Robotic Arm

Abstract

In general terms a first aspect of the invention provides a modular robotic arm in which respective joint modules and/or end effector modules can be swapped or exchanged for a replacement module. The modules are interconnected by pairs of interlocking features that can be readily and repeatably interlocked and separated.

Claims

1. A modular robotic arm comprising: a first joint module comprising: a first joint that is movable to cause movement between rigid first and second links, the first or second link comprising a first interlocking feature; and a first variable stiffness actuator having one or more resilient members actuatable to move the first joint; and a second module comprising a second interlocking feature configured to interlock with the first interlocking feature of the first module, wherein the robotic arm has an operating mode in which the second interlocking feature is interlocked with the first interlocking feature to thereby operatively connect the second module to the first module, and a reconfiguration mode in which the second interlocking feature is separated from the first interlocking feature to thereby enable the first or second module to be swapped for a replacement module, and wherein in the operating configuration the one or more resilient members do not engage the second module, wherein the one or more resilient members are each connected to the first link and the second link, and wherein the one or more resilient members each comprise an elastic portion that is configured to elongate under an applied tension and be biased to return to its original length upon removal of said applied tension.

2. A robotic arm according to claim 1, wherein the second module comprises either: an end effector module comprising an end effector arranged to manipulate an object; or a second joint module comprising a second joint that is movable to cause movement between rigid third and fourth links, the third or fourth link comprising the second interlocking feature, and a second variable stiffness actuator having one or more resilient members actuatable to move the second joint.

3. A robotic arm according to claim 1, wherein the first link comprises the first interlocking feature, the second link comprises a third interlocking feature, and the robotic arm comprises a third module having a fourth interlocking feature arranged to interlock with the third interlocking feature of the first module in the operating mode, the third and fourth interlocking features being separated in the reconfiguration mode to enable the first or third module to be swapped for a replacement module.

4. A robotic arm according to claim 1, wherein one of the first and second interlocking features comprises a female element and the other of the first and second interlocking features comprises a male element arranged to nest within the female element to thereby interlock the first and second interlocking features together.

5. A robotic arm according to claim 1, wherein the first and second interlocking features are interlocked via a sliding connection.

6. A robotic arm according to claim 1, wherein the first and second interlocking features are interlocked via a frictional engagement.

7. A robotic arm according to claim 1, wherein the first and second interlocking features are interlocked via a one-step connection.

8. A robotic arm according to claim 1, wherein the first and second interlocking features are interlocked without additional fastening means.

9. A robotic arm according to claim 1, wherein the first and second interlocking features comprise cooperating sliding dovetail joint features.

10. A robotic arm according to claim 3, wherein one of the third and fourth interlocking features comprises a female element and the other of the third and fourth interlocking features comprises a male element arranged to nest within the female element to thereby interlock the third and fourth interlocking features together.

11. A robotic arm according to claim 1, wherein the one or more resilient members do not extend across the interlocked first and second interlocking features in the operating mode.

12. A robotic arm according to claim 1, wherein the first and/or second variable stiffness actuator comprises a first resilient member of the one or more resilient members actuatable by an increase in tension to urge the joint to move in a first direction, and a second resilient member of the one or more resilient members actuatable by an increase in tension to urge the joint to move in a second direction opposite to the first direction

13. A robotic arm according to claim 1, wherein the first and/or second variable stiffness actuator comprises first and second bi-directional actuators, each bi-directional actuator comprising a first resilient member of the one or more resilient members actuatable by an increase in tension to urge the joint to move in a first direction, and a second resilient member of the one or more resilient members actuatable by an increase in tension to urge the joint to move in a second direction opposite to the first direction.

14. A robotic arm according to claim 1, wherein the first and/or second variable stiffness actuator is operable in a low stiffness mode in which a resultant tension in the one or more resilient members is relatively low and a high stiffness mode in which the resultant tension in the one or more resilient members is relatively high.

15. (canceled)

16. A robotic arm according to claim 1, wherein the first and/or second variable stiffness actuator comprises one or more actuators, each actuator comprising a first pulley rotatable relative to the first link and rotatable in tandem with the second link, a second pulley rotatable relative to the first link, and an actuation link extending between the first and second pulleys, the actuation link including at least one of the one or more resilient members extending between the first and second pulleys whereby rotation of the first or second pulley causes movement of the joint.

17. A kit of parts comprising a robotic arm according to claim 1, and a replacement second module comprising a further second interlocking feature arranged to interlock with the first interlocking feature of the first module, wherein either the second module or replacement second module can be operatively connected to the first module in the operating configuration.

18. A method of operating a robotic arm according to claim 1, comprising the steps of: disconnecting the first and second interlocking features; replacing the first or second module with a replacement module comprising a further interlocking feature; and interlocking the first or second interlocking feature with the further interlocking feature to arrange the robotic arm in the operating mode.

19. A system for harvesting fruit or vegetables comprising a movable base supporting one or more robotic arms according to claim 1.

