Industrial robots, and arm assemblies and drive apparatus therefor

Claim 2

A modular industrial robot characterized by the ability to be configured to serve a variety of applications, and comprising a first drive unit (21) having a base component (21a) and a secondary component (21b) which is rotatable with respect to its base component, said base component including a mounting flange (21c) at one end thereof, means (24,25) releaseably connecting said mounting flange of said first drive unit to an external member (13), a second drive unit (22) having a base component (22a) and a secondary component (22b) which is rotatable with respect to its base component, with said base component including a mounting flange (22c) at one end thereof, means (28,30) releaseably interconnecting the secondary components of said first and second drive units, and means (39,25) releaseably connecting said mounting flange of said second drive unit to a second external member (38).

Claim 3

The industrial robot as defined in Claim 1 further comprising a third drive unit (23) having a base component (23a) and a secondary component (23b) which is rotatable with respect to its base component, and with said base component including a mounting flange (23a) at one end thereof, means (28,30) releaseably interconnecting the secondary component of said third drive unit to the secondary component of each of said first and second drive units, and means (33,25) releaseably connecting said mounting flange of said third drive unit to a third external member (32).

Claim 4

The industrial robot as defined in Claim 2 wherein said first, second, and third drive units are of substantially identical configuration, and such that substantially all of the components thereof are interchangeable.

Claim 5

The industrial robot as defined in Claim 3 wherein said mounting flange of each of said first, second and third drive units has a circular periphery, and each of said means releasably connecting a mounting flange to an external member comprises a circular flange (24,39,33) positioned on each of the external members, with the flange of each of said external members conforming to the size of the flange of the associated drive unit, a split band (25) of generally V-shaped configuration and adapted to enclose the periphery of the circular flange and a similar circular flange on the associated external component when the flanges are placed in abutting relation, and release means (26) for selectively opening and tightening the band about the periphery of the abutting flanges to selectively retain the flanges in assembled relation.

Claim 6

A modular industrial robot characterized by the ability to be configured to serve a variety of applications, and comprising a support member (13), a first drive unit (21) having a base component (21a) and a secondary component (21b) which is rotatable with respect to its base component, coupling means (21c,24,25) releaseably connecting the base component of said first drive unit to said support member, a second drive unit (22) having a base component (22a) and a secondary component (22b) which is rotatable with respect to its base component, a third drive unit (23) having a tubular base component (23a) and a secondary component (23b) which is rotatable with respect to its base component, means (28,30) releaseably connecting each of the secondary components of said first, second and third drive units to each other and with the second and third drive units being coaxially disposed about a second axis (B) which is nonparallel to the rotational axis (A) of said first drive unit, and a drive shaft (38) fixed to the base component of said second drive unit and extending coaxially through said tubular base component of said third drive unit.

Claim 7

A modular industrial robot characterized by the ability to be configured to serve a variety of applications, and comprising a support member (13), a first drive unit (21) having a base component (21a) and a secondary component (21b) which is rotatable with respect to its base component, coupling means (21c,24,25) releaseably connecting the base component of said first drive unit to said support member, a second drive unit (22) having a base component (22a) and a secondary component (22b) which is rotatable with respect to its base component, a third drive unit (23) having a tubular base component (23a) and a secondary component (23b) which is rotatable with respect to its base component, means (28,30) releaseably connecting each of the secondary components of said first, second and third drive units to each other and with the second and third drive units being coaxially disposed about a second axis (B) which is nonparallel to the rotational axis (A) of said first drive unit, and a drive shaft (38) fixed to the base component of said second drive unit and extending coaxially through said tubular base component of said third drive unit.

Claim 8

The industrial robot as defined in Claim 5 wherein said second axis (B) is perpendicular to and intersects the rotational axis (A) of said first drive unit, and the first, second and third drive units are of substantially identical configuration, and the second and third drive units are of disposed in opposite orientations along said second axis.

Claim 9

The industrial robot as defined in Claim 5 further comprising a first arm (15), and first arm coupling means (23c,32,33,35,71,25) releaseably interconnecting said arm to said tubular base component of said third drive unit, and whereby the first arm may be pivoted about said second axis by said third drive unit.

Claim 10

The industrial robot as defined in Claim 7 further comprising an output shaft (75) mounted to said first arm for rotation about a third axis (C) disposed parallel to and laterally spaced from said second axis (B), a second arm (16),, second arm coupling means (76,77, 25) for releaseably connecting said second arm to said output shaft to permit rotation of said second arm about said third axis, and transmission means (74,81, 8 2) operatively connecting said output shaft to said drive shaft of said second drive unit, whereby the second arm may be pivoted about said third axis by said second drive unita

Claim 11

The industrial robot as defined in Claim 8 wherein said second arm coupling means and said first arm coupling means are of like configuration, whereby the first arm and second drive unit may be selectively removed from the robot and the second arm connected directly to the tubular base component of said third drive unit.

Claim 12

The industrial robot as defined in Claim 9 wherein said second arm coupling means and said first drive unit coupling means are of like configuration, whereby the first, second and third drive units, and the first arm, may all be selectively removed from the robot, and the second arm connected directly to the support member.

