ROBOT ARM

Abstract

The present invention relates to a robotic arm (10) with five or more degrees of freedom of motion and comprising substantially load-bearing polymeric parts.

Claims

1. A robotic arm with five or more degrees of freedom of motion and comprising substantially load-bearing polymeric parts.

2. A robotic arm according to claim 1 wherein the polymeric parts are formed using a mass-manufacturing process.

3. A robotic arm according to any of claim 1 or 2 wherein the polymeric parts are formed by any one of: injection moulding; CNC machining, vacuum forming; and casting.

4. A robotic arm according to any preceding claim wherein the polymeric parts are formed of an isotropic material.

5. A robotic arm according to any preceding claim wherein the polymeric parts are formed of a homogenous polymer.

6. A robotic arm according to any preceding claim with six or more degrees of freedom of motion.

7. A robotic arm according to any preceding claim with seven or more degrees of freedom of motion.

8. A robotic arm according to any preceding claim comprising a plurality of robotic arm segments with each segment comprising substantially load-bearing polymeric parts.

9. A robotic arm according to claim 8 wherein the casing of the plurality of robotic arm segments is composed of load-bearing polymeric parts.

10. A robotic arm according to claim 9 wherein the joint componentry joining the plurality of arm segments is composed of polymeric parts.

11. A robotic arm according to claim 10 wherein the joint componentry includes at least one of: gearing parts; drive transmission parts; and bearing parts.

12. A robotic arm according to any preceding claim wherein the maximum reach of the robotic arm is between 200 and 750 mm.

13. A robotic arm according to claim 12, wherein the maximum reach of the robotic arm is approximately 600 mm.

14. A robotic arm according to any preceding claim wherein the maximum payload of the robotic arm is between 0.3 and 3 kg.

15. A robotic arm according to claim 14, wherein the maximum payload of the robotic arm is approximately 1.5 kg.

16. A robotic arm according to any preceding claim wherein the maximum weight of the robotic arm is between 1 kg and 6 kg.

17. A robotic arm according to claim 16, wherein the maximum weight of the robotic arm is approximately 5 kg.

18. A robotic arm according to any preceding claim, wherein the load-bearing polymeric parts are composed of at least one of polyamide, acrylonitrile butadiene styrene, poly lactid acid, copolymer acetal, homopolymer acetal, polybutylene terephthalate, liquid crystal polymer, thermoplastic elastomer and polyphthalamide.

19. A robotic arm according to any preceding claim, wherein the load-bearing polymeric parts are between 1 and 15 mm thick.

20. A robotic arm according to any preceding claim, wherein the load-bearing polymeric parts are between 2 and 12 mm thick.

21. A robotic arm according to any preceding claim, wherein the load-bearing polymeric parts comprise ribbing.

22. A robotic arm according to any preceding claim, wherein the load-bearing polymeric parts house functional componentry of the robotic arm.

23. A robotic arm according to claim 22, wherein the functional componentry includes at least one of: a data communication conduit; a power conduit; a pneumatic conduit; a drive transmission; a joint; and an actuator.

24. A method of making a robotic arm according to any preceding claim made of a polymeric material.

25. A robotic arm substantially as herein described and/or as illustrated with reference to the accompanying figures.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0075] These and other aspects of the present invention will become apparent from the following exemplary embodiments that are described with reference to the following figures in which:

[0076] FIG. 1 is a perspective view of a robotic arm;

[0077] FIG. 2 is a side view of the robotic arm of FIG. 1 in different configurations;

[0078] FIG. 3 is a plan view of the robotic arm of FIG. 1 in different configurations;

[0079] FIG. 4 is an exploded perspective view of the robotic arm of FIG. 1;

[0080] FIG. 5 is a perspective view of a portion of the robotic arm of FIG. 1;

[0081] FIG. 6 is an exploded perspective view of a portion of the robotic arm of FIG. 1; and

[0082] FIG. 7 is a sectional side view of the portion of the robotic arm of FIG. 6.

