ADAPTABLE MULTIFUNCTION ROBOTIC HANDS

Abstract

Toolable modules, each having a set of functions and capabilities which are configurable to function cooperatively, to create a set of Robotic arms. Each finger of the module enables a specific task to be accomplished, providing multiple degrees of movements, enabling the Robotic arms to be deployed in highly precise applications and capable of responding to complex tasks. In coordination with an imaging system and a control system the functionality of the Robotic arms are programmable, scalable and configurable in addition to being able to communicate with the external interfaces in a predetermined protocol, thereby providing “Plug and Play” functionality.

Claims

1. A toolable multifunction robotic hand comprising: a base structure or support section; that is interchangeable and operatively connected to the external command interface through a standardised and polarised interface; at least five interchangeable finger units that are hermetically sealed and operatively connected through snap-on polarised connectors to the support section of the robotic hand; intelligently controlling said multifunction robotic hand through a communication interface using a plurality of commands to manipulate the mechanical movements of said fingers; a set of sensors such as pressure sensors, temperature sensor or displacement sensor selectively integrated at the tips of the robotic finger units, depending upon the tasks to be executed; a thumb finger unit operatively connected to the support section to aid in gripping the object; a first or index finger unit operatively connected to the support section such that it is selectively rotatable with respect to the support section about its vertical axis; a second or middle finger unit operatively connected to the support section such that it functions as a cleaning unit; a third or ring finger unit operatively connected to the support section such that it functions as a pick and place mechanism to move objects; a fourth or little finger unit operatively connected to the support section such that it functions as a bidirectional rotating tool; a bi-directional motor grated with an encoder and operatively mounted on the palm or support section of the robotic hand to enable certain tasks to be accomplished that require rotary movements; at least five interchangeable finger units that are operatively connected to the support section to selectively operate and thereby execute multiple tasks; said finger units being configured such that the task assigned to each one of them are independently controllable through a plurality of commands received from standardised interface.

2. A toolable multifunction robotic hand of claim 1, wherein the thumb finger unit is suitably integrated with a pressure sensor within the rubber pad to enable feedback and control of the gripping force of the object.

3. A toolable multifunction robotic hand of claim 1, wherein the index finger unit is mounted with a cleaning brush on one side of the finger tip and a rubber pad with a solution dispensing hole on the opposite side of the finger tip.

4. A toolable multifunction robotic hand of claim 1, wherein the middle finger unit is functionally mounted with a rubber pad on the finger tip in conjunction with a de-ionised air dispenser.

5. A toolable multifunction robotic hand of claim 4, wherein rubber pad is suitably integrated with a temperature sensor to control the temperature of the dispensed air.

6. A toolable multifunction robotic hand of claim 1, wherein the ring finger unit is functionally mounted with a suction cup to pick up objects from a predetermined location and place them at a different location.

7. A toolable multifunction robotic hand of claim 1, wherein the little finger unit is functionally integrated with an encoder coupled hi-directional motor, to aid in removing the foil covering of a sealed package to expose the object within.

8. A toolable multifunction robotic hand of claim 7, wherein positional information from the encoder integrated to the bi-directional motor, is utilised to start and end a predetermined operation that involves di-directional rotation, while engaging a work piece.

9. A toolable multifunction robotic hand of claim 1, wherein the bi-directional motor operatively mounted on the support section of the robotic hand is operatively integrated with a rotary gripper that is programmable to dynamically exert a gripping force around the object, irrespective of its diameter or profile to execute a predetermined Rotary task.

