U.S. patent application number 16/095336 was filed with the patent office on 2020-10-01 for method for producing a robot and device for carrying out said method.
This patent application is currently assigned to KASTANIENBAUM GMBH. The applicant listed for this patent is KASTANIENBAUM GMBH. Invention is credited to Sami Haddadin.
Application Number | 20200306999 16/095336 |
Document ID | / |
Family ID | 1000005087242 |
Filed Date | 2020-10-01 |
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United States Patent
Application |
20200306999 |
Kind Code |
A9 |
Haddadin; Sami |
October 1, 2020 |
METHOD FOR PRODUCING A ROBOT AND DEVICE FOR CARRYING OUT SAID
METHOD
Abstract
The invention relates to a method and to a device for producing
a robot with a robotic arm. Said method can be carried out using an
assembly robot wherein first housing segments are arranged in an
intended sequence for the robotic arm, drive units are inserted
into the first housing segments and the respective complimentary
second housing segments are placed on the first housing segments
comprising the drive units.
Inventors: |
Haddadin; Sami; (Hannover,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KASTANIENBAUM GMBH |
Munich |
|
DE |
|
|
Assignee: |
KASTANIENBAUM GMBH
Munich
DE
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20190315002 A1 |
October 17, 2019 |
|
|
Family ID: |
1000005087242 |
Appl. No.: |
16/095336 |
Filed: |
April 20, 2017 |
PCT Filed: |
April 20, 2017 |
PCT NO: |
PCT/EP2017/059449 PCKC 00 |
371 Date: |
July 1, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B25J 19/007 20130101;
B25J 9/1669 20130101; B25J 17/0258 20130101 |
International
Class: |
B25J 19/00 20060101
B25J019/00; B25J 9/16 20060101 B25J009/16 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 20, 2016 |
DE |
10 2016 004 788.7 |
Claims
1. Method for manufacturing a robot having at least one multi-axis
robotic arm which consists of a plurality of axis members which are
arranged movably relative to one another and each form an axis of
the robotic arm, at least some of the axis members being
constructed from at least two complementary housing segments which
each have at at least one of their ends a bearing device for
receiving a drive unit, comprising at least one of the steps:
arranging first housing segments in an order provided for the
robotic arm; inserting the drive units into the first housing
segments with connection of the drive units to the bearing devices
of the first housing segments provided for this purpose; placing
the respective complementary second housing segments on the first
housing segments comprising the drive units, with the drive units
being connected to the bearing devices of the second housing
segments provided for this purpose; and fastening the second
housing segments to the first housing segments by means of
fastening means, whereby the drive units are fixed in the axis
members; the method steps being automatically executable by at
least one assembly robot.
2. Method according to claim 1, further comprising the step which
can be performed by the at least one assembly robot: attaching
electrical lines and/or media lines and/or sensor modules to the
inserted drive units and/or in the housing segments.
3. Method according to claim 1, further comprising the steps which
can be performed by the at least one assembly robot: attaching a
base member to the lower axis member of the robotic arm; and/or
attaching an effector receiving member to the upper axis member of
the robotic arm.
4. Method according to claim 1, in which the at least one assembly
robot automatically removes the components of the robots to be
produced and/or the tools required in each case for the individual
assembly steps from a stationary and/or mobile storage.
5. Method according to claim 1, in which the at least one assembly
robot automatically changes its effectors required for the
individual assembly steps as a function of these assembly steps to
be carried out.
6. Method according to claim 1, further comprising the steps which
can be performed by said at least one assembly robot: connecting
the assembled robot to a power supply and/or data supply and/or
media supply.
7. Method according to claim 6, further comprising the step
executable by said at least one assembly robot: activating at least
one functional test for the assembled robot (R).
8. Method according to claim 1, in which the assembly steps can be
carried out if the robot to be assembled is arranged horizontally
in its longitudinal extension.
9. Method according to claim 8, further comprising the step which
can be performed by said at least one assembly robot: transferring
the assembled robot to a defined position.
10. Method according to claim 8, further comprising the steps:
connecting the assembled robot to a power supply and/or data
supply; and controlling the assembled robot so that it
automatically moves to a defined position.
11. Method according to claim 1, in which the at least one assembly
robot is designed to be compliant and/or sensitive.
12. Method according to claim 1, in which the robot to be assembled
is of identical design to the at least one mounting robot.