Claim 13

The industrial robot as defined in Claim 10 wherein each of (a) said first drive unit coupling means (b) said first arm coupling means, and (c) said second arm coupling means comprises a circular flange (21c,24,23c,33,76,77) positioned on each of the components to be connected, with the flanges having a like diameter, a split band (25) of generally V-shaped configuration and adapted to enclose the periphery of the mating flanges when they are placed in abutting relation, and release means (26) for selectively opening and closing the band circumferentially about the periphery of the abutting flanges to selectively retain the flanges in assembled relation.

Claim 14

The industrial robot as defined in Claim 7 wherein said first arm coupling means includes a tubular extension (32) coaxially disposed between said base component of said third drive unit and said first arm, and counterweight means (36) mounted to said extension for counter-balancing the weight of said second arm.

Claim 15

A three axis outer arm assembly for an industrial robot comprising a hand assembly (18) including a frame member (94), a transverse wrist pin (95) mounted to said frame member, and a wrist rotary member (96) rotatably mounted with respect to said frame member, a first tubular member (98), with said wrist pin of said hand assembly being transversely mounted at one end thereof, a second tubular member (99) rotatably mounted coaxially within said first tubular member, first gear means (104,105) operatively interconnecting said second tubular member and said frame member of said hand assembly, such that rotation of said second tubular member causes said frame member to pivot about the axis of said wrist pin, a third tubular member (100) rotatably mounted coaxially within said first tubular member, second gear means (107,108,109) operatively interconnecting said third tubular member and said wrist rotary member such that rotation of said third tubular member causes said wrist rotary member to rotate with respect to said frame member, and drive means for selectively rotating each of said first, second, and third tubular members about the common axis thereof and relative to each other, said drive means including first, second, and third electrical stepping motors (90,91,92) mounted adjacent the end of said tubular members opposite said hand assembly, and a gear train (113,114,115,116,118) operatively interconnecting each of said first, second, and third motors with said first, second, and third tubular members respectively, and wherein all of said gear trains have the same gear ratio.

Claim 16

A three axis outer arm assembly for an industrial robot comprising a hand assembly (18) including a frame member (94), a transverse wrist pin (95) mounted to said frame member, and a wrist rotary member (96) rotatably mounted with respect to said frame member, a first tubular member (98), with said wrist pin of said hand assembly being transversely mounted at one end thereof, a second tubular member (99) rotatably mounted coaxially within said first tubular member, first gear means (104,105) operatively interconnecting said second tubular member and said frame member of said hand assembly, such that rotation of said second tubular member causes said frame member to pivot about the axis of said wrist pin, a third tubular member (100) rotatably mounted coaxially within said first tubular member, second gear means (107,108,109) operatively interconnecting said third tubular member and said wrist rotary member such that rotation of said third tubular member causes said wrist rotary member to rotate with respect to said frame member, and drive means for selectively rotating each of said first, second, and third tubular members about the common axis thereof and relative to each other, said drive means including first, second, and third electrical stepping motors (90,91,92) mounted adjacent the end of said tubular members opposite said hand assembly, and a gear train (113,114,115,116,118) operatively interconnecting each of said first, second, and third motors with said first, second, and third tubular members respectively, and wherein all of said gear trains have the same gear ratio.

Claim 17

The outer arm assembly as defined in Claim 13 wherein said hand assembly further includes a gripper (19) mounted to said wrist rotary member and adapted to open and close upon a workpiece, and further comprising fluid line means (120,122,123,124) extending coaxially through said tubular members for selectively actuating said gripper.

Claim 18

The outer arm assembly as defined in Claim 14 wherein said fluid line means includes a first rotary union (122) disposed within said tubular members, a second rotary union (120) disposed in said hand assembly, and at least one flexible hose (123,124) extending between said rotary unions.

Claim 19

The outer arm assembly as defined in Claim 13 further comprising means mounting said second and third tubular members to permit limited axial movement thereof with respect to said first tubular member, and including biasing means for resiliently urging the second and third tubular members in a direction toward said hand assembly, to thereby assure proper meshing of said first and second gear means and to compensate for any wear thereof.

Claim 20

An industrial robot comprising at least two arms (15,16) which are operatively connected to each other and to a frame member for movement about two separate axes, and which is characterized by precisely controllable relative movement between the two arms, and comprising a support member (28), a first arm (15) mounted with respect to said support member for rotational movement about a first axis (B), first drive means (23) operatively mounted to said support member for rotating said first arm about said first axis, a second arm (16) rotatably mounted to said first arm for rotational movement about a second axis (C) which is parallel to and laterally spaced from said first axis, second drive means (22) operatively mounted to said support member for rotating said second arm about said second axis, and including (a) an input shaft (38) extending coaxially along said first axis and including a free end disposed within said first arm, (b) an output shaft (75) fixed to said second arm and extending coaxially along said second axis and including a free end disposed within said first arm, and (c) transmission means operatively connecting the free ends of said input shaft and output shaft, and including a sprocket (74,81) mounted at the free end of each of the input and output shafts, a flexible endless toothed conveyor (82) operatively entrained about said sprockets, and adjustable means (84,85,86,87) for contacting and deflecting each run of the conveyor so as to selectively deflect the runs in equal amounts and in opposite directions, and thereby permit the conveyor to be maintained in a tensioned condition and substantially avoid backlash in the rotation of the input and output shafts, and while avoiding relative rotation between the input and output shafts upon adjustment of the tension in said conveyor.