20-46. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0081] One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0082] FIG. 1 is a side view of a robotic arm according to an embodiment of the invention;

[0083] FIG. 2 is an isometric view of the robotic arm of FIG. 1;

[0084] FIG. 3 is an isometric view of a wrist joint module suitable for use in embodiments of the invention;

[0085] FIG. 4 is a plan view of the wrist joint module of FIG. 3;

[0086] FIG. 5 is a side view of the wrist joint module of FIG. 3;

[0087] FIG. 6 is an isometric view of a driver pulley wheel of the wrist joint module of FIG. 3;

[0088] FIGS. 7A-D are various views of a driven pulley wheel of the wrist joint module of FIG. 3;

[0089] FIG. 8 illustrates a resilient member suitable for use in embodiments of the invention;

[0090] FIG. 9 is an isometric view of an end effector module suitable for use in embodiments of the invention;

[0091] FIG. 10 is a partial view of the end effector module of FIG. 9 with a top cover part omitted to enable the cutting wire to be seen;

[0092] FIGS. 11-13 are views of a drive system of the end effector module of FIG. 9;

[0093] FIG. 14 is an isometric view of an end effector module suitable for use in embodiments of the invention;

[0094] FIG. 15 shows the end effector module of FIG. 14 with the belt omitted;

[0095] FIGS. 16A-C are views of a drive system of the end effector of FIG. 14;

[0096] FIGS. 17A and 17B schematically illustrate a trajectory carried out by an end effector of a robotic arm according to an embodiment of the invention, and a change in stiffness of one or more joints within that arm during movement through the trajectory, respectively;

[0097] FIGS. 18A and 18B illustrate embodiments of control architecture for a ballistic phase (FIG. 18A) and a closed-loop joint control phase (FIG. 18B) of movement of one or more joints of a robotic arm according to an embodiment of the invention;

[0098] FIG. 19 illustrates a fruit- or vegetable-picking system incorporating multiple robotic arms according to an embodiment of the invention;

[0099] FIGS. 20A and 20B illustrate an alternative elbow joint module suitable for robotic arms according to embodiments of the invention, the elbow joint module having swappable driver pulley wheels;

[0100] FIGS. 21A and 21B are side views of the elbow joint module of FIG. 20A;

[0101] FIG. 22 is a side view of the elbow joint module of FIG. 20A with the driver pulley wheel removed; and

[0102] FIG. 23 is an isometric view of a portion of the elbow joint module of FIG. 20A with one of the driver pulley wheels omitted for clarity.

DETAILED DESCRIPTION

[0103] FIGS. 1 and 2 illustrate side and isometric views, respectively, of a robotic arm 100 according to an embodiment of the invention. The arm comprises a base 10 via which the arm 100 can be mounted to a structure, and via which the arm can receive an electricity supply (not shown) and/or control signals.

[0104] The arm 100 has a plurality of articulated joints, including a shoulder joint 20, an elbow joint 30, and a wrist joint 40.

[0105] The joints together provide movement with six degrees of freedom; in Cartesian space this corresponds to displacement along x, y and z axes, and rotation about each of the x, y and z axes. Movement of the joints controls the position and orientation of the end effector 50 (not shown in FIGS. 1 and 2) to thereby enable an object to be manipulated by the end effector.

[0106] The wrist joint 40 enables relative movement about an axis 40A between a rigid first link 41 that extends towards the end effector 50 and a rigid second link 43 that extends towards the elbow joint 30. The first link 41 comprises an end effector connector 42 configured to enable an end effector 50 (not shown in FIGS. 1 and 2) to be removably attached to the arm 100 via a rigid connection, and the second link 43 comprises an elbow connector 44 configured to enable the second link 43 to be removably attached to the elbow joint 30. The wrist joint 40 thus comprises a wrist joint module.

[0107] Similarly, the elbow joint 30 enables relative movement about an axis 30A between a rigid third link 32 that extends towards the wrist joint 40 and a rigid fourth link 34 that extends towards the shoulder joint 20. The third link 32 comprises an elbow connector 33 configured to be removably engaged with the elbow connector 44 of the second link 43 to provide a rigid connection between the third 32 and second 43 links. The fourth link 34 comprises a shoulder connector 35 configured to be removably engaged with a corresponding connector of the shoulder joint to enable the fourth link 34 to be removably attached to the shoulder joint 20. The elbow joint 30 thus comprises an elbow joint module.

[0108] The shoulder joint 20 forms a shoulder joint module, and will not be described in detail herein. The skilled reader will readily understand how the principles described in relation to the elbow and wrist joints may be applied to the shoulder joint 20, or to any other joint in the robotic arm 100.

[0109] The shoulder joint 20, elbow joint 30 and wrist joint 40 each comprise a variable stiffness joint which enables the passive compliance of the joint (i.e. the resistance to deflection resulting from an externally applied force/torque) to be controlled. The principles of the variable stiffness joint will be described below in relation to the elbow joint 30 and wrist joint 40, though the skilled reader will readily understand how these principles may be applied to the shoulder joint 20 or to any other joint in the robotic arm 100.

[0110] In the wrist joint 40, which can be seen most clearly in FIGS. 3-7, relative movement between the first 41 and second 43 links is controlled by first 45a and second 45b bi-directional actuators that together enable the wrist joint 40 to act as a variable stiffness joint. Each bi-directional actuator 45a, 45b comprises a motor (not shown) driving a driver pulley wheel 46a, 46b rigidly connected to the first link 41 but rotatable relative to the second link 43, each driver pulley wheel engaging a flexible actuation link 47a, 47b. The actuation links 47a, 47b each comprise a pliable elongate cord that extends in a continuous loop between the driver pulley wheel 46a, 46b and a driven pulley wheel 48a, 48b to thereby enable each driver pulley wheel to drive its respective driven pulley wheel via a belt drive arrangement.

