure plates  267 ,  271  can hold a bearing  268  inside of the elbow clutch packs  269 ,  270 . For example, when the elbow clutch packs  269 ,  270  are pressed together, rotary power can be transferred from the clutchpacks  269 ,  270  to the elbow joint housing  252 . The elbow clutch pressure plates  267 ,  271  can be keyed to avoid rotation movement around the elbow worm shaft  281 , for example transferring torque from the surfaces of the clutch pressure plates  267 ,  271  to the clutchpacks  269 ,  270 . The elbow clutch bellevue  272  can provide force that can compress the elbow clutch packs  269 ,  270  together. The elbow clutch bellevue  272  can be made of steel, titanium, aluminum, plastic, or combinations thereof. The elbow clutch nut  273  can support the elbow clutch bellevue  272 . The elbow clutch nut  273  can hold the elbow clutch bellevue  272  in place on the elbow worm shaft  281  as the elbow clutch bellevue  272  applies pressure on the elbow clutch pressure plates  267 ,  271  and the elbow clutch packs  269 ,  270 . The elbow clutch nut  273  can be adjusted to adapt the spacing. As the surfaces wear down on the clutch packs the clutch nut can be adjusted to keep the adjacent parts held tightly together, for example to maintain maximum torque transfer. The elbow clutch nut  273  can include a starred washer, for example for spreading the load of the bellevue  272 . The elbow clutch nut  273  can include a variety of locking mechanisms, keys, set screws, pins, washers, or combinations thereof, to keep the elbow clutch nut  273  from rotating with respect to the threaded elbow worm shaft  281  during use. 
         [0066]    The motor  277  can be connected to a 14--to-1 gearbox  278 . The elbow worm pinion support  279  can align and/or support the elbow worm shaft  281 . 
         [0067]    As shown in  FIG. 13 , the elbow sensor gear  217  can interface with an elbow worm pinion  284  attached to a gear motor system for the upper elbow joint  275 . The elbow sensor gear  217  can rotate with the upper arm relative to the lower arm, when the gear motor system for the upper elbow joint  275  is actuated. The sensor gear  217  can send a position value of the upper arm to the control microprocessor. 
         [0068]    As shown in  FIGS. 13-14 , the elbow housing cover gaskets  216 ,  220  can seal the elbow housing covers  215 ,  221  and can protect and seal the components of the elbow joint  250 . The elbow clutch cap gasket  222  can seal the elbow clutch cap  223 , and can protect and seal the components of the elbow joint  250 . 
         [0069]    The o-rings  218 ,  219 ,  280 ,  287  can seal the motor  277 , gearbox  278  and other components from moisture, particles and other elements. The o-rings  219 ,  280  and  287  can be about 1.5 mm in thickness with about a 40 mm diameter. The o-ring  218  can be about 2 mm in thickness with about a 47 mm diameter. 
         [0070]    The thrustbearings  283 ,  285 , and the bearings  282 ,  286  can protect the rotation of the elbow shaft  281 . The thrustbearings  283 ,  285  can be about 8 mm in diameter. The bearings  282 ,  286  can be about 14×8×4 mm. 
         [0071]    The I/O connector  227  can connect to additional input/output devices, which may include Ethernet, USB, IEEE 1394 (FireWire), audio, or combinations thereof. The I/O connector  227  can communicate with the robotic arm control board  116 , and/or the control board of the robotic system  10 . The I/O connector can be USB, and can support up to  127  extra devices (as per the USB specification). For example, the I/O connector can have 1 to 127 nodes available. Additional devices such as the camera  229 , or additional motors can be attached to the USB bus, and managed by a USB controller in software or hardware. The individual motor controllers for each axis of motion of the robotic arm system  90  can also be attached to and controlled via the USB bus. 
         [0072]    The camera connector  228  can be connected to the camera  229 . The camera connector  228  can communicate with the control board of the robotic system  10 . The camera  229  can connect to the camera connector  228 . The camera  229  can be a webcam, a forward-looking infrared (FLIR) camera, CCD, CMOS, CCIQ, multiple cameras, a zoom camera, wide angle camera, or any combinations thereof. Localized lighting for each camera, such as LED&#39;s, IR LED&#39;s, a camera flash, or any other suitable lighting source or combination thereof may also be attached to the camera connector  228 , the camera  229 , or an I/O connector  227 . 
         [0073]    The robotic arm system  90  can have a supplemental camera. For example, the supplemental camera can be attached to a boom or mini arm extending from the robotic arm. The supplemental camera can be positioned to look down at the primary camera  229  and/or the gripper. For example, the supplemental camera can provide a second, simultaneous view from a different perspective than the primary camera  229 . The visual data from supplemental camera and the primary camera  229  can be processed with the relative position data for each camera (e.g., from respective sensors, such as potentiometers) to create a three-dimensional image or a navigatable virtual space. The primary camera  229  can have a primary light attached to the primary camera  229  or on the arm adjacent to the camera  229 . The supplemental light can have a supplemental light attached to the supplemental camera or on the boom or arm adjacent to the supplemental camera. 