SPECIFIC DESCRIPTION

[0083] FIG. 1 shows a robotic arm 10 with six degrees of freedom. The robotic arm 10 is composed of four segments 12 attached to one another by three joints 14. Two of the segments 12-1 12-3 can rotate axially in addition to being rotatable about the joints 14. The last segment 12-4 (also referred to as the tool segment) has a tool interface 16 for fixing a tool to the robotic arm. The tool can be rotated in the segment axis. The first segment 12-1 (also referred to as the base segment) has a base portion 18 for fixing the robotic arm to a surface. The six degrees of freedom are indicated in FIG. 1 with arrows. With six degrees of freedom the robotic arm 10 can trace any desired trajectory with the tool interface 16 within the reach of the robotic arm 10. Additionally, a tool fixed to the robot arm can be guided to a destination with any desired orientation and the tool can be moved in space with six degrees of freedom (e.g. translation in 3 orthogonal directions and rotation around three orthogonal axes).

[0084] FIG. 2 shows a side view of the robotic arm 10 in seven different configurations 20 within a plane. Grey shading indicates the area that the robotic arm 10 can access within the maximum reach of the arm within that plane through rotation of the second joint 14-2, third joint 14-3 and fifth joint 14-5 alone. Two configurations 20-1 20-2 show the second segment 12-2 at either extreme that the second joint 14-2 permits, at 90 from vertical in either direction. Two configurations 20-3 20-4 show the third segment 12-3 at either extreme that the third joint 14-3 permits, in extension of the second segment 12-2 and at 155 from that extension. Two configurations 20-5 20-6 show the fourth segment 12-4 at either extreme that the fifth joint 14-5 permits, at 120 from the extension of the third segment 12-3 in either direction. One configuration 20-7 shows the fourth segment 12-4 in the extension of the third segment 12-3. The remaining first joint 14-1, fourth joint 14-4 and sixth joint 14-6 permit 360 of rotation about a segment axis: the first joint 14-1 in the axis of the first segment 12-1, the fourth joint 14-4 in the axis of the third segment 12-3 and the sixth joint 14-6 in the axis of the fourth segment 12-4.

[0085] One of the configurations 20-3 shows the arm 10 in maximum vertical extension. In this configuration 20-3 the reach is 600 mm from the axis of the first joint 14-1. The reach in this configuration 20-3 with the first segment included is 810 mm. The maximum horizontal reach is 600 mm from the axis of the first joint 14-1 in either direction. The maximum reach of the third and fourth segments 12-3 12-4 together (when in extension of one another) is 300 mm. In a variant a gantry, a mobile platform or a UAV (typically a stable flying platform such as a quadrocopter would be more suited to this augmentation) may be provided to extend the maximum reach of the robot arm.

[0086] FIG. 3 shows a plan view of the robotic arm 10 in 5 different configurations 20 within a plane. Grey shading indicates the area that the robotic arm 10 can access within the maximum reach of the arm within that plane. The footprint of the arm is 120 mm by 120 mm. The base segment 12-1 can rotate 360 around a vertical axis.