13. Robot having a multi-axis robotic arm which comprises a
plurality of axis members which are arranged movably relative to
one another and which each form an axis of the robotic arm, at
least some of the axis members being constructed from at least two
complementary housing segments, the robot being producible
according to claim 1.
14. Device for manufacturing a robot which has at least one
multi-axis robotic arm which comprises a plurality of axis members
which are arranged so as to be movable relative to one another and
each form an axis of the robotic arm, at least some of the axis
members being constructed from at least two complementary housing
segments which each have at at least one of their ends a bearing
device for accommodating a drive unit, having at least one assembly
robot which is designed to perform various assembly steps for
manufacturing the robot; and with a working space which is assigned
to the at least one assembly robot, the working space comprising a
holding device for at least one housing segment of the robotic
arm.
15. Device according to claim 14, in which the holding device is
designed at least partially complementary to the contour of the
housings of the axis members of the robotic arm.
16. Device according to claim 14, in which the holding device is
designed to position the robotic arm horizontally in its
longitudinal extension.
17. Device according to claim 16, in which the holding device has
an abutment for the two ends of the robotic arm, respectively.
18. Device according to claim 17, in which an abutment for a base
element of the robotic arm is designed such that the assembled
robot can be tilted into a defined position about this abutment
with the aid of the assembly robot.
19. Device according to claim 14, in which at least one support for
the components for mounting the robot is provided in the region of
the working space.
20. Device according to claim 14, in which at least one conveying
device is provided in the region of the working space, along which
the components for mounting the robot can be moved.
21. Device according to claim 14, in which at least one holder for
various effectors of the assembly robot is provided in the region
of the working space.
22. Device according to claim 14, in which the at least one
assembly robot is designed to be compliant and/or sensitive.
23. Device according to claim 14, in which at least two assembly
robots are assigned to the working space, the assembly robots being
designed to carry out different or similar assembly steps
simultaneously or sequentially.
Description
[0001] The present invention relates to a method for manufacturing
a robot and a device allowing such a method to be carried out.
[0002] In state-of-the-art methods for manufacturing a robot, such
as of a robotic arm or a lightweight manipulator, the individual
components such as drive units, housing structures, sensor units,
cabling, etc. are usually assembled by hand with the aid of
assembly tools. A fully automated assembly is hardly feasible for
such robots, since the radially closed housing structures of the
individual axis elements only allow a very complicated assembly.
The axis links are only accessible from their respective open end
faces.
[0003] Based on this, the present invention has the objective of
providing a novel method for the manufacture of a robot, whereby
the steps of the manufacturing method should be capable of being
carried out at least predominantly independently by machine,
preferably the entire manufacturing method shall be carried out
completely automatically. Furthermore, the invention has the
objective of providing a corresponding device with which this novel
method can be carried out.
[0004] Preferably, but not exclusively, the invention relates to a
method for the manufacture of a lightweight robot, in particular
for the manufacture of a robotic arm or manipulator for such a
robot.
[0005] This object is solved by a method for manufacturing a robot
according to claim 1, by a robot according to claim 13 produced by
this method and by a device for carrying out the method for
manufacturing a robot according to claim 14.
[0006] The method according to the invention relates to a robot
having at least one multi-axis robotic arm or manipulator
consisting of a plurality of axis members movably arranged relative
to each other each forming an axis of the robotic arm, at least
part of the axis members being constructed of at least two
complementary housing segments each having at least one of their
ends a support or bearing device for receiving a drive unit, and is
further characterized by at least one of the steps: [0007]
arranging first housing segments in an order provided for the
robotic arm; [0008] inserting the drive units into the first
housing segments while connecting the drive units to the support
devices of the first housing segments provided for this purpose;
[0009] mounting the respective complementary second housing
segments onto the first housing segments comprising the drive units
while connecting the drive units to the support devices of the
second housing segments provided for this purpose; and [0010]
fixing the second housing segments to the first housing segments by
means of fixing means, whereby the drive units are fixed in the
axis members; the method steps being automatically executable by at
least one assembly robot.
[0011] The method in accordance with the invention is preferably
made possible by the fact that the housing structures of individual
axis members of the manipulator are designed and constructed in
such a way that they are at least partially open along their axis
and thus accessible, e.g. by at least two form-complementary,
half-shell-like housing halves which are assembled in the course of
assembly, as this is described e.g. in the German patent
application No. 10 2015 012 960.0, the disclosure content of which
is expressly referred to herein.
