Field of Invention

The present invention relates generally to a coupling assembly for effecting swapping between end-effectors on machineries, automation equipment and robotic systems.

Background

End-effectors are the main life line for most robotic arms and automations and are usually available in a variety of designs to suit a particular task or a range of tasks. As such, it is not uncommon for multiple end-effectors to be available for use by, for example, a robotic arm which uses a coupling system to couple an end-effector thereto and to decouple an end- effector therefrom when swapping to another end-effector. However, such coupling systems used by the robotic arms, and other automated systems or manipulators, have complex mechanisms and will require a separate set of actuator, including electromagnets, which in turn, requires separate controls to operate. Differing end-effector designs may also result in multiple actuators being required to effect tool swaps between end-effectors. Therefore, there is an apparent need for an improved approach for addressing the foregoing problems.

Summary

In accordance with an aspect of the invention, there is disclosed a coupling assembly comprising a first coupling portion and a second coupling portion. The first coupling portion comprises a first base structure defining a first axis, a protrusion extending from the first base structure, and at least one magnet coupled with the protrusion. The second coupling portion comprises a second base structure defining a second axis, and a sleeve being shaped and dimensioned for receiving the protrusion therewithin along the second axis. At least a portion of the sleeve being ferromagnetic such that when the protrusion is inserted into the sleeve to position the at least one magnet adjacent the sleeve, the protrusion magnetically couples with the sleeve to thereby couple the first coupling portion to the second coupling portion. One of the first base structure and the second base structure being coupled to an end- effector and the other of the first base structure and the second base structure being coupled to a manipulator. In accordance with a second aspect of the invention, there is disclosed a coupling assembly comprising a first coupling portion and a second coupling portion. The first coupling portion comprises a first base structure defining a first axis, a protrusion extending from the first base structure, and at least one first coupler coupled with the first base structure. The second coupling portion comprises a second base structure defining a second axis, a receptacle being shaped and dimensioned for receiving the protrusion therewithin along the second axis, and at least one second coupler coupled to the second base structure. The at least one first coupler is for magnetically coupling with the at least one second coupler. The first base structure is displaceable towards the second base structure when the protrusion is being inserted into the receptacle to align the at least one first coupler with the at least one second coupler such that when the first base structure is adjacent the second base structure, the at least one first coupler couples with the at least one second coupler to thereby couple the first coupling portion with the second coupling portion. One of the first base structure and the second base structure is coupled to an end-effector and the other of the first base structure and the second base structure being coupled to one of a manipulator and a docking structure for the end- effector.

In accordance with a third aspect of the invention, there is disclosed a first coupling portion comprising a first base structure defining a first axis, a protrusion extending from the first base structure, and at least one first coupler coupled with the first base structure. The first coupling portion is for coupling with a second coupling portion. The second coupling portion comprises a second base structure defining a second axis, a receptacle being shaped and dimensioned for receiving the protrusion therewithin along the second axis, and at least one second coupler coupled to the second base structure, the at least one first coupler for magnetically coupling with the at least one second coupler. The first base structure being displaceable towards the second base structure when the protrusion is being inserted into the receptacle to align the at least one first coupler with the at least one second coupler such that when the first base structure is adjacent the second base structure, the at least one first coupler couples with the at least one second coupler to thereby couple the first coupling portion with the second coupling portion. One of the first base structure and the second base structure being coupled to an end-effector and the other of the first base structure and the second base structure being coupled to one of a manipulator and a docking structure for the end-effector.