[0087] FIG. 4 shows an exploded perspective view of a robotic arm 100. The parts in FIG. 4 are: [0088] 100 Forearm [0089] 102 Wrist cover [0090] 104 Wrist attachment flange [0091] 106 Wrist articulation unit [0092] 108 Lower forearm shell/wrist attachment bracket [0093] 110 Wrist drive belt [0094] 112 Upper forearm shell [0095] 114 Lower forearm bearing cage [0096] 116 Lower forearm ball bearings [0097] 118 Elbow outer mounting bracket [0098] 120 Wrist driver pulley [0099] 122 Outer forearm shell with internal bearing raceway [0100] 124 Inner forearm shell (goes inside the outer shell and contains motor to drive forearm gear), with internal bearing raceway [0101] 126 Upper-forearm ball bearings [0102] 128 Upper-forearm bearing cage [0103] 130 Elbow pulley [0104] 132 Right elbow inner mounting bracket with internal bearing raceway [0105] 134 Right elbow bearing cage [0106] 136 Right elbow ball bearings [0107] 138 Right elbow gear attachment point with internal bearing raceway [0108] 140 Wrist motor mounting bracket [0109] 142 Wrist motor retainer [0110] 144 Left elbow gear insert [0111] 146 Wrist-twist motor mount [0112] 148 Elbow cap [0113] 150 Left elbow ball bearings [0114] 152 Left elbow bearing cage [0115] 154 Left elbow inner mounting bracket [0116] 156 Arm [0117] 158 Elbow drive belt [0118] 160 Shoulder stiffening flange [0119] 162 Shoulder attachment bracket [0120] 164 Upper arm shell [0121] 166 Elbow motor bracket [0122] 168 Elbow driver pulley [0123] 170 Shoulder [0124] 172 Right shoulder shell [0125] 174 Shoulder bearing cage [0126] 176 Shoulder ball bearings [0127] 178 Shoulder internal gear [0128] 180 Shoulder drive gear [0129] 182 Shoulder drive belt [0130] 184 Square cross section structural stiffeners [0131] 186 Shoulder joint mounting [0132] 188 Reinforcing rod for motor mount [0133] 190 Shoulder joint axle with internal bearing raceways [0134] 192 Left shoulder shell [0135] 194 Shoulder motor bracket (motor drives gear 180) [0136] 196 Waist [0137] 198 Shoulder motor lower mount [0138] 200 Combined cage retainer [0139] 202 Waist planetary gears with integrated bearing raceway [0140] 204 Waist planetary gear bearing cage and balls [0141] 206 Waist planetary gear retainer with integrated bearing raceway [0142] 208 Waist integrated planetary gear [0143] 210 Waist shell with integrated bearing raceway [0144] 212 Waist upper bearing cage [0145] 214 Waist ball bearings [0146] 216 Waist lower bearing cage [0147] 218 Waist motor mount with integrated bearing raceway [0148] 220 Waist motor bracket [0149] 222 Base unit with integrated microprocessor, microcontroller, switched-mode power supply

[0150] Within the robotic arm 6 motors are included to move the robotic arm as desired. The 6 motors are mounted at the wrist cover 102, the wrist motor mounting bracket 140, the wrist-twist motor mount 146, the elbow motor bracket 166, the shoulder motor bracket 194 and the waist motor bracket 220. The motors are of metal and the belts are of rubber, but all other parts are of plastics. Examples of plastics are nylon, acrylonitrile butadiene styrene, and poly lactid acid. Typical material performances of some representative plastics are:

Nylon 66 HI (ST801) Such as Premier Plastic Resin Product Number PPR-6605HI

[0151] Tensile strength: 6800 psi/46.9 Mpa (ASTM test method D-638) [0152] Elongation at break: 180% (ASTM test method D-638) [0153] Flexural modulus: 245000 psi/1690 Mpa (ASTM test method D-790) [0154] Flexural strength: 9500 psi/66 Mpa (ASTM test method D-790) [0155] Izod impact: 18 ft-lb/in/960 J/m (ASTM test method D-256) [0156] Melting point: 491 F./255 C. (ASTM test method D-3418) [0157] Specific gravity: 1.08 (ASTM test method D-792) [0158] Heat deflection temperature at 264 psi: 160 F./71 C. (ASTM test method D-648)

ABS Low Gloss Natural Such as Premier Plastic Resin Product Number PPR-ABS04

[0159] Tensile strength: 6000 psi/41.4 Mpa (ASTM test method D-638) [0160] Elongation at break: 35% (ASTM test method D-638) [0161] Flexural modulus (tangent): 310000 psi/2140 Mpa (ASTM test method D-790) [0162] Flexural strength: 10500 psi/72.4 Mpa (ASTM test method D-790) [0163] Izod impact (notched): 2.7 ft-lb/in/140 J/m (ASTM test method D-256) [0164] Specific gravity: 1.06 (ASTM test method D-792) [0165] Melt flow rate (230 C./3800 g): 5 g/10 minutes (ASTM test method D-1238) [0166] Heat deflection temperature at 264 psi: 185 F./85 C. (ASTM test method D-648) [0167] Heat deflection temperature at 66 psi: 195 F./91 C. (ASTM test method D-648) [0168] Linear mould shrinkage: 0.006 (ASTM test method D-955)