[0012] In the case of the generally completely self-contained and
closed housing structures of axis members of state of the art robot
manipulators, the assembly of the units, cabling, etc. is only
possible from one of the open end faces of the axis members,
whereby in addition, there are assembly openings which can be
closed by covers, but which reduce the strength and torsional
stiffness of the housing. The assembly of a manipulator in such
robots is extremely cumbersome due to the difficulty of access to
the inside of the housing and is even detrimental to the
economically viable automation of the manufacturing process.
[0013] For an automated insertion of the drive units into the open
housing segments it is advantageous, according to the invention, if
the drive units are pre-assembled as a module and have
corresponding connecting elements which form a positive and/or
non-positive connection with connecting elements arranged in or on
the housing segments during the insertion of the drive units, which
connection elements determine the position of the drive units in
the housing segments before the upper housing segments are placed
on top.
[0014] For this purpose, for example, the drive units may be
designed and constructed so as to have connecting elements in the
form of circumferential annular grooves which can be connected in a
force- and torque-transmitting manner to a housing portion of a
first axis member and to a housing portion of a second axis member,
the second axis member being rotatably mounted with respect to the
first axis member, and the connecting elements being constructed so
as to cooperate with the axis members in the radial direction with
respect to the axis of rotation of the drive device.
[0015] The pre-assembled drive units may have standardized
connections and the housing segments may have receptacles or guides
which enable that the at least one assembly robot to independently
attach electrical cables and/or media cables and/or sensor modules
to the drive units already inserted and/or in the housing
segments.
[0016] Manipulators of robots, especially of lightweight
construction, usually have a foot-like base element on which the
multi-axis robotic arm is arranged. The end effector of the
manipulator is to be provided opposite the base element. The method
according to the invention can therefore also comprise the steps
that can be performed by the at least one assembly robot, in which
a base element is attached to the lower axis member of the robotic
arm and/or an effector receiving element for the end effector is
attached to the upper axis member of the robotic arm.
[0017] In an embodiment of the method in accordance with the
invention, the method is designed in such a way that the at least
one assembly robot automatically removes the components required in
each case for the individual assembly steps (housing parts, drive
modules, sensor modules, connecting or fastening elements, cables
or lines, etc.) for the robot to be produced and/or the various
tools or effectors required for this from a stationary and/or
mobile storage.
[0018] Stationary storages or shelfs can be formed, for example, by
brackets located in the work area of the assembly robot. However,
it is also conceivable to have mobile storages, such as assembly
lines, which guide the parts to be picked up past the assembly
robot, depending on the assembly step, whereby the sequence of the
parts can also be selected arbitrarily.
[0019] All commercially available tools can be used as tools, which
can be picked up by the assembly robot e.g. by means of an
appropriately distinctive gripping mechanism.
[0020] It has to be emphasized that according to the invention, the
assembly robot does not require any individualized tool parts and
corresponding connections intended for its use and serving as an
effector, but can use tools freely available on the market, such as
conventional cordless screwdrivers, as described in detail below
and which have their own inventive significance. The tools
themselves can also be provided in holders provided for this
purpose in the area of the assembly robot.
[0021] In this context, the method according to the invention also
provides that, depending on the assembly steps to be performed, the
at least one assembly robot automatically changes the effectors or
tools required for the individual assembly steps.
[0022] For example, it can use appropriately shaped gripper jaws
for picking up and inserting the drive units and differently shaped
gripper jaws for picking up an electric screwdriver and feeding the
screwdriver to the appropriate positions for screwing together the
housing segments, whereby the gripper mechanism of the assembly
robot then picks up these gripper jaws from the appropriate
locations as required and uses them according to their intended
application.
[0023] For this purpose, the assembly robot has a gripping
mechanism on its end member of the manipulator which is designed so
that different gripper elements or jaws can be picked up, which are
directed at the respective element to be picked up or activity to
be performed. The gripper jaws can be replaced independently by the
assembly robot via a type of universal connection, as described,
for example, in the German patent application No. 10 2016 004
087.4, the disclosure content of which is expressly referred to
herein.