In accordance with a fourth aspect of the invention, there is disclosed a first coupling portion comprising a first base structure defining a first axis, a receptacle, and at least one first coupler coupled with the first base structure. The first coupling portion is for coupling with a second coupling portion. The second coupling portion comprises a second base structure defining a second axis, a protrusion extending from the first base structure, and at least one second coupler coupled to the second base structure. The receptacle being shaped and dimensioned for receiving the protrusion therewithin along the second axis. The at least one first coupler for magnetically coupling with the at least one second coupler. The first base structure being displaceable towards the second base structure when the protrusion is being inserted into the receptacle to align the at least one first coupler with the at least one second coupler such that when the first base structure is adjacent the second base structure, the at least one first coupler couples with the at least one second coupler to thereby couple the first coupling portion with the second coupling portion. One of the first base structure and the second base structure being coupled to an end-effector and the other of the first base structure and the second base structure being coupled to one of a manipulator and a docking structure for the end-effector.

Brief Description of the Drawings

FIG. 1 shows partial front perspective view of a coupling assembly according to a first embodiment of the invention with a first coupling portion and a third coupling portion being held on a receiver structure and a second coupling portion being aligned with the first coupling portion;

FIG. 2 shows a partial side view of the second coupling portion of FIG. 1 ;

FIG. 3 shows a partial perspective view of the second coupling portion of FIG. 2;

FIG. 4 shows a partial perspective view of the first coupling portion of FIG. 1 ;

FIG. 5 shows a partial perspective view of the third coupling portion of FIG. 1 ;

FIG. 6 shows a partial front perspective view of the coupling assembly of FIG. 1 with the first coupling portion being coupled to the second coupling portion and displaced away from the receiver structure;

FIG. 7 shows a partial front perspective view of the coupling assembly of FIG. 1 with the second coupling portion being aligned with the third coupling portion;

FIG. 8 shows a partial front perspective view of the coupling assembly of FIG. 1 with the second coupling portion engaging with the third coupling portion prior to rotational displacement about a fourth axis to couple with the third coupling portion;

FIG. 9 shows a partial front perspective view of the coupling assembly of FIG. 1 with the second coupling portion engaging with the third coupling portion subsequent to rotational displacement about the fourth axis to couple with the third coupling portion; FIG. 10 shows a partial front perspective view of the coupling assembly of FIG. 1 with the third coupling portion being coupled to the second coupling portion and displace away from the receiver structure;

FIG. 11 shows partial front perspective view of two coupling assemblies according to a second embodiment of the invention with a first coupling portion and a second coupling portion of each of the coupling assemblies being inter-coupled, the first coupling portion of each of the coupling assembly being attached to one of a manipulator and a docking structure while the second coupling portions of both the coupling assemblies being attached to an end- effector;

FIG. 12 shows a partial front perspective view of the coupling assemblies of FIG. 11 with first coupling portion and the second coupling portion of each of the coupling assemblies being inter-coupled;

FIG. 13 shows a side view of the coupling assemblies of FIG. 12 with first coupling portion and the second coupling portion of each of the coupling assemblies being inter-coupled; and

FIG. 14 shows a partial side sectional view of the coupling assemblies of FIG. 13 with first couplers of each of the first coupling portion being spatially displaced from second couplers of the second coupling portions.

Detailed Description

Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the embodiment, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of embodiments of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the embodiments of the present invention

An exemplary embodiment of the invention, a coupling assembly 20, is described with reference to FIGS 1 to 10. The coupling assembly 20 preferably comprises a first coupling portion 22 and a second coupling portion 24. The first coupling portion 22 comprises a first base structure 26 defining a first axis 28, a protrusion 30 extending from the first base structure 26, and at least one magnet 32 coupled with the protrusion 30. The second coupling portion 24 comprises a second base structure 34 defining a second axis 36, and a sleeve 38 being shaped and dimensioned for receiving the protrusion 30 therewithin along the second axis 36.