Poly Lactic Acid Such as FKuR Kunstoff GmbH Product Number Bio-Flex V 135001 (Trial Grade)

[0169] Modulus of elasticity: 2960 Mpa (ISO test method 527) [0170] Tensile strength: 61.5 MPa (ISO test method 527) [0171] Tensile strain at tensile strength: 5.3% (ISO test method 527) [0172] Tensile stress at break: 38 MPa (ISO test method 527) [0173] Tensile strain at break: 10.5% (ISO test method 527) [0174] Flexural modulus: 3295 MPa (ISO test method 178) [0175] Flexural strain at break: no break (ISO test method 178) [0176] Flexural stress at 3.5% strain: 88.8 MPa (ISO test method 178) [0177] Notched impact strength (Charpy), room temperature: 2.8 kJ/m.sup.2 (ISO test method 179-1/1 eA) [0178] Impact Strength (Charpy), room temperature: 30.8 kJ/m.sup.2 (ISO test method 179-1/1 eA) [0179] Density: 1.24 g/cm.sup.3 (ISO test method 1183) [0180] Melting temperature: >155 C. (ISO test method 3146-C) [0181] Melt flow rate (190 C./2.16 kg): 3-5 g/10 minutes (ISO test method 1133)

DuPont Performance Polymers Delrin 988PA NC010 Acetal (POM)

[0182] Tensile Strength, Yield: 72.0 MPa (ISO 527-1/-2) [0183] Elongation at Yield: 12% (ISO 527-1/-2) [0184] Tensile Modulus: 3.20 GPa (ISO 527-1/-2) [0185] Flexural Modulus: 3.00 GPa (ISO 178) [0186] Density: 1.42 g/cc (ISO 1183) [0187] Melt Flow: 21 g/10 min at load 2.16 kg, temperature 190 C. (cm.sup.3/10 min; ISO 1133) [0188] Melting Point: 178 C. (10 C./min; ISO 11357-1/-3) [0189] Flammability, UL94: HB at thickness 0.800 mm (IEC 60695-11-10)

Celanese Zenite 7130 WT010 LCP

[0190] Specific Gravity: 1.65 g/cc (ASTM D 792) [0191] Density: 1.67 g/cc (ISO 1183) [0192] Filler Content: 30% [0193] Linear Mold Shrinkage, Flow: 0.00100 cm/cm at thickness 15.7 mm; 0.00 cm/cm at thickness 3.17 mm (ASTM D955) [0194] Linear Mold Shrinkage, Transverse: 0.0080 cm/cm at thickness 3.17 mm; 0.0090 cm/cm at thickness 1.60 mm (ASTM D955) [0195] Hardness, Rockwell M: 63 (ASTM D 785) [0196] Hardness, Rockwell R: 110 (ASTM D 785) [0197] Tensile Strength at Break: 150 MPa (ISO 527) [0198] Elongation at Break: 1.4% (ISO 527) [0199] Tensile Modulus: 16.5 GPa (ISO 527) [0200] Flexural Strength 210 MPa at temperature 23.0 C. (ISO 178) [0201] Flexural Modulus: 13.0 GPa at temperature 23.0 C. (ISO 178) [0202] Compressive Strength: 89.0 MPa (ASTM D 695) [0203] Shear Strength: 57.0 MPa at thickness 0.800 mm; 58.0 MPa at thickness 3.17 mm (ASTM D732) [0204] Izod Impact, Notched: 18.0 kJ/m.sup.2 at temperature 23.0 C. (ISO 180/1A) [0205] Izod Impact, Unnotched: 30.0 kJ/m.sup.2 at temperature 23.0 C. (ISO 180/1U) [0206] Charpy Impact, Unnotched: 3.00 J/cm.sup.2 at temperature 23.0 C. (ISO 179/1eU) [0207] Charpy Impact, Notched: 2.00 J/cm.sup.2 at temperature 23.0 C. (ISO 179/1eA) [0208] Volume Resistivity: 1.00e+16 ohm-cm (ASTM D 257) [0209] Surface Resistance: 1.00e+15 ohm (ASTM D 257) [0210] Dielectric Constant 3.5 at frequency 1.00e+6 Hz, temperature 23.0 C. 0.8 mm (ASTM D 150) [0211] Melting Point: 352 C. (10 C./min; ISO 11357-1/-3) [0212] Deflection Temperature at 1.8 MPa: 310 C. (ISO 75-1/-2 1993/N2) [0213] Glass Transition Temp, Tg: 120 C. (ASTM D 3418)