[0111] The driven pulley wheels 48a, 48b are each rotatably mounted on the second link 43. In this way, rotation of the driven pulley wheels 48a, 48b in response to rotation of the driver pulley wheels 46a, 46b causes relative movement between the first and second links, and thus movement of the wrist joint 40.

[0112] As shown best in FIGS. 4 and 7, the driven pulley wheels 48a, 48b each comprise a double pulley having two adjacent pulley tracks 67, 68 sharing a common rotational axis. Each actuation link 47a, 47b is fixed to its respective driver wheel 46a, 46b so that a portion of the actuation link moves in tandem with the driver wheel in an arc around the axis 40A. In the illustrated embodiment this is achieved by clamping two free ends 63a, 63b of the elongate actuation link between the driver wheel and a clamp member 61 as shown in FIG. 6, but in other embodiments each actuation link may comprise a continuous loop clamped or otherwise fixed to the driver wheel. Each actuation link 47a, 47b then extends around a first pulley track 67 of the respective driven pulley wheel 48a, 48b through a passageway 69 to the second pulley track 68, and from there around the second pulley track 68 and back to the driver wheel 46a, 46b.

[0113] This double pulley arrangement provides a doubled torque output compared to a single pulley arrangement. However, arrangements in which the driven pulley wheels 48a, 48b comprise single pulley wheels are encompassed by this application.

[0114] In some embodiments each actuation link comprises a loop having two generally non-extensible portions that engage the driver and driven pulley wheels, respectively, a first tendon portion 60a, 60b (also referred to as a first resilient member 60a, 60b) that extends between the driver and driven pulley wheels, and a second tendon portion 62a, 62b (also referred to as a second resilient member 62a, 62b) that extends between the driver and driven pulley wheels. In other embodiments the actuation links may not comprise any generally non-extensible portions.

[0115] The first 60a, 60b and second 62a, 62b tendon portions each have a monotonically increasing non-linear relationship between applied force and resulting elongation. That is, the resistance to elongation (stiffness) increases with increased applied force.

[0116] An embodiment of the first 60a, 60b and second 62a, 62b tendon portions is illustrated in FIG. 8. Each tendon portion comprises an elongate elastic core 64 around which a helical- or spiral-shaped stiffening portion 66 is wrapped. The elastic core 64 has a circular cross-section and is formed from an elastomeric material that is able to provide a significant degree of elongation (e.g. up to 700% increase in length) when under tension and return to its original shape and size when the tension is removed. An appropriate material for the elastic core 64 is a TPE thermoplastic elastomer such as Filaflex™, produced by Recreus. In contrast, the material from which the stiffening portion 66 is made is generally non-elastic; a suitable material is nylon.

[0117] When an elongating tensile force is applied to each of the tendons, the spiral shape of the stiffening portion 66 means that it becomes longer in the longitudinal direction (the direction in which the force is applied) while becoming narrower in the lateral direction (perpendicular to the longitudinal direction). This lateral contraction is resisted by the elastic core 64, and this resistance and the consequential deformation of the elastic portion causes a progressive increase in resistance to elongation with an increase in applied force. In this way, as the tendon is elongated, the elastic portion initially carries the majority of the load, but as the elongation increases the relatively stiff portion carries a progressively higher proportion of the load to provide an increasing resistance to further elongation.

[0118] In use, each bi-directional actuator 45a, 45b is able to provide movement of the wrist joint 40 in both a first direction (clockwise movement of the second link 43 relative to the first link 41, as seen in FIGS. 1 and 2) and a second direction opposite to the first direction. Movement in the first direction is caused by operating the motor to turn each driver pulley 46a, 46b to thereby increase tension in the first tendon portion 62a, 62b and thereby reduce tension in the second tendon portion 64a, 64b. Similarly, movement in the second direction is caused by operating the motor to turn each driver pulley 46a, 46b to increase tension in the second tendon portion 64a, 64b and thereby reduce tension in the first tendon portion 62a, 62b.

[0119] In this way, each of the bi-directional actuators 45a, 45b is operable in a first configuration to urge the wrist joint 40 in the first direction, and in a second configuration to urge the joint in the second direction. By controlling movement of the joint via independent control of both the first 45a and second 45b bi-directional actuators it is possible to vary the stiffness (the resistance to externally-applied forces) of the joint while controlling its position.

[0120] That is, in a high torque mode (cooperating mode) each of the bi-directional actuators 45a, 45b may be operated to work in tandem (i.e. both in the first configuration or second configuration) to maximise the available torque output. In this mode the joint has a relatively low stiffness and relatively high passive compliance. At the other end of the spectrum, the bi-directional actuators 45a, 45b may be operated in a high stiffness mode (antagonist mode) in which they counter-act each other (i.e. one in the first configuration and the other in the second configuration). In this mode the joint has a relatively high stiffness and relatively low passive compliance.

[0121] The bi-directional actuators 45a, 45b can also be operated at any point along the continuous spectrum between the high torque mode and high stiffness mode, so that as the stiffness of the joint is reduced the available torque output can be increased, and vice versa. In this way, when low joint stiffness is required (such as during ballistic phase movements described below) the torque output of the joint can be maximised.