At least a portion of the sleeve 38 is ferromagnetic such that when the protrusion 30 is inserted into the sleeve 38 to position the at least one magnet 32 adjacent the sleeve 38, the protrusion 30 magnetically couples with the sleeve 38 to thereby couple the first coupling portion 22 to the second coupling portion 24. One of the first base structure 26 and the second base structure 34 is coupled to an end-effector and the other of the first base structure 26 and the second base structure 34 being coupled to a manipulator. Preferably, the manipulator is one of a mechanism, a machinery, an automation equipment and a robotic system for performing pick-and-place tasks therewith. It is preferred that the sleeve 38 has a substantially rectilinear cross-section with the cross-section of the protrusion 30 substantially shape-matching the cross-section of the sleeve 38. Preferably, the cross- section of the sleeve 38 is one of square-shaped, rectangular-shaped, triangular-shaped, polygonal-shaped and U-shaped, C-shaped.

The protrusion 30 protrudes from the second base structure 34 along the second axis 36 to terminate at a free end 44. The protrusion 30 is preferably tapered at the fee end 44 thereof.

At least a portion of the sleeve 38 is made of metal. However, it is preferred that the protrusion 30 be substantially non-ferromagnetic. Preferably, the at least one magnet 32 is embedded in the protrusion 30 at or adjacent the surface thereof. Further, the at least one magnet 32 is positioned adjacent to where the protrusion 30 couples with the first base structure 26 to enable travel of at least a portion of the protrusion 30 into the sleeve 38 before the at least one magnet 32 magnetically couples with the sleeve 38. To substantially mitigate eccentricity or imbalance of magnetic coupling forces introduced to the first coupling portion 22 and the second coupling portion 24, the at least one magnet 32 comprises at least one pair of magnets positioned on outwardly opposing faces of the protrusion 30.

When in use, it is preferred that the first base structure 26 is coupled to the end-effector and the second base structure 34 is coupled to the manipulator.

Functioning in conjunction with the first coupling portion 22 and the second coupling portion 24, the coupling assembly further comprises a receiver structure 50 defining a third axis 52, a notch 54 and an opening 56 to the notch 54. The notch 54 is for receiving the protrusion 30 displaced through the opening 56 along the third axis 52 with the first axis 28 being substantially perpendicular to the third axis 52. The notch 54 is shaped for accommodating a portion of the protrusion 30 therewithin to enable the receiver structure 50 to interpose the first base structure 26 and the sleeve 38. Wherein when the second coupling portion 24 is displaced away from the receiver structure 50 along the first axis 28 with a portion of the protrusion 30 being received in the notch 54 of the receiver structure 50, the second base structure 34 abuts the receiver structure 50 to decouple the first coupling portion 22 from the second coupling portion 24. The notch 54 is shaped and dimensioned to enable the receiver structure 50 to form a collar around a portion of the protrusion 30 for supporting the protrusion 30 when the second coupling portion 24 is decoupled therefrom.

The receiver structure 50 is further shaped and dimensioned for positionally locating and aligning the first coupling portion 22 to enable subsequent insertion of the protrusion 30 into the sleeve 38 when the second coupling portion 24 displaces along the first axis 28 towards the receiver structure 50 with the first axis 28 being substantially aligned with the second axis 36 to consequently magnetically recouple the protrusion 30 with the sleeve 38.

Thereafter, the second coupling portion 24 is displaceable along the third axis 52 away from the receiver structure 50 with the first coupling portion 22 being magnetically coupled to the second coupling portion 24.

Preferably, the second base structure 34 comprises a plate 60 where from the protrusion 30 extends and a pair of outwardly extending blades 62 extending from the sleeve 38 to terminate at respective free ends 64. The plate 60 interposes and form a substantially planar structure with the pair of blades 62. The second base structure 34 further comprises a stub 66 formed adjacent or at the free end 64 of each of the blades 62. The stub 66 on each of the blades 62 is preferably substantially cylindrically shaped and is a magnet or a housing with an internally disposed magnet. Preferably, the stub 66 extends from the respective blade 62 in the same direction the protrusion 30 extends from the second base structure 34. Preferably, the centre of the stubs 66 on the blades 62 are of equidistance from the second axis 36 such that when the second base structure 34 is rotationally displaced about the second axis 36, only a single path is scribed and shared between the stubs 66 on both the blades 62. The pair of blades 62 are preferably resiliently biased.