DuPont Performance Polymers Hytrel 6356 TPC-ET

[0214] Density: 1.22 g/cc (ISO 1183) [0215] Melt Density: 1.06 g/cc at temperature 230 C. [0216] Water Absorption: 0.50% at time 24 hour (ASTM D 570); 0.60% at thickness 2.00 mm (similar to ISO 62) [0217] Moisture Absorption: 0.200% at Thickness 2.00 mm (similar to ISO 62) [0218] Linear Mold Shrinkage, Flow: 0.015 cm/cm (ISO 294-4, 2577) [0219] Linear Mold Shrinkage, Transverse: 0.015 cm/cm (ISO 294-4, 2577) [0220] Melt Flow: 9.0 g/10 min at load 2.16 kg, temperature 230 C. (ISO 1133) [0221] Hardness, Shore D: <=63; 57 at time 15.0 sec (ISO 868) [0222] Tensile Strength at Break: 43.0 MPa (ISO 527-1/-2) [0223] Tensile Stress: 12.0 MPa at Strain 5.00%; 18.8 MPa at Strain 50.0%; 19.0 MPa at Strain 100% (ISO 527-1/-2) [0224] Tensile Strength, Yield: 19.0 MPa (ISO 527-1/-2) [0225] Elongation at Break: >=300%; 500% Nominal (ISO 527-1/-2) [0226] Elongation at Yield: 33% (ISO 527-1/-2) [0227] Tensile Modulus: 0.280 GPa (ISO 527-1/-2) [0228] Flexural Modulus: 0.290 GPa (ISO 178) [0229] Izod Impact, Notched: 81.0 kJ/m.sup.2 at Temperature 23.0 C. (ISO 180/1A) [0230] Charpy Impact, Notched: 12.0 J/cm.sup.2 at Temperature 23.0 C. (ISO 179/1eA) [0231] Impact: 300 at Temperature 23.0 C. (kJ/m.sup.2 Tensile notched impact strength; ISO 8256/1) [0232] Tensile Creep Modulus, 1 hour: 248 MPa (ISO 899-1) [0233] Tensile Creep Modulus, 1000 hours: 182 MPa (ISO 899-1) [0234] Tear Strength: 145 kN/m normal; 158 kN/m parallel (ISO 34-1) [0235] Abrasion: 110 mm.sup.3 (ISO 4649) [0236] Volume Resistivity: 8.00e+13 ohm-cm (IEC 60093) [0237] Surface Resistance: >=1.00e+15 ohm (IEC 60093) [0238] Dielectric Constant: 4.1 at Frequency 1.00e+6 Hz; 4.6 at Frequency 100 Hz (IEC 60250) [0239] Dielectric Strength: 20.0 kV/mm (IEC 60243-1) [0240] Dissipation Factor: 0.012 at Frequency 100 Hz (IEC 60250) [0241] CTE, linear, Parallel to Flow: 178 m/m- C. (ISO 11359-1/-2) [0242] CTE, linear, Transverse to Flow: 176 m/m- C. (ISO 11359-1/-2) [0243] Specific Heat Capacity: 2.15 J/g- C. (melt) [0244] Thermal Conductivity: 0.150 W/m-K (Melt) [0245] Melting Point: 210 C. (10 C./min; ISO 11357-1/-3) [0246] Deflection Temperature at 0.46 MPa: 80.0 C. (ISO 75-1/-2) [0247] Deflection Temperature at 1.8 MPa: 45.0 C. (ISO 75-1/-2) [0248] Brittleness Temperature: 96.0 C. (ISO 974) [0249] Glass Transition Temp, Tg: 0.000 C. (10 C./min; ISO 11357-1/-2)
Polyphthalamide (PPA), 50% Glass Fiber Reinforced (Typical Values for Products from Different Providers)