[0122] The relationship between the first 45a and second 45b bi-directional actuators can be described by way of the differential position, p, of the driver pulleys 46a, 46b. That is, in the high torque mode the differential position may have a maximum value of ‘1’, in the high stiffness mode a maximum value of ‘−1’, and values between ‘1’ and ‘−1’ may represent differential positions in the spectrum between these extremes.

[0123] In alternative embodiments, each of the bi-directional actuators 45a, 45b may be replaced by a uni-directional actuator (not illustrated). For example, the first uni-directional actuator 45a may comprise only the first tendon portion 60a and no second tendon portion, and the second uni-directional actuator 45b may comprise only the second tendon portion 62b and no first tendon portion. In this way, movement of the wrist joint 40 in the first direction may be achieved by operating the driver pulley 46a of the first uni-directional actuator 45a to increase tension in the first tendon portion 60a, and movement of the wrist joint 40 in the second direction may be achieved by operating the driver pulley 46b of the second uni-directional actuator 45b to increase tension in the second tendon portion 62b. Moreover, the first and second uni-directional actuators may be operated together to control the overall stiffness of the wrist joint 40 in a similar manner to that described above in relation to the high stiffness mode (antagonist mode) of the bi-directional actuator embodiment.

[0124] Each of the joints of the arm 100, including the shoulder joint 20, and elbow joint 30 may have a variable stiffness joint as described above in relation to the wrist joint 40. The wrist joint 40 is described merely as being exemplary of any variable stiffness joint in the arm 100.

[0125] In particular, the elbow joint 30 is broadly similar to the wrist joint 40, and for that reason description herein will focus on the features of the elbow joint 30 that are different.

[0126] In the elbow joint 30, relative movement between the third 32 and fourth 34 links is controlled by first 35a and second 35b bi-directional actuators that together enable the elbow joint 30 to act as a variable stiffness joint. Each bi-directional actuator 35a, 35b comprises a motor (not shown) driving a driver pulley wheel 36a, 36b rotatably mounted on the fourth link 33, each driver pulley 36a, 36b engaging a flexible actuation link 37a, 37b. The actuation links 37a, 37b each comprise a pliable elongate cord that extends in a continuous loop between the driver pulley wheel 36a, 36b and a driven pulley wheel 38a, 38b to thereby enable each driver pulley wheel to drive its respective driven pulley wheel via a belt drive arrangement.

[0127] The driven pulley wheels 38a, 38b are each rigidly connected to the third link 31 but rotatable relative to the fourth link 33. In this way, rotation of the driven pulley wheels 38a, 38b in response to rotation of the driver pulley wheels 36a, 36b causes relative movement between the third and fourth links, and thus movement of the elbow joint 30.

[0128] The first 35a and second 35b bi-directional actuators are identical to the first 45a and second 45b bi-directional actuators of the wrist joint 40, with the exception that the driven pulleys 38a, 38b of the elbow joint 30 comprise single pulleys, rather than double pulleys. In other respects, the features of the actuators, including the actuation links thereof, and how they may be operated, described above in relation to the wrist joint 40 apply equally to the elbow joint 30.

[0129] In the illustrated embodiments each of the connectors, including the end effector connector 42, elbow connectors 32, 44, and shoulder connector 34, comprise sliding dovetail joint connection features. In more general terms each pair of cooperating connectors, one connector comprises a male protruding feature and the other connector comprises a female feature with which the male feature can be engaged to provide a rigid connection therebetween. The male feature generally comprises a protruding portion that tapers outwardly in a width direction and the female feature generally comprises a recess that tapers inwardly in a corresponding manner to provide a close sliding fit therebetween.

[0130] The skilled reader will understand that the specific shape and configuration of the male and female features are not critical, the important feature being that they can be readily interconnected via a one-step connection step to provide a rigid connection therebetween and readily disconnected subsequently.

[0131] The end effector 50 comprises an end effector module that can be integrated into the robotic arm 100 by interlocking the wrist connector 52 of an end effector 50 (see below) with the end effector connector 42 of the wrist joint 40.

[0132] The wrist joint 40 comprises a wrist joint module that can be integrated into the robotic arm 100 by interlocking elbow connectors 34, 44, and interlocking end effector connector 42 with a corresponding wrist connector 52 of an end effector 50 (see below).

[0133] Similarly, the elbow joint 30 comprises an elbow joint module that can be integrated into the robotic arm 100 by interlocking elbow connectors 34, 44, and interlocking shoulder connector 35 with a corresponding elbow connector of the shoulder joint.

[0134] Finally, the shoulder joint 20 comprises a shoulder joint module that can be integrated into the robotic arm 100 by interlocking respective connectors thereof with corresponding connectors of the base 10 and elbow module.

[0135] This arrangement enables the robotic arm 100 to be modular such that each of the joint modules 20, 30, 40 can be swapped out for a replacement joint, and the end effector 50 can be swapped out for a replacement end effector.

[0136] For example, each joint module may be removed and replaced with an equivalent joint module to cater for maintenance requirements or in-service faults, or it may be replaced with a joint module in which the actuators provide a different level of torque or speed output to allow the operating characteristics of the arm 100 to be tuned for different operating conditions.