         [0074]    As shown in  FIGS. 1-3 , an end effector  300  can be attached or detached at the end of the robotic arm  300 . The end effector can be attached at any portion of a modular arm  200  including a lower arm  225 , an upper arm  275 , or modular arm joint  250 , interfacing through the lower arm elbow joint housing  251  or the upper arm elbow joint housing  252 . The robotic arm system  90  can have multiple end effectors  300 . Each end effector can interact with the environment and can provide additional functionality (i.e., different than the other end effectors) to the robotic arm system  90  and/or the robotic system  10 . The end effector  300  can be detachable and replaced with en alternate end effector  300 . The end effector  300  can have one or more grippers, hooks, shovels, blowers, winches, pokers, sampling devices, pressure sensitive devices, cameras, microphones, chemical sensors, optical sensors, temperature sensors, or combinations thereof. The blower can be a pressurized blower, for example a compressed air delivery device, pressure vessel (e.g., can) of compressed air, fan, or combinations thereof. 
         [0075]    The end effector  300  can be attached to a wrist joint  98  at the end of the modular arm  200  to enable additional degrees of motion and precision control. 
         [0076]    As shown in  FIG. 16 , the end effector  300  can include a motor  301 . The motor  301  can be connected directly or through a gearbox to the gripper shaft  306  to actuate at least one gripper finger  330 . The motor  301  can be connected to the gripper shaft  306  through a gearbox  302  and a clutch device  305 . The clutch device  305  can be a continuous slip clutch, a ball-de-tent, or a combination thereof. The gearbox  302  can be about a 189-to-1 gearbox. The gripper motor  301  can be mounted on a gripper motor mount  303 . One or more gripper motor mount standoffs  304  can be used, for example if extra spacing is needed within the arm for extra components such as a clutch device  305 . The gripper motor mount standoff  304  can be made of aluminum, any structural metal, resin, plastic, composite, or combinations thereof. 
         [0077]    The gripper worm pinion support  308  can support and align the elbow worm pinion  312  on the gripper worm shaft  316 . The gripper worm pinion support  308  may include interfaces for sealing with o-rings  307 , 309 . The gripper worm pinion support  308  can interface with the gripper housing  315 . The gripper worm pinion support  308  can interface with a wrist joint, for example to provide an additional axis of rotation to at least one gripper finger  330 . 
         [0078]    The gripper housing  315  can contain a gripper worm shaft  316 . The gripper worm shaft  316  can interface with an elbow worm pinion  312 . The elbow worm pinion  312  can interface with at least one gripper worm gear  322  inside the gripper housing  315 . 
         [0079]    The elbow worm pinion  312  can interface with two identical gripper worm gears. Each gripper worm gear can torque a corresponding gripper finger  330 . The gripper worm gear  322  can interface with the gripper worm shaft  316 . The gripper worm shaft  316  can interface with the gripper shaft torquer  329 , for example to torque a gripper finger  330 . The gripper housing can be closed and sealed with a gripper housing cap  324 . The gripper housing cap  324  can align and protect the components inside the gripper housing  315 . 
         [0080]    The gripper shaft torquer  329  can interface with the gripper finger  330  via the gripper digit  331 . The gripper shaft torquer  329  can interface with the gripper worm shaft  316 . For example when the gripper worm shaft  316  torques, the gripper shaft torquer  329  can torques the entire gripper finger  330 . The interface between the gripper shaft torquer  329  and the gripper digit  331  can be keyed. The interface between the gripper shaft torquer  329  and the gripper worm shaft  316  can be keyed. The keying can be a hex-keying pattern. 
         [0081]    The gripper worm shaft  316  can be protected and aligned using shims  317 ,  320 ,  323 . The shim  317  can be about 14×8×0.3 mm. The shim  320  can be about 14×8×0.1 mm. The shim  323  can be about 14×8×0.1 mm. The gripper oil seal  318  can seal in lubricant to protect and align the gripper worm shaft  316 . The bearing  319  can be about 14×8×4 mm. 
         [0082]    The gripper locking hub  321  can interface with the gripper worm shaft  316 , and the gripper worm gear  322 . When the gripper worm gear  322  rotates, the gripper kicking hub  321  can transmit torque to the gripper worm shaft  316 . 
         [0083]    The end effecter  300  can include at least one gripper finger  330 . The gripper finger  330  can include a gripper digit  331 . The gripper digit  331  can be connected to a gripper grip  333  using a fastener such as a shoulder bolt  332 . The gripper finger  330  may include a gripper pad  334 , for example to protect fragile objects or surfaces the gripper finger  330  contacts. The gripper pad  334  can be made of foam rubber, elastomers, synthetic and natural rubbers, or combinations thereof. 