[0024] In other words, the gripper jaws for receiving and inserting
the drive units are adapted in their contours to the external shape
of the drive units, while the gripper jaws for receiving a
screwdriver for connecting the housing segments by means of screws
are adapted in their contours to the shape or handle of the
screwdriver. Other gripper jaws with different designs can also be
used to make electrical and media connections or even to actuate
external switches in the area of the assembly device.
[0025] Since the assembly robot is designed to accommodate
individualized gripper jaws, the method in accordance with the
invention may also comprise the steps which can be carried out by
the at least one assembly robot, and by means of which steps the
robot, which is fully assembled in terms of its housing structure,
can be connected to a power supply and/or data supply and/or media
supply, the assembly robot also using corresponding gripper jaws
here.
[0026] If the robot to be assembled is fully assembled, i.e. all
mechatronic components are inserted and connected, and the housing
segments are connected and fastened, the method according to the
invention may further include the step which can be performed by at
least one assembly robot, and in which step at least one functional
test for the assembled robot is activated.
[0027] The assembled robot is supplied with power, for example, by
the assembly robot independently actuating an external switch, so
that a test routine can be carried out by test software, which
checks whether all drive units, sensor modules, etc., and the
associated electrical contacts exist or function correctly.
[0028] Finally, according to the method of the invention, it may be
provided that the assembled robot, which preferably consists only
of the base element and the manipulator arranged on it, is erected
by the assembly robot. In this case, the base element can be
articulated on an abutment of the assembly device so that the
manipulator is quasi tilted about the axis of the abutment by the
assembly robot.
[0029] However, in a preferred embodiment of the method according
to the invention, it is provided, since the assembled robot
contains all drive units and connections in a functional
arrangement after a successfully passed functional test, if
necessary, that the assembled robot is supplied with power and
thereby automatically straightens up into a defined position,
taking into account a pre-programmed motion sequence, before it can
then be removed from the assembly device or moved away from it by
means of a conveyor device.
[0030] All the assembly steps mentioned above can preferably be
carried out using at least one assembly robot which is compliant
and/or sensitive in design.
[0031] Robots with position-controlled axes are not suitable for
the manufacturing method according to the invention, since for
position control the forces acting on the robot from the outside
must be measured, which form the basis for a desired dynamic
behavior that is then transmitted to the robot via inverse
kinematics, also called admittance control. In the present case,
the programming effort would be too high for a single assembly
robot due to the fact that the assembly activities have to be
carried out at many different positions and alternate in nature.
The required position control would have to be highly precise so
that the individual robot-side and tool-side or effector-side
coupling elements for changing the tools or gripper jaws and for
carrying out the individual assembly steps described above, such as
in particular inserting the drive units into the open housing
segments with simultaneous joining of the connecting elements
provided for this purpose, positioning of the complementary housing
segments, etc., could be implemented at all. Due to the control
principle used, such robots are therefore not in a position to
detect errors or deviations, for example if, for some reason, the
actual position of the open housing segment for pressing in a drive
unit deviates slightly from the target position provided for this
purpose in order to react accordingly. The housing segments can
preferably be connected to each other via a tongue-and-groove
connection, which in addition does not have to run linearly along
the dividing line between the segments and does not necessarily
have to run in one plane. Joining to form the tongue-and-groove
connection is almost impossible using a strictly
position-controlled robot, especially since the shape of the
individual axis elements and thus of the housing segments and
therefore the course of the dividing lines of the tongue-and-groove
connection differ for each axis of such a robot. A perfect
insertion of the drive units or other components into the housing
segments and the exact merging of the housing segments as well as
the screw connections of the housing segments would only be
possible if the effectors or tools for this purpose were stored
exactly in the position specified by the programming, for example
in a stationary holding device arranged in the working area of the
robot, and if the robot to be mounted or the corresponding housing
segments were also located in corresponding stationary holders or
positions. Even the use of a tool magazine with several
exchangeable, possibly different tools or effectors (gripper,
gripper jaws, screwdriver, pushbutton etc.) would considerably
increase the programming effort and thus the susceptibility to
errors.
[0032] According to a preferred embodiment of the method according
to the invention, at least one assembly robot, preferably all
assembly robots used, should have such an integrated compliance
control or be equipped with intrinsic compliance or with a
combination of active and passive compliance, which is why assembly
should also be preferably, but not exclusively, carried out by such
programmable multi-axis robots, preferably lightweight robots.