[0137] Similarly, the end effector module 50 may be swapped out for an equivalent replacement end effector module to cater for maintenance requirements or in-service faults, or alternatively may be replaced with an end effector having different functionalities. For example, an end effector module having fingers suitable for grasping a fruit or vegetable to enable it to be picked may be swapped for an end effector module, such as end effector module 50A described below, having a blade suitable for cutting the stem of a fruit or vegetable.

[0138] A key feature that enables this modular arrangement is that no actuation links extend across any connector or pair of cooperating/interlocking connectors. Thus, a whole joint module can be removed and replaced without the need to remove, alter or otherwise adjust the bi-directional actuators or their actuation links. Indeed, the removal of a module should be possible simply by disconnecting its connector(s).

[0139] In variations of the illustrated embodiments the torque vs. speed characteristics of any of the joints 20, 30, 40 may be varied by modifying the effective diameter of the driver and/or driven wheel pulleys of the respective actuators. Thus, the gear ratio—i.e. the ratio between the track diameter of the driven pulley wheel and driver pulley wheel—of each actuator can be varied.

[0140] This may be achieved in a number of different ways. For example, one or more of the pulleys may be swapped with another pulley having a different effective diameter (i.e. in which the track around which the actuation links pass has a different diameter). Alternatively, one or more of the pulleys may comprise a plurality of tracks about which the actuation links can pass, each track having a common axis but a different diameter, so that the actuation link can be swapped between the tracks. Finally, one or more of the pulleys may comprise a track with a variable diameter; for example, the track may comprise multiple separate regions that can move in a radial direction to increase or decrease the overall track diameter.

[0141] Taking the elbow joint 30 as an example, the driver pulley wheels 36a, 36b of the bi-directional actuators 35a, 35b may be exchanged or otherwise modified to provide a larger or smaller track diameter to thereby alter the ratio between the diameter of the driver pulley wheels 36a, 36b and the driven pulley wheels 38a, 38b. Such an arrangement is illustrated in FIGS. 20 to 23, which show an elbow joint 130 that can be exchanged with the elbow joint 30 of the embodiment illustrated in FIGS. 1 to 9.

[0142] In FIG. 20A the driver pulley wheels 136a, 136b of the elbow joint 130 have a relatively small diameter to provide a relatively high torque output, while in FIG. 20B the driver pulley wheels 136a, 136b have been replaced with equivalent pulley wheels with a relatively large diameter to thereby provide a relatively high speed output. The driven pulley wheels 138a, 138b each incorporate a tension control mechanism 140 by which the effective length of the respective actuation link 137a, 137b—and thus the tension therein—can be readily and straight-forwardly controlled when the driver pulley wheels 136a, 136b are exchanged for a smaller or larger pulley wheel.

[0143] The tension control mechanism 140 of each driven pulley wheel 138a, 138b comprises a pair of slider mechanisms 142, each of which has a slider 144 that clamps a free end of the actuation link 137a, 137b, the slider 144 being slidable within a slider block 146. As the slider 144 slides within the slider block 146 the free end of the actuation link 137a, 137b is moved to thereby alter its overall length and thus the tension therein. The position of the slider 144 within the slider block 146 is controlled by rotation of a screw 148 comprising a male screw thread which cooperates with a female screw thread in the slider 144.

[0144] Thus, the tension on the actuation link 137a, 137b can be readily modified simply by rotation of the screw 148 of one or both of the sider mechanisms 142. FIG. 21A illustrates the tension control mechanism 140 in a pre-tensioned configuration, while FIG. 21B illustrates the mechanism after tensioning by sliding the sliders 144 along their respective slider blocks 146.

[0145] Each slider 144 can be removed from its respective slider block 146 by rotating the screw 148 until it is disconnected from the slider 144. The uninstalled slider 144 is then connected to the actuation link 137a, 137b but otherwise unconnected to the driven pulley wheel 138a, 138b. To remove the driver pulley wheels 136a, 136b the tension control mechanisms 140 are used to reduce the tension in each of the actuation links 137a, 137b by sliding each of the sliders 144 along their respective slider blocks 146 to the position illustrated in FIG. 21A. The sliders 144 are then removed from their respective slider blocks 146 entirely so that there is no connection between the actuation link 137a, 137b and the driven pulley wheel 138a, 138b.

[0146] The driver pulley wheels 136a, 136b are then removed as shown in FIG. 22 and the actuation links 137a, 137b are removed with them (FIG. 22 illustrates an arrangement in which the driver pulley wheels 136a, 136b are removed before the sliders 144 are removed from the slider blocks 146, but it is envisaged that these steps will more likely be carried out in the reverse order). FIG. 23 shows in more detail the mounting plate 139b to which the driver pulley wheel 136b fastens. Each mounting plate 139a, 139b provides an interface between the motor enclosed within the fourth link 133 whereby the motor is operable to rotate the mounting plate 139a, 139b.

[0147] The driver pulley wheels 136a, 136b are then replaced with pulley wheels having a different effective diameter by fastening the replacement driver pulley wheels to their respective mounting plates 139a, 139b. The actuation links 137a, 137b are also replaced with corresponding replacement actuation links having a different effective length appropriate to the diameter of the replacement pulley wheels. In preferred arrangements each of the original or replacement actuation links is durably connected to its respective original or replacement driver pulley wheel. For example, the driver pulley wheels 136a, 136b may comprise double pulleys of the type described above in relation to driven pulley wheels 48a, 48b illustrated in FIGS. 4, 6 and 7, in which the actuation links are clamped to the pulley wheel.