Preferably, the second coupling portion 24 may be used with a third coupling portion 70. The third coupling portion 70 comprises a third base structure 72 and a pair of outwardly protruding arms 74 disposing the third base structure 72 therebetween. The third base structure 72 is preferably planar and defines a fourth axis 76 and an aperture 78 centred with the fourth axis 76. The third coupling portion 70 further comprises a pair of discs 80, each being formed on the pair of arms 74. Each of the disc 80 defines a slot 82 extending from an edge opening 84 to an abutment end 86 adjacent the diametric centre of the disc 80. The abutment end 86 is shaped to enable seating of at least a portion of the stub 66 therein with the slot 82 further being shaped and dimensioned for functioning as a pathway for guiding the stub 66 from the edge opening 84 towards the abutment end 86. The pathway formed by the slot 82 is either straight or has an arcuate. The disc 80 is preferably made from a ferromagnetic material and is displaced away from the third base structure 72. Preferably, the slot 82 of one of the discs 80 directionally opposes the slot 82 of the other of the discs 80

Preferably, the third coupling portion 70 further comprises a pair of L-shaped hooks 88, each being disposed between the fourth axis 76 and the corresponding one of the pair of discs 80. The free-end of the respective hooks 88 points in the same direction as the edge opening 84 of the slot 82 of the adjacent disc 80. The third base structure 72 may have a tool or an end- effector coupled thereto. Preferably, the distance between the second axis 36 and the diametric centre of each of the stubs 66 substantially dimensionally matches the distance between the fourth axis 76 and the diametric centre of each of the discs 80.

Preferably, the receiver structure 50 has a first segment, whereat the notch 54 and opening 56 are defined, and a second segment whereat the third coupling portion 70 is attached. A locating pin-and-hole arrangement is used to enable easy attachment and detachment of the third coupling portion 70 to the second segment of the receiver structure 50 while impeding rotational displacement of the third coupling portion 70 about the fourth axis 76.

The second coupling portion 24 may be couplable with the third coupling portion 70 by first displacing the second coupling portion 24 towards the third coupling portion 70 to align the second axis 36 with the fourth axis 76. The sleeve 38 is then displaced towards the aperture 78. The aperture 78 is shaped and dimensioned to accommodate the sleeve 38 therethrough without the sleeve 38 touching the aperture 78. With the second axis 36 being substantially coincident the fourth axis 76, the second coupling portion 24 is rotationally displaced about the fourth axis 76 while being spatially displaced towards the third coupling portion 70 until the stubs 66 are positioned at the edge opening 84 of the slot 82 of each of the discs 80. Spatial displacement of the second coupling portion 24 towards the third coupling portion 70 is then terminated while angular displacement of the second coupling portion 24 about the fourth axis 76 continues to displace the stubs 66 along the pathway defined by the slot 82 towards the abutment end 86 of the respective discs 80. As the stubs 30 begins to travel along the slots 82, the blades 62 are brought under the L-shaped hooks 88 which impedes movement of the second coupling portion 24 away from the third coupling portion 70. When the stubs 66 approach the abutment ends 86 of the respective slots 82, the stubs 66 magnetically couples with the discs 80 to couple the second coupling portion 24 with the third coupling portion 70. The third coupling portion 70 is then displaced in a pre-defined direction to detach the third coupling portion from the receiver structure 50 with the tool or end-effector coupled thereto in tow.

To decouple the third coupling portion 70 from the first coupling portion 20, the third coupling portion 70 is positioned for reattachment with the receiver structure 50 to impede rotational movement thereof about the fourth axis 76. Then, the second coupling portion 24 is rotationally displaced about the fourth axis 76 to overcome the magnetic coupling force between the stubs 66 and the discs 80 to displace the stubs 66 along the slot 82 from the abutment end 86 towards the edge opening 84. Once the stubs 66 reaches the edge opening 84 and emerges from under the L-shaped hooks 88, the third coupling portion 70 is decoupled from the second coupling portion 24 and the second coupling portion 24 can be displaced away from the third coupling portion 70.