10. A toolable multifunction robotic hand comprising: a base structure or support section; that is interchangeable and operatively connected to the external command interface through a standardised and polarised interface; at least five interchangeable finger units that are hermetically sealed and operatively connected through snap-on polarised connectors to the support section of the robotic hand; intelligently controlling said multifunction robotic hand through a communication interface using a plurality of commands to manipulate the mechanical movements of said fingers; a set of sensors such as pressure sensors, temperature sensor or displacement sensor selectively integrated at the tips of the robotic finger units, depending upon the tasks to be executed; a thumb finger unit operatively connected to the support section to aid in gripping the object; a first or index finger unit operatively connected to the support section to aid in in gripping the object; a second or middle finger unit operatively connected to the support section to aid in gripping the object; a third or ring finger unit operatively connected to the support section to aid in gripping the object; a fourth or little finger unit operatively connected to the support section to aid in gripping the object; a high resolution camera and operatively mounted on the palm or support section of the robotic hand to enable certain tasks such locating, aligning and inspection an object, to be accomplished;

11. A toolable multifunction robotic hand of claim 10, wherein the support section of the robotic hand, comprises a pedestal operatively integrated with vacuum to enable holding an object in place for the purpose of inspection.

12. A method for removing a sealed cover of a container held by at least two fingers of a multifunction robot hand, the method comprising: locating the position of blister foil covering the container using the intelligent camera mounted on the support section of the robot hand; moving the finger unit integrated with the motor to suitably engage with the blister foil; moving said finger unit towards a predetermined position while simultaneously energising the motor to rotate in a direction that peels the blister foil from the container; stopping the movement of said finger unit reaches the predetermined position wherein the blister foil has been completely removed, exposing the object held in the container; and the said finger unit moved to another position to dispose the blister foil. cm 13. A method as in claim 12, wherein the container is suitably positioned by finger units of the robotic hand with optimum gripping force with the aid of pressure sensors integrated in the rubber pads positioned at the fingertips.

14. A method for engaging a container held by at least two fingers of a multifunction robot hand to loosen or tighten the cap of a container, the method comprising: locating the position of container cap using the intelligent camera mounted on the support section of the robot hand; moving the other multifunction robot hand to align its rotary gripper suitably mounted on the support section to engage with the container cap; energising the rotary gripper and bi-directional motor in a direction to loosen or tighten the container cap; and repositioning the container to begin the next process step.

15. A method as in claim 14, wherein the rotary gripper is coupled with a bi-directional motor suitably integrated with an encoder for positional feedback.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0017] The above features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings, in which:

[0018] FIG. 1 shows a configuration of the present invention according to a first embodiment.

[0019] FIG. 2 is an isometric view of a typical empty contact lens blister pack.

[0020] FIG. 3 is an isometric view of a hermetically sealed blister package containing a contact lens with the Robotic Right hand motor shaft engaged with the edge of the blister foil.

[0021] FIG. 4 is an isometric view of a blister package with its blister foil peeled exposing the contact lens.

[0022] FIG. 5 is a perspective view of the Multifunction Robotic Right back hand according to the first embodiment.

[0023] FIG. 5a is another perspective view of the Multifunction Robotic Right Front hand (showing the palm) according to the first embodiment.

[0024] FIG. 6 is a side view of the Multifunction Robotic Right hand index finger unit according to the first embodiment.

[0025] FIG. 7 is a side view of the Multifunction Robotic Right hand middle finger unit according to the first embodiment.

[0026] FIG. 8 is a side view of the Multifunction Robotic Right Ring finger unit according to the first embodiment.

[0027] FIG. 9 is a side view of the Multifunction Robotic Right hand little finger unit according to the first embodiment.

[0028] FIG. 10 is a perspective view of the Multifunction Robotic Right hand according to the second embodiment.

[0029] FIG. 11 is another perspective view of the Multifunction Robotic left hand according to the first embodiment.

[0030] FIG. 12 shows a flow diagram showing the steps during the process of contact lens inspection and characterization according to the first embodiment.

DETAILED DESCRIPTION OF DRAWINGS

[0031] Hereinafter, a Multifunction Robotic hands, interchangeable Robotic finger units and a Robotic device according to exemplary embodiments of the invention will be described referring to the accompanying drawings, it is important to note that the same reference numerals are given to the same or like members and parts in the different drawings,

[0032] As shown in FIG. 1, the Multifunction Robotic Hands 20 and 40 according to the first embodiment includes five finger units in each hand. A miniature motor 25 is integrated into the little finger unit of the Robotic Right hand 20 with interchangeable shafts 30. The second Multifunction Robotic hand 40, functions as a manipulator to locate and position objects under the imaging system 18 comprising a Camera 10, optical lens 12 and illumination module 15. The Robotic hands are designed to be quickly interchangeable through snap-on polarised connectors 42 as shown in FIG. 1 for the Robotic left hand 40.