[0033] For example, the compliance control is based on the
so-called impedance control, which, in contrast to the admittance
control already mentioned, has as its object torque control at
joint level. Depending on the desired dynamic behaviour and taking
into account the deviations of an actual position from a defined
nominal position and/or an actual speed from a nominal speed and/or
an actual acceleration from a nominal acceleration, forces or
moments are determined which are then mapped via the known
kinematics of the assembly robot, which results from the number and
arrangement of the joints and axes and thus degrees of freedom, to
corresponding joint torques which are set via the torque control.
The torque sensor elements integrated in the joints for this
purpose record the one-dimensional torque prevailing at the output
of the gearbox of the drive unit located in the joint, which can
take the elasticity of the joint into account as a measured
variable within the framework of the control. In particular, the
use of an appropriate torque sensor device, in contrast to the use
of only one force torque sensor at the end effector, as in
admittance control, also permits the measurement of forces which
are not exerted on the end effector but on the members of the
assembly robot as well as on an object held by or to be processed
by the assembly robot. Torques can also be measured by force
sensors in the structure and/or base of the robot system. In
particular, joint mechanisms between the individual axes of the
manipulator can also be used, which allow multi-axis torque
measurement. Also conceivable are translational joints equipped
with corresponding force sensors.
[0034] The regulation of compliance and sensitivity realized in
this way proves to be advantageous for the invention in question in
many respects.
[0035] In principle, such a compliance control allows the assembly
robot used for the intended manufacturing process or for individual
method steps to be enabled to carry out its own controlled
movements, whereby these own movements then correspond to
individual assembly steps, such as e.g. inserting or pressing the
drive units into the housing segments, linking the internal
connections of the drive units, connecting the external
connections, inserting or guiding the cabling in the housing
segments, actuating functional switches or the like and in
particular screwing the housing segments together. All this is
combined with an independent change of different tools or
effectors, e.g. different gripper jaws.
[0036] In addition, such an assembly robot is capable of
"searching" for and "sensing" the different positions of the robot
to be assembled, in particular with respect to an exact alignment
of two housing segments of an axis member to be assembled with one
another, when the tongue-and-groove connection is joined and when,
for example, the fastening elements are inserted into openings of
the housing segments provided for this purpose, as well as when the
tool is guided relative to the openings, and of "searching" for
positions on the assembly device and also for tool elements or
effectors and "sensing" them without damage.
[0037] In this way, any number of functionally different assembly
steps can be carried out by one and the same assembly robot.
[0038] A further advantage of the compliance control is that it
basically permits a less precise or not exactly positioned coupling
or connection between the components and connecting elements,
whereby these can be manufactured with higher tolerances. The
inaccuracies caused by this can be compensated in an appropriate
manner by means of a correspondingly compliant control by reducing
the contact forces when connecting the components, e.g. when
inserting the drive units into the housing segments open on one
side, inserting the connecting elements provided therein, such as
slot or groove blocks, into the ring grooves, and also when forming
the tongue-groove connection between the housing segments. The same
applies to screwing the housing halves together when the tool, e.g.
the screwdriver attachment of a cordless screwdriver, is inserted
into the openings.
[0039] The stationary position or changing position (e.g. with a
conveyor belt) of the individual components for the robot to be
assembled in the area of the assembly device, the respective
positions of the effectors or tools likewise arranged thereon, the
position of actuating switches and connections, in each case also
in relation to the position of the assembly robot, as well as the
poses to be assumed by the assembly robot in each case within the
scope of assembly, determine the motion sequences to be performed
by the assembly robot as well as their accuracy. All these
parameters must be taken into account in a coordinate system
assigned to the assembly robot, whereby the selection of the type
of coordinates (e.g. Cartesian, cylindrical, spherical coordinates)
is determined by the desired behaviour of the assembly robot in the
task space provided for this purpose, whereby different assembly
steps can then define different task spaces. The behaviour of the
assembly robot is based on a corresponding compliance control,
which is why robots with such an integrated compliance control,
especially lightweight robots, are particularly suitable for use as
assembly robots in the invention-based method.
[0040] In accordance with a particularly preferred embodiment of
the method according to the invention, it is intended that at least
one assembly robot be identical in design to the robot to be
assembled. It is therefore preferable to use a lightweight
robot.
[0041] In other words, the assembly robot, supported by the
compliance control and sensitivity described above, is capable of
replicating itself. By providing an appropriate assembly device
with, if necessary, continuously fed components, a robot of this
type can be manufactured and duplicated by shortening cycle times
and thus significantly reduced production costs.