[0148] The replacement actuation links each have a replacement slider corresponding to the sliders 144 connected to a free end thereof. Once the replacement driver pulley wheels have been installed, the replacement sliders are each installed in their respective slider blocks 146 and the tension control mechanisms 140 then used to increase the tension therein to an operating tension by sliding each of the sliders 144 along their respective slider blocks 146 to, or towards, the position illustrated in FIG. 21B.

[0149] The end effector module 50 may be selected from a set of end effector modules having end effectors with different characteristics suited to different applications. For example, a suitable end effector 50 for picking soft fruit may comprise two opposing rigid finger members with a pliable pad at a free end thereof, the finger members moveable in a pincer configuration to grip an object (not shown) between the pliable pads. Alternatively, the end effector may comprise a plurality of flexible fingers.

[0150] FIGS. 9 to 13 illustrate an end effector module 50A comprising a blade for cutting a stem of a fruit or vegetable, and FIGS. 14 to 16 illustrate a related end effector module 50B comprising a belt, or band, for grasping a fruit or vegetable while its stem is being cut.

[0151] The end effector blade module 50A comprises a rigid static portion 52 comprising a base portion with two diverging arms that together form a V-shape. The base portion includes a wrist connector 53 configured to interconnect with the end effector connector 42 to provide a rigid connection between the static portion 52 and the first link 41 of the arm 100. A cutting wire 54 extends around rotatable pulleys 55 at the free end of each arm of the static portion 52 to form a cutting portion 54A therebetween. The wire 54 then passes along each arm to a drive system 56 comprising a motor 57 that drives a pair of toothed gears 58 so that they rotate in tandem about aligned gear axes. Each free end of the cutting wire 54 is attached to a fixing location 59 on a respective one of the toothed gears 58 that is offset from the gear axis. In this way, as the toothed gears 58 rotate the cutting wire 54 reciprocates along its length. Thus, the wire in the cutting portion 54A moves in a sawing motion relative to the static portion 52 so that the cutting portion 54A can be urged against the stem of a vegetable or fruit to cut therethrough.

[0152] The cutting wire 54 is able to cut equally at all positions around its surface. In the present embodiment the cutting wire 54 comprises a braided wire in which four strands of steel wire are braided, or twisted, together, each strand comprising a wire core with a thinner steel wire wrapped around it in a helical arrangement. The thinner steel wire thus forms blunt, or rounded, protrusions that project radially from each wire core. These protrusions are thus harmless when the cutting wire 54 is not moving, but act as cutting teeth, or serrations, when the cutting wire 54 is reciprocated. The skilled reader will understand that other forms of cutting wire able to cut equally at all positions around its surface are available, and are appropriate for use in the present embodiment.

[0153] The belt module 50B comprises a rigid static portion 52′ including a base portion supporting a drive system 56′, two belt guides 51′, and a wrist connector 53′ configured to interconnect with the end effector connector 42 to provide a rigid connection between the static portion 52′ and the first link 41 of the arm 100. A belt 54′ extends in a loop between the belt guides 51′. One end of the belt 54′ is fixed and the other end comprises a free end that is movable relative to the fixed end by the action of the drive system 56′ to thereby increase or decrease the size of the loop. The drive system 56′ comprises a motor 57′ that drives a pair of driven rollers 58′. The belt 54′ passes between the driven rollers 58′ and a pair of passive rollers 59′ so that rotation of the driven rollers 58′ causes the free end of the belt to move relative to the fixed end.

[0154] In use, one robotic arm 100 comprising the belt module 50B is controlled so that the loop of the belt 54′ encircles a vegetable or fruit to be picked. The drive system 56′ is then operated to decrease the size of the loop and thereby grip the vegetable or fruit with the belt 54′. A second robotic arm 100 comprising the blade module 50A is controlled so that the cutting portion 54A of the cutting wire 54 is urged against a stem of the vegetable or fruit so that the reciprocating motion of the wire causes the cutting portion 54A to cut through the stem. The cut vegetable or fruit is then removed by the robotic arm comprising the belt module to a collection container and the drive system 56′ operated to increase the size of the loop of the belt 54′ to thereby release the vegetable or fruit.

[0155] In preferred embodiments the robotic arm 100 also comprises a sensor-control phase stereo camera (not shown) and colour camera (not shown) mounted on an end link of the arm (e.g. the first link 41 or a static portion of the end effector module) so that they move in tandem with the end effector 50. In this way, the sensor-control phase stereo camera and colour camera provide continuous images of the region of the environment within which the end effector 50 can operate, and a limited portion of the environment surrounding the end effector 50. The sensor-control stereo camera and colour camera are used in the sensor control (final approach) phase of movement of the robotic arm 100, as described further below.

[0156] In embodiments in which the end effector 50 comprises two or more fingers movable towards one another to grip an object the sensor-control phase stereo camera and/or colour camera may alternatively be mounted to a central region between the fingers to thereby provide a particularly close association between the location of the camera(s) and the end effector location.

[0157] Each robotic arm 100 also has an associated joint control phase stereo camera (250 in FIG. 19; not shown in FIGS. 1 and 2) that is positioned in a fixed position with respect to the base 10, and provides images including all points accessible by the end effector 50 of that arm 100.