[0033] The dual Multifunction Robotic hands together with the imaging system operate in synchronization to perform complex tasks in different environments. Due to their hermetically sealed design, the Multifunction Robotic hands may be deployed in clean rooms, toxic, hot or humid workplaces, operating theatres for surgical procedures, humanoids, food packing industry, Pharmaceutical and Glass industries to name a few.

[0034] The system and method illustrated in FIG. 1 relates to peeling the blister foil 65 from the Contact lens holder 50 without any human interaction, wherein the Robotic left hand 40 is used for grasping the object (for egg the Contact lens container 50) and positioning it under the imaging system camera 10. The imaging system 18 detects the edge of the blister foil 65 and communicates the location to the Robotic Right hand 20 which moves the Motor shaft 30 to engage the blister foil 65 of the blister pack 50 held by the Multifunction Robotic left hand 40.

[0035] FIG. 2 is an empty blister shell 50 without a blister foil covering the package.

[0036] FIG. 3 is an isometric view wherein the Motor shaft 30 of the motor 25 has engaged with the edge of blister foil 60 at the location 65. As earlier explained the motor is suitably integrated to the little finger of the Multifunction Robotic Right hand and with the aid of the imaging system 18 in FIG. 1, accurately engages with the blister foil edge 65, before the shaft 30 in FIG. 3 is energised to rotate in the clockwise direction or the peeling direction while synchronously moving the Multifunction Robotic Right hand in the direction 28 and in the process peel the blister foil from the Top surface of the blister pack or Shell 50.

[0037] FIG. 4 shows how the process of peeling the blister foil that has been partially completed with the contact lens 70 exposed, with the motor 25 positioned at the opposite end of the blister pack. In the next step (not shown), the motor 25 continues to rotate the shaft 30 until the blister foil 60 is completely detached from the blister pack 50 and subsequently discarded.

[0038] FIGS. 5 and 5a shows a perspective view of the Multifunction Robotic Right Hand from the back and front respectively according to the first embodiment of the present invention, and includes five finger hermetically sealed units, the thumb 80, the first or index finger unit 83, second or middle finger unit 90, third or Ring finger unit 95 and the fourth or little linger unit 20. A support section 98 drives the five finger units and interconnects to the external interfaces via drive section 22. External interfaces may include a humanoid arm, or an automated manipulator to name a few. Commands received at the interface is subsequently communicated to the support section 98 to manipulate the five finger units and their respective features such as motors, air jets, brush, solution dispenser, X&Y displacement drives, Bottle openers and to monitor a host of sensors incorporated in the fingers to read pressure, temperature, positional data. Section 22 through a unique interlocking interface to the external control system, aids in channelling the pneumatics, electrical and bidirectional computer interface for communication of the Robotic Right hand. It is suitably designed for easy interchangeability, adaptability and scalability.

[0039] The five finger units in the first embodiment of the present invention are designed with specific features such as tactile sensors, Hall effect sensors, Pressure sensors and gauges to apply them different tasks. The Robotic finger units are also modularly designed with standardised interface for mechanical, Electrical and Pneumatic control, to enable the Robotic hand to be quickly reconfigured for different applications.

[0040] According to the first embodiment of the present invention and referring to FIG. 5a, the thumb 80 is designed with a rubber adapter 82 wherein the surface is rough but soft to enable it to grip objects. The Robotic Right hand index finger unit 83 in addition to the rubber gripper 84 and an opening 86 to dispense a solution through an electrically controlled valve (not shown) on one side, is also integrated with a brush 85 (FIG. 5) on the other side, to aid in cleaning and brushing of an object. The middle finger unit 90 consists of a rubber gripper 87 and an opening 88 to blow clean and deionised air through an electrically controlled pneumatic valve (not shown) to enable cleaning and drying of an object. The Robotic Right hand ring finger unit 95 is integrated with a Suction cup 92 suitable for picking up objects from a predetermined location and placing them at multiple locations. The little finger unit 20 is incorporated with a miniature motor 25 with an interchangeable shaft or tool 30 to perform multiple tasks. A rotary gripper 40 is integrated in the palm area of Robotic Right hand 98 that may be utilised to loosen or tighten screws, nuts and caps from bottles or any other task that requires Gripping and Rotational movement.