[0042] In this context, the invention also concerns a device for
producing a robot which has at least one multi-axis robotic arm
which consists of a plurality of axis members which are arranged so
as to be movable relative to one another and each form an axis of
the robotic arm, at least some of the axis members being
constructed from at least two complementary housing segments which
each have at least one of their ends a support or bearing device
for receiving a drive unit, [0043] with at least one assembly robot
which is designed to carry out various assembly steps for
manufacturing the robot; and [0044] with a working space which is
assigned to the at least one assembly robot, wherein the working
space comprises a holding device for at least one housing segment
of the robotic arm, preferably, in sections, a plurality of holding
devices for a plurality of housing segments of successive axis
members of the robotic arm.
[0045] It may be provided that the holding device(s) is/are at
least partially complementary to the contour of the housing
segments of the axis members of the robotic arm.
[0046] Ideally, the holding devices are designed so that they
position the manipulator or robotic arm of the robot to be mounted
horizontally in its longitudinal extension, preferably with all the
axis members of the manipulator being in a common plane, which
facilitates the insertion of the respective components into the
open housing segments and the positioning of the upper housing
segments completing the axis members.
[0047] In order to prevent the position of the manipulator, which
consists of several adjacent open housing segments, from possibly
changing during the execution of individual assembly steps, such as
pressing in the drive units, an abutment for each of the two ends
of the manipulator is provided on the holding device so that the
latter is fixed in its axial, horizontal position.
[0048] An abutment for the base element of the robotic arm can be
designed in such a way that the assembled robotic arm can be tilted
by means of the assembly robot around this abutment into a defined,
preferably upright or vertical position, the assembly robot being
able to engage the effector on the side opposite the base element
for this purpose.
[0049] In the area of the working area, at least one storage area
is provided for the components for the assembly of the robot, in
which these, such as the drive units, are stationarily stored.
Preferably at least one conveyor device is provided in the area of
the working space assigned to the assembly robot, along which the
components for the assembly of the robot can be moved continuously
or in a clocked manner.
[0050] Furthermore, in the region of the working space assigned to
the assembly robot, at least one holder or magazine for various
effectors and tools (screwdriver, gripper mechanism with several
exchangeable gripper jaws, etc.) can be provided, which the at
least one assembly robot uses independently.
[0051] In a preferred embodiment of the assembly device according
to the invention, at least two assembly robots are provided, which
are either assigned to a common working space or which each define
an independent working space within the assembly device. The
assembly robots can be designed to carry out different or similar
assembly steps simultaneously or sequentially. For example, it is
conceivable that one assembly robot only serves to insert or press
in the drive units, while the other assembly robot only serves to
place the upper housing segments after the drive units have been
inserted and, if necessary, connected, and that, in addition,
another assembly robot serves to screw together the housing
segments. This considerably reduces the cycle times.
[0052] According to the invention, the method described above
should preferably be carried out fully automatically, i.e. the
assembly robot(s) assemble another robot, preferably of the same
type, independently. However, some of the manufacturing steps
mentioned above can also be performed manually by a human, while
the assembly robot(s), which have a corresponding compliance
control and are therefore suitable for such a human-robot
collaboration, are used for further support.
[0053] Further features and advantages of the invention result from
the following description of the embodiments shown in the enclosed
drawings.
[0054] FIG. 1a is a perspective view of a device for manufacturing
a robot according to the invention;
[0055] FIG. 1b is another perspective view of a device for
manufacturing a robot according to the invention;
[0056] FIGS. 2a, b and c are illustrations relating to the
performance of a step of the method of manufacturing a robot
according to the invention in which a drive unit is to be inserted
into a housing segment;
[0057] FIG. 3 is an explosive view of a schematic structure of
housing segments of the robot to be manufactured;
[0058] FIGS. 4a, b and c are illustrations relating to the
performance of a further step of the method of manufacturing a
robot in accordance with the invention in which a housing segment
is to be placed on another housing segment;
[0059] FIGS. 5a and b are illustrations relating to the performance
of a further step in the method of manufacturing a robot in
accordance with the invention in which housing segments are to be
bolted together;
[0060] FIGS. 6a and b are illustrations relating to the performance
of a further step in the method of manufacturing a robot in
accordance with the invention in which a connector plug is to be
mounted on the robot;
[0061] FIGS. 7a and b are illustrations relating to the performance
of a further step in the method of manufacturing a robot in
accordance with the invention in which a switch is to be operated;
and
[0062] FIGS. 8a and b are illustrations relating to the performance
of a further step of the method of manufacturing a robot in
accordance with the invention in which the assembled robot is to
stand up independently.