An exemplary second embodiment of the invention, a coupling assembly 120, is described with reference to FIGS 11 to 14. The coupling assembly 200 preferably comprises a first coupling portion 122 and a second coupling portion 124. The first coupling portion 122 comprises a first base structure 126 defining a first axis 128, a protrusion 130 extending from the first base structure 126, and at least one first coupler 132 coupled with the first base structure 126. The second coupling portion 124 comprises a second base structure 134 defining a second axis 136, and a receptacle 138 being shaped and dimensioned for receiving the protrusion 130 therewithin along the second axis 136. The second coupling portion 124 further comprises at least one second coupler 140 coupled to the second base structure 134. The at least one first coupler 132 is for magnetically coupling with the at least one second coupler 140.

The first base structure 126 is displaceable towards the second base structure 134 when the protrusion 130 is being inserted into the receptacle 138 to align the at least one first coupler 132 with the at least one second coupler 140 such that when the first base structure 126 is adjacent the second base structure 134, the at least one first coupler 132 couples with the at least one second coupler 140 to thereby couple the first coupling portion 122 with the second coupling portion 124.

One of the first base structure 26 and the second base structure 34 is coupled to an end- effector 141 and the other of the first base structure 26 and the second base structure 34 being coupled to one of a manipulator 142 and a docking structure 145 for the end-effector 141. Preferably, the manipulator 142 is one of a mechanism, a machinery, an automation equipment and a robotic system for performing pick-and-place tasks therewith. It is preferred that the cross-section of the protrusion 130 substantially shape-matching the cross-section of the receptacle 138.

The protrusion 130 protrudes from the second base structure 134 along the second axis 136 to terminate at a free end. The protrusion 130 is preferably tapered or rounded at the fee end 44 thereof to facilitate location and insertion of the protrusion 130 into the receptacle 138.

Preferably, each of the first base structure 126 and the second base structure are 134 of a material that is non-electrically conductive. It is preferred that at least a portion of each of the protrusion 130 and the receptacle 138 is made of metal. It is further preferred that each of the at least one first coupler 132 and the at least one second coupler 140 is a magnet or is made from a ferromagnetic material.

The first base structure 126 defines a first face 150 and the second base structure 134 defines a second face 152 for abutting the first face 150 of the first base structure 126 when the protrusion 130 is substantially fully inserted into the receptacle 138. The at least one first coupler 132 is positioned one of at and adjacent the first face 150 of the first base structure 126 and the at least one second coupler 140 is positioned one of at and adjacent the second face 152 of the second base structure 134. For example, in the case of the first base structure 126, the at least one first coupler 132 can be a disc-shaped magnet that is embedded in the first base structure 126 just beneath the first face 150 or is flushed with the first face 150. Alternatively, the at least one coupler 1126 may protrude slightly from the first face 150. Either way, the at least one coupler may be exposed or be occluded with a layer of material of an appropriate thickness that will not affect the magnetic functionality of the disc-shaped magnet when in use.

Preferably, the protrusion 130 and the receptacle 138 are electrically conductive to enable electrical and signal communication between the first coupling portion 122 and the second coupling portion 124 therevia. Preferably, one of the protrusion 130 and the receptacle 138 is electrically coupled to an electrical power source while the other of the protrusion 130 and the receptacle 138 is coupled to an electrically active system. The electrically active systems can comprise, for example, linear or rotary actuators for actuating the end-effector 141 or a gripper forming the end-effector 141, sensors such as temperature sensors, proximity sensors or force sensors, or vision systems coupled to and supported on the end-effector 141. Alternatively, only a portion of the receptacle 138, for example an extremity or an innermost portion thereof, is electrically conductive.