[0041] FIG. 6 is a side view of the Robotic Right hand index finger unit 83. As illustrated, the tip of the index finger unit is incorporated with a Rubber pad 84 made from flexible resin, a small opening 86 for spraying a fine jet of solution through a tube 81 for cleaning purposes and a brush 85 for scrubbing the object. The jet is controlled by a computer triggered valve (not shown). The fingertip of the index finger unit 83 is designed to be rotatable around the joint 82 along the axis A1 to enable the brush 85 to be turned 180 degrees from its original position.

[0042] FIG. 7 is a side view of the Robotic Right hand middle finger unit 90. As shown, the tip of the middle finger unit is also incorporated with Rubber pad 87 made from flexible resin and a small opening 88 connected to an air jet valve (not shown) through a pneumatic tube 96. The air jet may be controlled to deliver deionised hot or cold air to the object for removing any static charge and to also clean and dry the object before the next process step.

[0043] FIG. 8 is a side view of the Robotic Right hand ring finger unit 95. It is used to pick up an object using a suction pad 92 whenever an object needs to be moved to another location. For eg: The Ring finger unit 95 may pick up a contact lens 70 in FIG. 4 using the suction cup 92 in FIG. 8 and place it on the pedestal 44 in FIG. 11 before the Robotic left hand in FIG. 11 position itself suitably under the imaging system 18 in FIG. 1 for contact lens inspection and subsequently presenting itself to the Robotic Right hand finger unit 95 in FIG. 8 for the contact lens 70 to be picked up from the pedestal 44 in FIG. 11 and placing it at another location such as a container or tray. The suction pressure is created at 92 in FIG. 8 through the tube 89 via a computer controlled valve (not shown).

[0044] In FIG. 9, a side view of the Robotic Right hand little finger unit 20 shows a miniature motor 25 suitably integrated to the base. An interchangeable rotor or tool bit enables multiple tasks to be accomplished.

[0045] In a second embodiment of the present invention FIG. 5a illustrates a configurable bottle opener 40 which is suitably integrated into the palm area of the Multifunction Robotic Right hand, that provides Rotary action in both clockwise and anti-clockwise direction, combined with force and Torque control to enable bottle caps to be loosened or tightened. The design of the bottle opener 40 is such that it caters to different and multiple forms of bottle cap profiles. The Bottle cap opening method is illustrated in FIG. 10 wherein the bottle cap 105 of bottle 104 is engaged with the Rotary fixture 40 in FIG. 5a mounted on the Robotic right hand area 98. This feature may be applied to any task that requires a rotary motion in combination with a gripper to hold and rotate the object. Other applications include, Nut or Bolt loosening or tightening . . . etc.

[0046] in FIG. 11 a third embodiment of the present invention is shown, FIG. 11 illustrates a configuration of the Multifunction Robotic left hand which is primarily used for gripping and positioning of objects as depicted by 40 in FIG. 1. The palm is incorporated with an optional Camera 43 to enable fine alignment and tracking where required. It may also house a pedestal 44 (FIG. 11) in the palm area to hold and present a contact lens placed by the suction cup 92 in FIG. 5a of the Robotic Right hand Ring finger unit 95 in FIG. 5a, for the imaging system 18 in FIG. 1 to inspect it. Quality Inspection features may include but are not limited to defects such as tears, bubbles and contamination, dimensional measurements such as diameter, lens thickness and refractive power detection. The rubber pads at the tips of the finger units 41, 46, 47, 48 & 49 may include Hall effect sensors, Biometric sensors and other optional sensors as required by a specific process. The Robotic Right hand, the Robotic left hand working in close coordination with each other's capabilities, adds a very important capability in automating different processes, not realizable in related art.