[0063] FIGS. 1a and 1b each show an example of a device for
carrying out the method according to the invention.
[0064] Two assembly robots M1 and M2 are positioned on an assembly
table or work area 1, respectively, which are used for the assembly
of another robot R.
[0065] The assembly robots M1 and M2 are robots with a manipulator
2 consisting of several axis links or elements 3 and an effector 4
at its end, which in this case carries a gripping mechanism 5. The
two assembly robots M1 and M2 are lightweight robots equipped with
an appropriate compliance control.
[0066] As can be seen, preferably, but not necessarily a robot R of
the same type as the two assembly robots M1 and M2, i.e. a
manipulator 2 consisting of several axis members 3, at the end of
which an effector 4 is also provided and a base element 6 opposite
this effector 4, is to be assembled according to the manufacturing
method according to the invention.
[0067] The two assembly robots M1 and M2 are arranged and
programmed in such a way that they can carry out the assembly steps
intended for them simultaneously or one after the other.
[0068] The robot R to be mounted is supported essentially
horizontally with its lower housing segments 7 on a holding device
8, so that the upwardly open housing segments 7 of adjacent axis
members 3 continuously provide a receiving surface for the drive
units 9 to be inserted in the joint regions between two axis
members 3, a common dividing line running essentially in one plane
being formed.
[0069] In a first step of the method in accordance with the
invention, the lower housing segments 7 for the manipulator 2 can
be picked up by the assembly robots M1 and M2 from a support or
holder, e.g. by a conveyor belt 10 passing them, and deposited on
the holding device 8 in the orientation and sequence provided for
the structure of the manipulator 2.
[0070] The conveyor belt 10 can have mounting brackets 11 for the
drive units 9, while the upper housing segments 12, for example,
can be loosely placed on the conveyor belt 10.
[0071] In addition to such a mobile support, however, it is also
conceivable that the drive units 9 are placed on a stationary
bracket 13 in the area of the mounting device, as shown in FIG.
2a.
[0072] In this holder 13 the drive unit 9 is stored in such a way
that the gripping mechanism 5 of one of the assembly robots M1 or
M2 can securely grip the housing of the drive unit 9 by providing
corresponding gripper jaws 15 on gripper fingers 14 of the gripping
mechanism 5, which are complementary to the contour of the housing
of the drive unit 9.
[0073] As shown by the sequence of movements illustrated by the
illustrations of FIGS. 2a, 2b and 2c, the assembly robot M1 or M2
removes the drive unit 9 from the holder 13 (FIG. 2a) and guides it
to the joint between two adjacent axis elements 3 (FIG. 2b), in
which the two lower housing segments 7 are open at the top, and
inserts the drive unit 9 in this joint region (FIG. 2c).
[0074] Such an automated assembly of the drive units 9 is possible
because the housing structure of an axis member 3 of the robot 2 to
be assembled is composed of two half-shell-shaped housing halves or
segments 7 and 12 on the one hand, and because the drive units 9
including motor, gearbox, control, output housing and, if
necessary, further components are pre-assembled as a modular unit
on the other hand.
[0075] This concept, which has its own inventive significance, is
illustrated in FIG. 3, which schematically shows the structure of a
joint between two adjacent axis elements 31 and 32 for a
manipulator 2 of the robot R to be mounted.
[0076] Both axis members 31 and 32 each consist of a lower
half-shell-shaped housing segment 7 and an upper half-shell-shaped
housing segment 12.
[0077] The drive unit 9 has connecting elements in the form of
radially surrounding annular grooves 16 and 17, the drive unit 9
having an output housing 18 which is rotatable relative to the
motor/gearbox housing 19 of the drive unit 9. The annular groove 16
of the motor/gearbox housing 19 accommodates groove blocks 20 which
are provided at corresponding locations on the inside of the lower
housing segment 7 of one axis member 31, while at the same time
when the drive unit 9 is pressed in, the annular groove 17 of the
output housing 18 engages groove blocks 21 of the lower housing
segment 7 of the other axis member 32.