Claim 21

An industrial robot comprising at least two arms (15,16) which are operatively connected to each other and to a frame member for movement about two separate axes, and which is characterized by precisely controllable relative movement between the two arms, and comprising a support member (28), a first arm (15) mounted with respect to said support member for rotational movement about a first axis (B), first drive means (23) operatively mounted to said support member for rotating said first arm about said first axis, a second arm (16) rotatably mounted to said first arm for rotational movement about a second axis (C) which is parallel to and laterally spaced from said first axis, second drive means (22) operatively mounted to said support member for rotating said second arm about said second axis, and including (a) an input shaft (38) extending coaxially along said first axis and including a free end disposed within said first arm, (b) an output shaft (75) fixed to said second arm and extending coaxially along said second axis and including a free end disposed within said first arm, and (c) transmission means operatively connecting the free ends of said input shaft and output shaft, and including a sprocket (74,81) mounted at the free end of each of the input and output shafts, a flexible endless toothed conveyor (82) operatively entrained about said sprockets, and adjustable means (84,85,86,87) for contacting and deflecting each run of the conveyor so as to selectively deflect the runs in equal amounts and in opposite directions, and thereby permit the conveyor to be maintained in a tensioned condition and substantially avoid backlash in the rotation of the input and output shafts, and while avoiding relative rotation between the input and output shafts upon adjustment of the tension in said conveyor.

Claim 22

18, The industrial robot as defined in Claim 17 wherein said adjustment means includes a pivot arm (84) mounted within said first arm for pivotal movement about an axis positioned between and parallel to the first and second axes, a roller (86) mounted at each end of the pivot arm, and adjustable linkage means (87) interconnecting said pivot arm and said first arm whereby the pivot arm may be positioned such that the rollers contact the outside surface of the conveyor on respective runs thereof.

Claim 23

The industrial robot as defined in Claim 18 wherein the rotational axis of said pivot arm (84) is positioned on a line extending perpendicularly between the first and second axes.

Claim 24

The industrial robot as defined in Claim 19 wherein said conveyor comprises a toothed belt.

Claim 25

A drive apparatus (22) for an industrial robot or the like and which comprises at least one element (22b) which is operatively connected to a second element (22a) for relative movement about an axis, and wherein the drive apparatus is adapted for effecting relative movement of the two elements about said axis, and is characterized by the ability to permit accurately controllable movement of the two elements relative to each other, said drive apparatus comprising a drive motor (42) fixedly mounted to one of said elements, with said motor having an output shaft, drive control means (55,56,57,58) for selectively operating said drive motor, a gear wheel (52) disposed coaxially about said axis and mounted to the other of said elements, and including a face gear (51) in the form of a circular rack, and gear means (46,48,50) operatively interconnecting the output shaft of said drive motor with said face gear of said gear wheel.

Claim 26

A drive apparatus (22) for an industrial robot or the like and which comprises at least one element (22b) which is operatively connected to a second element (22a) for relative movement about an axis, and wherein the drive apparatus is adapted for effecting relative movement of the two elements about said axis, and is characterized by the ability to permit accurately controllable movement of the two elements relative to each other, said drive apparatus comprising a drive motor (42) fixedly mounted to one of said elements, with said motor having an output shaft, drive control means (55,56,57,58) for selectively operating said drive motor, a gear wheel (52) disposed coaxially about said axis and mounted to the other of said elements, and including a face gear (51) in the form of a circular rack, and gear means (46,48,50) operatively interconnecting the output shaft of said drive motor with said face gear of said gear wheel.

Claim 27

The drive apparatus as defined in Claim 21 wherein said drive motor comprises an electrical stepping motor, and said drive control means comprises a electrical pulse generator means (55), and program means (56) for controlling the output of said pulse generator means.

Claim 28

The drive apparatus as defined in Claim 22 further comprising an electrical brake (44) having an output shaft, and said gear means operatively interconects said output shaft of said brake with said face gear.

Claim 29

The drive apparatus as defined in Claim 23 wherein said gear means includes a drive gear (46) mounted to each of said output shafts, and pinion gear means rotatably mounted to said one element and including an input gear (48) operatively meshing with each of said drive gears, and an output gear (50) fixed for rotation with said input gear, and wherein said output gear is disposed to operatively mesh with said face gear of said gear wheel.

Claim 30

The drive apparatus as defined in Claim 24 wherein said output shafts are disposed parallel to each other.

Claim 31

The drive apparatus as defined in Claim 25 wherein said drive control means further comprises position verification means (57) for said stepping motor, and means for comparing the signals from said position verification means with signals from said program means.