[0158] In use, the robotic arm 100 is controlled to control the position of the end effector 50 by controlling the position of each of the joints, including the wrist joint 40, elbow joint 30, and shoulder joint 20, while simultaneously controlling the stiffness of each of those joints.

[0159] FIGS. 17A and 17B illustrate an embodiment of the invention in which the robotic arm 100 is controlled via a four-phase movement. This four-phase movement is considered to be particularly suitable for applications in which an object is to be engaged or otherwise manipulated by the end effector 50, such as fruit- or vegetable-picking applications.

[0160] FIG. 17A illustrates an example trajectory for a fruit- or vegetable-picking movement, while FIG. 17B schematically illustrates the change in joint stiffness at the elbow joint 30 (or shoulder joint 20, wrist joint 40, or other joint) over that trajectory. The end effector 50 starts at t.sub.0 and travels in a ballistic phase through t.sub.1 and t.sub.2 to t.sub.3. The trajectory from t.sub.3 to t.sub.4 represents a closed-loop joint control phase, while the trajectory from t.sub.4 to t.sub.6 represents a sensor-control phase. At t.sub.6 the end effector 50 grasps, engages or otherwise manipulates the fruit or vegetable, and the trajectory from t.sub.6 to t.sub.7 represents an optional detachment phase where the fruit or vegetable is detached from the stem, cane, bush, vine, stem or tree on which it has grown.

[0161] The control architecture for the ballistic phase and closed-loop joint control phase are illustrated in FIGS. 18A and 18B, respectively. In the following the movement of only one joint—the wrist joint 40—is described in order to aid understanding, but the skilled reader will understand that in fact all joints of the arm 100 will move to achieve movement of the end effector 50.

[0162] The ballistic phase (FIG. 18A) has as inputs a desired joint angle, θ.sub.d, and desired joint stiffness, c. An inverse joint model is used to map the desired joint angle and desired joint stiffness to the corresponding differential position, p, of the driver pulleys 46a, 46b, based on the desired joint angle and desired joint stiffness. Then, an equilibrium equation is used to determine the angular position, α.sub.1, of the driver pulley 46a of the first bi-directional actuator 45a and the angular position, α.sub.2, of the pulley 46b of the second bi-directional actuator 45b that will achieve both the differential position, p, and the desired joint stiffness, c.

[0163] The output of the ballistic phase of joint control at t.sub.3 is a joint angle, θ, which is close to θ.sub.d, preferably more than 50% of θ.sub.d, and ideally 60%, 70%, 80% or 85% or more of θ.sub.d. The ballistic phase thus moves the end effector 50 to a nearby location in the vicinity of the initial estimated location of the fruit to be picked, as described further below.

[0164] The closed-loop joint control phase (FIG. 18B) also has as inputs the desired joint angle, θ.sub.d, and desired joint stiffness, c. The current joint angle, θ, is fed back to the controller to determine a joint angle difference, Δθ, between the current joint angle, θ, and the desired joint angle, θ.sub.d, and thereby reduce that difference, Δθ. A feedback control law step determines, based on the joint angle difference, Δθ, a change in differential position, Δp, that will reduce the joint angle difference Δθ. This is then transformed into a differential position, p, which is used by an equilibrium equation to determine the angular position, α.sub.1, of the driver pulley 46a of the first bi-directional actuator 45a and the angular position, α.sub.2, of the pulley 46b of the second bi-directional actuator 45b that will achieve both the differential position, p, and the desired joint stiffness, c.

[0165] The output of the closed-loop joint control phase of joint control at t.sub.4 is a joint angle, θ, that is even closer to θ.sub.d, preferably exactly at θ.sub.d. However, since the joints of the arm 100 are not rigid, but are compliant to a greater or lesser degree, achieving the desired joint angle, θ.sub.d, may not result in the end effector being located in precisely in the right position to engage or otherwise manipulate the fruit. Moreover, the target may be moving (e.g. by the action of wind) and/or the location data provided by the joint control phase stereo camera may be inaccurate. The sensor-control phase corrects for these errors at the end of the trajectory, from t.sub.4 to t.sub.6.

[0166] Movement through the trajectory of FIG. 17A will now be described, by way of an example of how the arm is controlled in use. As above, in the following the movement of only one joint—the wrist joint 40—is described in order to aid understanding, but the skilled reader will understand that in fact all joints of the arm 100 will move to achieve movement of the end effector 50.

[0167] At t.sub.0 the ballistic phase stereo camera is used to generate a three-dimensional point cloud containing target positions of fruit to be picked (or other target positions in other applications). Each target has a position in a Cartesian coordinate system with an origin, or reference point, at or near the base 10 of the arm 100. Once a point of interest has been selected from the point cloud, the ballistic phase trajectory to t.sub.3 is generated and the angular positions, α.sub.1, of the driver pulley 46a of the first bi-directional actuator 45a and the angular position, α.sub.2, of the driver pulley 46b of the second bi-directional actuator 45b at each of t.sub.1, t.sub.2 and t.sub.3 are calculated using the control architecture described above in relation to FIG. 18A.

[0168] The joint is then moved from t.sub.1 to t.sub.2 and then to t.sub.3 by controlling the bi-directional actuators 45a, 45b to reach the calculated angular positions and thereby ensure the relative positions of the driver pulleys 46a, 46b at each point of the ballistic phase trajectory is such that the joint has the desired joint pose with the desired level of stiffness.