         [0084]    The o-rings  307 ,  309  can seal the gripper motor  301 , gearbox  302  and clutch device  305 . The o-rings  307 ,  309  can protect the gripper motor  301 , gearbox  302  and clutch device  305  from moisture, particles and other elements. The o-rings  307  and  309  can be about 1.5 mm thick and about 40 mm in diameter around the entire o-ring. 
         [0085]    The thrustbearings  311 ,  313 , and the bearings  310 ,  314  can protect the rotation of the gripper shaft  306 . The thrustbearings  311 ,  313  can be about 8 mm in diameter. The bearings  310 ,  314  can be about 14×8×4 mm. 
         [0086]    The bearing  325 , o-ring  326 , gripper oil seal  327  and shim  328  can seal, align and protect the rotation of the gripper finger  330 . The bearing  325  can be about 14×8×4 mm. The o-ring  326  can be about a 1.5 mm internal diameter thickness with about a 36 mm diameter. The gripper oil seal  327  can be a single lip or double lip shaft seal. The shim  328  can be about 14 mm by about 8 mm by about 0.3 mm. 
         [0087]    As shown in  FIG. 17 , the power and control wiring for the end effector  300  can be fed through hollow portions of the modular arm  200 . Wiring to connect each motor controller to the control board of the robotic system  10  or the robotic arm system  90  can go through mouse holes and other mechanical clearances. The wiring can be routed through the centers of the gears and shafts. The motor controllers may be connected to a centralized motor controller. The centralized motor controller can receive inputs from encoders on one or more elbow motors, shoulder motors, elbow angle sensors, shoulder angle sensors, wrist motors, and wrist position sensors, or combinations thereof. Multiple devices, including an LED driver, a camera controller, a zoom module, and additional payloads can be connected to an additional bus connection, for example a Universal Serial Bus (USB). The bus may be centralized at any point throughout the robotic arm system. The bus may be distributed in any fashion across the base  100 , the modular arm  200 , and/or the end effector  300 . The control wiring may be enclosed in a sheath or a conduit. The sheath or conduit may be housed internally or externally relative to the robotic arm system  90 . For example the control and power wiring could be fed from the shoulder casing, through the shoulder arm housing  201 , through the lower arm  225 , through both the lower elbow joint housing  251  and the upper elbow joint housing  252  of the elbow joint  250 , and through the upper arm  275  to interface with the end effector, or any combination thereof. The wiring path may terminate at any point to interface with another end effector, or another device, such as a camera, a microphone, a sensor, a sprayer, a blower, or any combination thereof. 
         [0088]      FIGS. 18 and 19  illustrate that the end effector  300  can have an end effector override mechanism. Sensors, such as two “through hole” potentiometers  398 ,  399  that can sense the rotation of the wrist joint, and can provide override protection. The two potentiometers  398 ,  399  can read 360 degrees or about 360 degrees of rotation of the wrist joint about an axis of rotation concurrent with the longitudinal axis of the end effector  300  and/or upper arm  275 . The position and angle of the gripper finger  330  can be determined by the slider potentiometer  397 . The slider potentiometer  397  can sense a gripper position. An additional slider potentiometer  396  can sense the acme nut  394  position, the position of the lead screw  395 , the position of the lead screw  395  into the acme nut  394 , rack  393  or combinations thereof. When the potentiometers detect that the position, velocity, acceleration or jerk (i.e., change of acceleration with respect to time) of the rotation of the gripper finger  330 , acme nut  394 , the lead screw  395 , rack  393 , or combinations thereof, is beyond an acceptable limit, the potentiometers signal can trigger (e.g., through a processor) a signal to activate the release device  440  to disengage the gearbox  430  from the gear interface  450 , for example by opening the clutch. The clutch in the release device  440  can additionally be designed to mechanically slip when the position, velocity, acceleration or jerk (i.e., change of acceleration with respect to time) of the rotation of the gripper finger  330 , acme nut  394 , the lead screw  395 , rack  393 , or combinations thereof, is beyond an acceptable limit. 
         [0089]    The brass acme nut  394  can slide inside of the rack  393 . The rack  393  can move in a linear motion to open and close the gripper finger  330 . When a large, overloading force is applied to the gripper finger  330 , the overloading force can be transferred to the rack  393  in the. form of a linear motion. The transfer of the force can overcome the press-fit between the rack  393  and gripper finger  330 , causing the difference in the two potentiometer values to change. That way, the logic software can conclude that the gripper finger  330  was stressed, and can correct the potentiometer values by closing the gripper finger  330 , and using the motor to force the acme nut  394  to slide inside of the rack  393 . 