[0047] In a fourth embodiment of the present invention a configuration that is capable of being implemented in the glass inspection industry is described. The Robotic left hand camera 43 in Fig H in coordination with the imaging system unit 18 in FIG. 1 of the Robotic Right hand, may be utilised to inspect a glass object (for example: a mobile phone screen or bezel glass) for defects and dimensions to determine if the glass is defective.

[0048] In a fifth embodiment of the present invention a configuration may be implemented in the Surgical accessories manufacturing, industry wherein accuracy and hygiene is particularly important and mandatory. Accessories may include but not limited to Cardiothoracic instruments, delicate microsurgical heart valves. . . etc. Post manufacturing the same set of Robots may be used to implement the quality assurance processes to inspect the manufactured products, before dispatch to customers.

[0049] In a sixth embodiment of the present invention a configuration may be implemented wherein the Robotic hands are adapted to read and interpret printed information on packages such as envelopes, boxes and containers for the purpose of sorting and binning them according to a predetermined set of rules. For eg. The Multifunction Robotic hands may be adaptable in the postal department and warehousing industry to sort and bin the packages according to their LIP codes.

[0050] The Multifunction Robotic hands with built-in artificial intelligence, are capable of reconfiguring themselves by replacing an entire Robotic hand with a differently configured Robotic hand or to replace a specific set of Robotic finger units, without any human intervention. This feature enables the Robotic hands to scale and adapt themselves, whenever they are required to operate for a new application or if a modified process is required to be implemented in the same application. The interchangeability and interoperable functions that is achieved through standardised interface (22 in FIG. 5 and FIGS. 5a and 42 in FIG. 11) makes the Robotic hands reconfigurability simple, enabling quick and easy deployment in new processes under the same or different operating conditions, not possible in prior arts.

[0051] Referring to FIG. 12, the flow of the process starts at 100 wherein a contact lens within a blister pack is to be removed and inspected. In Step 102, the blister pack 45 in FIG. 1 is presented under the imaging system 18 in FIG. 1, to identify the package outline and locate the edge of the blister foil 65 in FIG. 1. The positional information determined in Step 104 of FIG. 12 is communicated to the computer system (not shown) in Step 106 which instructs the Robotic Right hand 20 in FIG. 1 to engage the motor shaft 30 in FIG. 1 with the blister foil 65 in FIG. 1. At step 108 the foil engagement is complete. If not complete the process restarts at step 106 to retry the foil engagement process. In step 110 the motor 30 in FIG. 1 begins to rotate in the clockwise direction while simultaneously moving the motor assembly towards the backend of the blister, and in the process peeling the blister foil 65 in FIG. 1 until it is fully detached from the top side of the blister pack 50 in FIG. 1. In the next step 112 of the Robotic right hand, the blister foil is discarded and the Robotic Right hand moves to the next step 114. In step 114, the imaging system commands the Robotic Right hand to pick up the contact lens from the blister pack 50 in FIG. 1 and place it on a pedestal 44 in FIG. 11 for the imaging system 18 in FIG. 1 to inspect the lens. The imaging system characterises the contact lens based on a set of rules and communicates the results in step 115 to the Robotic Right hand which will then pick up the contact lens from the pedestal. The results arc consolidated in step 115 and communicated at 116 after which sorting takes place in step 117. The contact lens is picked up from pedestal 44 in FIG. 11 and placed into different containers based on the decision in step 118 into containers 120-124. It is important to note that the number of categories of containers can vary based on the configuration of the Quality assurance system. The process ends at step 126 after discarding the empty blister in the Robotic left hand in step 119.

[0052] The unique design of the Multifunction Robotic hands and its associated finger units makes it possible to realize all possible actions and movements that include gripping, holding, cleaning, brushing, dosing, pickup and placement of an object, opening and closing a cap of multiple variety of containers, enable them for deployment not only in the quality inspection processes but also in manufacturing processes where accuracy, reliability, consistency and hygiene are of great importance.

[0053] Hereinbefore, the Multifunction Robotic hands according to the embodiments of the invention are described, but the invention is not limited to the above embodiments, and may include various modifications appropriately made in a range without departing from the spirit thereof.