Based on the number of magnets and the size and type of magnets used for any of the at least one first coupler 132 and the at least one second coupler 140, the magnetic coupling force between the first coupling portion 122 and the second coupling portion 124 can be determined. For example, each of the at least one first coupler 132 and the at least one second coupler 140 can comprise a pair of magnets configured so that both pairs of magnets will be aligned for coupling with each other when the first face 150 abuts the second face 152 with the protrusion 130 being received in the receptacle 138. The magnetic coupling force will set a limit on the amount of payload and the weight of the end-effector 141 that can be carried by the manipulator 142 using the coupling assembly 120 should the direction of the weight, or force, acting on the coupling assembly 120 be substantially parallel the first axis 128. When the end-effector 141 is to be detached from the manipulator 142, the end-effector 141, or the one of the first coupling portion 122 and the second coupling portion 124 whereto the end-effector 141 is attached, can be docked on the docking structure 145. Once docked, the manipulator 142 can be displaced to exert a force beyond the magnetic coupling force for detaching the first coupling portion 122 from the second coupling portion 124. However, for typical use, the work process should be should preferably be designed to avoid forces being exerted on the end-effector 141 substantially along the first axis 128 and in a direction away from the manipulator 142 when the coupling assembly 120 is applied between the manipulator 142 and the end-effector 141.

Another set of the coupling assembly 120 may be implemented for coupling the end-effector 141 to the docking structure 145. If this is so, the end-effector 141 have, coupled thereto or formed therewith, two of the first coupling portion 122 or two the second coupling portion 124, or a combination of one of the first coupling portion 122 and one of the second coupling portion 124. With this configuration where more than one of the coupling assembly 120 is implemented, it is preferred that neither of the first axes 128, second axes 136 or first axis 128 and second axis 136 from different set of the coupling assembly 120 can be parallel or substantially parallel to one another.

Further, the first coupling portion 122 can comprise a plurality of the protrusion 130 and the second coupling portion 124 can comprise a plurality of the receptacle 138 for corresponding with the plurality of the protrusion 130 to provide multiple channels of electrical and signal communication between the first coupling portion 122 and the second coupling portion 124 and to isolate movement between the first coupling portion 122 and the second coupling portion 124 to only along the first axis 128 and the second axis 136.

In an example of application of the coupling assembly 120, more than one of the coupling assembly 120 will be used. The end-effector 141 will have one of the second coupling portion 124 coupled thereto and corresponding with one of the first coupling portion 122 coupled to the manipulator 142 to form a first set of the coupling assembly 120. The end- effector will have another one of the second coupling portion 124 coupled thereto and corresponding with one of the first coupling portion 122 coupled to the docking structure 145 to form a second set of the coupling assembly 120. The second axis 136 of the second coupling portion 124 of the first set is preferably substantially perpendicular the second axis 136 of the second coupling portion 124 of the second set. The end-effector 141 will initially be docked to the docking structure 145 with the first coupling portion 122 of the second set being coupled to the second coupling portion 124 of the second set.

For the manipulator 142 to utilise the end-effector 141, the manipulator 142 first aligns the first axis 128 and the protrusions 130 of the first coupling portion 122 of the first set with respectively the second axis 136 and the receptacles 138 of the second coupling portion 124 of the first set before displacing the first coupling portion 124 along the second axis 136 towards the second coupling portion 124 of the first set until the first coupling portion 122 and the second coupling portion 124 of the first set inter-couples. Next, the manipulator 142 displaces the end-effector 141 along the first axis 128 in a direction away from the first coupling portion 122 of the first set to decouple the first coupling portion 122 and the second coupling portion 124 of the first set.

In a forgoing manner, a coupling assembly is described according to two exemplary embodiments of the invention. Although only two embodiment of the invention is disclosed in this document, it will be apparent to one skilled in the art in view of this disclosure that numerous changes and/or modifications can be made to the disclosed embodiment without departing from the scope and spirit of the invention.