[0078] The dividing line between the housing segments 7 and 12 is
designed as a tongue-and-groove connection 34/35.
[0079] The upper housing segments 12 are then placed so that, on
the one hand, the ring grooves 16 and 17 in the upper area also
engage with the corresponding groove blocks 20 and 21 and, on the
other hand, the tongue-groove connection 34/35 is formed between
these housing segments 7 and 12. The final fastening of the groove
blocks 20 and 21 in the ring grooves 16 and 17 as well as the
fastening of the lower housing segment 7 with the upper housing
segment 12 is done by means of screws 22.
[0080] The structure of the axis links 31 and 32 described here as
well as the installation of a drive unit 9 in a joint between these
axis links 31 and 32 is, for example, described in the German
Patent Application No. 10 2015 012 960.0, which is expressly
referred to here. In this way, the axis link 32 is then finally
mounted so that it can rotate relative to the axis link 31.
[0081] The sequence of FIGS. 4a, 4b and 4c shows a further step in
the method according to the invention, in which an assembly robot
M1 or M2 picks up the upper housing segment 12 from a tray by
engaging the gripping mechanism 5 on the outer contour of the upper
housing segment 12. For this purpose, the gripper fingers 14 have
correspondingly designed further gripper jaws 23, which are based
on the contour of the upper housing segment 12.
[0082] The gripper jaws 23 are designed so that they grip the
housing segment 12 so that it cannot fall out of the gripper
mechanism 5 by itself. A friction-enhancing coating on the inside
of the gripper jaws 23, for example, is conceivable for this
purpose. The gripper jaws can also have 12 pin-like projections,
pins or the like, which engage in the holes 26 already provided in
the housing segment for the screw connections (see FIG. 3) and thus
center the housing segment 12 correctly in the gripper mechanism 5
at the same time.
[0083] Then both housing segments 7 and 12 are screwed together as
shown in FIGS. 5a and 5b.
[0084] For this purpose, the gripper mechanism 5 has gripper jaws
24, which are designed to receive a conventional electric
screwdriver 25, normally designed for manual operation, and then
lead sequentially to the corresponding openings 26 in the housing
segments 7, 12 and insert the screwdriver element of the
screwdriver 25 there. In advance, the screws 22 can be loosely
inserted into these openings 26 by one of the assembly robots M1 or
M2 or the screws 22 are magnetized and are picked up with the
screwdriver element of the screwdriver 25 directly via a guide of
the assembly robot M1 or M2 from a corresponding tray.
[0085] Due to the fact that the assembly robots M1 and M2 are
designed to grip standard tools and guide them to the appropriate
places, there is no need for individually designed and therefore
expensive tool devices, which would then have to be connected to
the effector via additional coupling mechanisms. There is also no
need for time-consuming programming for the coupling and guiding of
such tool adapters, which must also be equipped with corresponding
additional sensor devices for their exact control.
[0086] Once all the axis members 3 of manipulator 2 have been fully
assembled, effector 4 and base element 6 have been fitted and the
wiring for the power supply and control of the drive units 9 has
been laid in the appropriate places inside, the robot 3 can be
fitted with a power and control connection. As FIGS. 6a and 6b
show, it is possible that the gripping mechanism 5 has
corresponding gripper jaws 27, which grip a plug 28 and plug into a
corresponding socket 29 on the base element 6.
[0087] This allows the assembled robot R to be supplied with power.
According to the invention, it is conceivable that an on/off switch
30 could then be actuated by one of the assembly robots M1 or M2,
as shown in FIGS. 7a and 7b. The gripper mechanism 5 has
correspondingly shaped gripper jaws 33 for this purpose.
[0088] The assembly robots M1 and M2 are designed in such a way
that they are able to change independently between different
gripper jaws 15, 23, 24, 27 and 33 depending on the assembly step
to be carried out, since these have an identical coupling between
the gripper fingers 14 and the gripper jaws 15, 23, 24, 27 and 33,
which enables easy changing. Such a universal connection is for
example described in detail in the German patent application No. 10
2016 004 087.4, the disclosure content of which is expressly
referred to herein.
[0089] If the assembled robot R is then supplied with power, a
corresponding program control causes it to erect itself
independently by controlling the individual drive units 9, as shown
in FIGS. 8a and 8b.
* * * * *