         [0090]    Another end effector  300  is shown in  FIGS. 24-27 . As shown in  FIG. 24 , a As shown in  FIGS. 26-27 , this end effector  300  can use identical gripper digits  331 ,  337  that can be articulated with the motion of a single rack  393 . 
         [0091]    The gripper digits  331 ,  337  can be identical to improve manufacturing, servicing, and assembly of the end effector  300 , but can alternatively be different digits or mechanical devices, depending on the functionality of the end effector  300 . 
         [0092]    The gripper grip  333  can be aligned or angled with a finger alignment plate  335 . The finger alignment plate  335  can interface with the gripper grip  333  using a keyed interface or other interlocking or non-interlocking interface, but any suitable interface can be used. The finger alignment plate  335  can adjust the angle or alignment of the gripper grip  333 . 
         [0093]    The digit locking plate  336 ,  338  can attach, support and align the gripper digits  331 ,  337  in position around a rack  393 , such that when the position of the rack  393  is adjusted, the gripper digits  331 ,  337  can move simultaneously. Gripper digits can be fixed relative to the rack  393  or another gripper digit. 
         [0094]    As shown in  FIG. 28 , an alternative joint structure for elbow joints, shoulder joints and wrist joints on the robotic arm system  90  can include at least two linked elements in the joint  2811 ,  2812 , which can be connected by a shaft  2815  which can interface with a hypoid gear  2816  inside linked element  2812 , and can also interface with a friction clutch  2814  or slip clutch or other mechanical release inside linked element  2811 . A single sensor  2818  can track the movement of the shaft, however, Even though linked elements  2817  and  2818  can be limited to 180 degree rotation, since the shaft  2815  can rotate 360 degrees due to the slip clutch, using at least two sensors  2817 ,  2818  can be used to more accurately track the position of the joint elements with respect to one another, measuring the rotation of the shaft  2815  as it rotates on the hypoid gear side (inside linked element  2812 ) and on the friction clutch side (inside linked element  2811 ) particularly when the friction clutch is slipping on the interface to the joint element  2811 , and the difference in movement can be calculated from the relative measurements of the sensors  2817 ,  2818 . The sensors  2817 ,  2818  can be potentiometers, but may also be optical wheel encoders, or any other suitable sensor. The inside  2819  of the shaft  2815  can be used for a wire pass. 
         [0095]    A cooling device can be attached to the base  100  or any joint that uses a motor controller for active cooling in extreme operating conditions (e.g. high temperatures). The cooling device can use heat pipes to pull heat out of the electronics and motors toward a heatsink that is cooled by a blower/fan on the outside of the arm. The cooling device can be configured to perform a refrigeration cycle and have a compressor and an evaporator. The cooling device can be configured to cool the motors and/or joints. The robotic arm system  90  can have a thermostat that can turn the cooling system on or off, for example, based on the temperature of a component, such as the motors and/or joints. 
         [0096]    Throughout the entire robotic arm system  90 , fasteners such as machine screws, bolts, snaps, hooks, rivets, nails, ties, glue, welds, spot welds, or combinations thereof, can be used to connect any or all of the components together. 
         [0097]    The elbow joints can have a single rotational degree of freedom. The elbow joints can have single linear hinge joints. The axis of rotation of the rotational degree of freedom of the elbow joint can be perpendicular to the longitudinal axis of one or both arms, base or end effectors interfacing with the joint. 
         [0098]    The wrist joints can have one or two rotational degrees of freedom. The wrist joints can have one or two linear hinge joints. Each hinge joint can have a rotational axis perpendicular to the rotational axis of the other hinge joint in the wrist joint 
         [0099]    The axes of rotation of the rotational degree of freedom of the wrist joint can be perpendicular and/or parallel (e.g., coaxial, coincident) to the longitudinal axis of one or both arms, base or end effectors interfacing with the joint. 
         [0100]    The shoulder joints can have three rotational degrees of freedom. The shoulder joints can have three linear hinge joints. Each hinge joint can have a rotational axis perpendicular to the rotational axis of the other hinge joints in the shoulder joint, and/or a ball-in-socket joint. 
         [0101]    “Interface” is used throughout this disclosure to mean connect to, rotatably and/or translatably attach to, releasably or non-releasably fix to, press against, contact, or combinations thereof. 
         [0102]    The robotic system  10  can include any of the systems and elements disclosed in U.S. Pat. No. 8,100,205, issued 24 Jan. 2012, which is incorporated herein by reference in its entirety. 
         [0103]    As a person skilled in the art will recognize from the previous detailed description and from the figures and claims, modifications and changes can be made to the variations of the invention without departing from the scope of this invention defined in the following claims. Elements, characteristics and configurations of the various variations of the disclosure can be combined with one another and/or used in plural when described in singular or used in plural when described singularly.

Technology Classification (CPC): 8