[0169] It can be seen from FIG. 17B that the stiffness of the joint is relatively low during the ballistic phase, though rises from t.sub.3 to t.sub.4 on the approach to the closed-loop joint control phase. During this phase the joint moves relatively fast and the open loop control further speeds up arrival at t.sub.3 by reducing the number of control steps required. This fast movement with limited control has the potential to result in collisions between the arm 100 and an external body, such as a person or structure. However, the relatively low joint stiffness ensures that the arm 100 has a relatively high level of passive compliance during the ballistic phase, with the result that such collisions should not cause damage to either the arm 100 or the external body. The high torque mode may be utilised during the ballistic phase to maximise the torque available to move the joint.

[0170] At t.sub.3 the closed loop joint control phase commences. The control architecture described above in relation to FIG. 18B is used to calculate each change in angular position, α.sub.1, of the driver pulley 46a and angular position, α.sub.2, of the pulley 46b required to reduce the joint angle difference, Δθ. The joint is progressively moved towards t.sub.4 by controlling the bi-directional actuators 45a, 45b to reach the calculated angular positions, and repeating until the joint angle difference, Δθ, is zero or within an allowable margin of zero.

[0171] It can be seen from FIG. 17B that the stiffness of the joint continues to rise in the closed-loop joint control phase from t.sub.3 to t.sub.4, to a level at which the joint stiffness is relatively high. Passive compliance in this high stiffness mode is thus reduced, but accuracy of joint position increases.

[0172] In the sensor-control phase from t.sub.4 to t.sub.6 the high stiffness mode is maintained. During this phase the movement of the joint is controlled based on visual data obtained by the sensor-control phase stereo camera and colour camera. Images obtained by the colour camera are analysed to identify the fruit or vegetable to be picked or otherwise engaged or manipulated using image recognition algorithms. For example, a cluster of pixels in a certain colour range or in a certain pattern may indicate the presence of a fruit or vegetable. The image may also be analysed to determine whether the identified fruit or vegetable is ripe and/or whether it is blemished, and therefore whether or not it should be picked.

[0173] Once the fruit or vegetable has been identified images obtained by the approach phase stereo camera are analysed to determine the sensed location of the identified fruit or vegetable in a Cartesian coordinate system that is local to the end effector.

[0174] The determined sensed location is compared to the known location of the end effector 50, and the trajectory to be travelled by the end effector 50 is calculated. The angular positions of the driver pulleys 46a, 46b required to achieve the joint positions required to achieve movement along the calculated trajectory are determined, and the joint is moved to move the end effector to the sensed location. The sensed location may change over time as new data from the cameras is obtained. For example, the fruit or vegetable may be moving slightly, or the accuracy of the determined location may improve as the end effector gets closer to the fruit or vegetable. This process may therefore be repeated until the end effector 50 reaches a final location in which it is able to grasp, engage or otherwise manipulate the fruit.

[0175] By using sensors (stereo camera and colour camera) that are located in a fixed position relative to the end effector (i.e. able to move in tandem with the end effector) it is possible to calculate the trajectory to be travelled by the end effector in the sensor-control phase within a local coordinate system, which reduces the processing steps required to calculate the necessary joint movements and thereby maximises the speed of motion of the end effector in the sensor-control phase.

[0176] Moreover, during the sensor-control phase the position (angle) of the joint(s) may be controlled by open loop control or by closed loop control. Open loop control is preferred, since this will result in fewer control commands, quicker processing, and thus quicker movement of the joint(s).

[0177] In the optional detachment phase from t.sub.6 to t.sub.7 the end effector 50 is rapidly moved downwardly to detach the fruit or vegetable, in applications in which the fruit or vegetable can be detached from a stem in this way. Joint movements in this phase are controlled in a similar way to the ballistic phase, via open loop control. It can be seen from FIG. 17B that the joint stiffness is rapidly decreased to a minimum stiffness level in this phase. The rapid decrease in joint stiffness may be caused by a rapid release of highly pre-tensioned tendons in the bi-directional actuators 45a, 45b. This rapid release provides an explosive release of energy at the initial part of the detachment phase, which may help to detach the fruit or vegetable from its stem.

[0178] FIG. 19 illustrates an embodiment of a fruit- or vegetable-picking system according to the invention. The system comprises a multi-arm mobile platform 200 which is movable by way of wheels 210 or alternatively by way of a rail or gantry system (not shown). The platform 200 supports four robotic arms 100 according to the first embodiment described above stacked vertically above one another, and each mounted via their base 10 to a vertical support 220 of the platform 200. Each robotic arm 100 delivers picked fruit or vegetables to a dedicated storage container 230, such as a punnet or tray. The platform 200 also supports a cooling storage unit 240 in which the storage containers 230 are placed once full, in order to maximise the shelf life of the fruit or vegetables.

[0179] Each robotic arm 100 has an associated ballistic phase stereo camera 250 that provides images including all points accessible by the end effector 50 of that arm 100. Each arm 100 also includes an LED light source (not shown) mounted on the arm so as to have a fixed position relative to the end effector 50, and so as to illuminate an area encompassed by images captured by the colour camera and approach phase stereo camera. This illumination enables fruit or vegetable picking in dark conditions, such as during the night, and also helps to control the light conditions to prevent fluctuations in data quality due to variations in the environmental light quality.