TABLE-US-00001 Physical Properties Metric Comments Density 1.55-1.99 g/cc Average value: 1.64 g/cc Grade Count: 60 Filler Content 45.0-50.0% Average value: 47.8% Grade Count: 39 Water Absorption 0.0200-3.60% Average value: 0.567% Grade Count: 18 0.850-0.950% Average value: 0.917% Grade @Temperature 70.0-70.0 C. Count: 6 Moisture Absorption at 1.00-1.20% Average value: 1.13% Grade Equilibrium Count: 3 Linear Mold Shrinkage 0.000100-0.00600 cm/cm Average value: 0.00249 cm/cm Grade Count: 51 Linear Mold Shrinkage, 0.00100-0.0100 cm/cm Average value: 0.00566 cm/cm Transverse Grade Count: 33 Mechanical Properties Metric Comments Hardness, Rockwell R 124-126 Average value: 125 Grade Count: 10 Ball Indentation Hardness 340-360 MPa Average value: 353 MPa Grade Count: 3 Tensile Strength, Ultimate 13.9-290 MPa Average value: 199 MPa Grade Count: 53 60.0-225 MPa Average value: 107 MPa Grade @Temperature 60.0-230 C. Count: 5 107-145 MPa Average value: 107 MPa Grade @Temperature 130-180 C. Count: 5 107-145 MPa Average value: 107 MPa Grade @Time 3.60e+6-7.20e+7 sec Count: 5 8.38-321.27 MPa Average value: 107 MPa Grade @Strain 0.100-4.30% Count: 3 8.38-321.27 MPa Average value: 107 MPa Grade @Temperature 40.0-150 C. Count: 3 Tensile Strength, Yield 24.8-260 MPa Average value: 211 MPa Grade Count: 7 Elongation at Break 0.600-3.10% Average value: 2.10% Grade Count: 58 2.00-7.20% Average value: 4.29% Grade @Temperature 60.0-230 C. Count: 5 Modulus of Elasticity 11.0-22.1 GPa Average value: 17.1 GPa Grade Count: 56 1.10-17.0 GPa Average value: 10.4 GPa Grade @Temperature 60.0-175 C. Count: 5 10.3-10.3 GPa Average value: 10.4 GPa Grade @Temperature 135-135 C. Count: 1 10.3-10.3 GPa Average value: 10.4 GPa Grade @Time 3.60e+6-3.60e+6 sec Count: 1 Flexural Yield Strength 177-420 MPa Average value: 332 MPa Grade Count: 42 94.5-267 MPa Average value: 158 MPa Grade @Temperature 100-175 C. Count: 1 Flexural Modulus 12.5-18.6 GPa Average value: 15.5 GPa Grade Count: 48 4.90-13.0 GPa Average value: 7.76 GPa Grade @Temperature 100-175 C. Count: 1 Compressive Yield 159-314 MPa Average value: 213 MPa Grade Strength Count: 7 Poissons Ratio 0.380-0.410 Average value: 0.398 Grade Count: 6 Shear Modulus 0.350-4.00 GPa Average value: 1.75 GPa Grade @Temperature 0.000-350 C. Count: 3 Shear Strength 75.8-108 MPa Average value: 91.3 MPa Grade Count: 8 Izod Impact, Notched 0.590-4.97 J/cm Average value: 1.36 J/cm Grade Count: 25 0.690-0.690 J/cm Average value: 0.690 J/cm Grade @Temperature 135-135 C. Count: 1 0.690-0.690 J/cm Average value: 0.690 J/cm Grade @Time 3.60e+6-3.60e+6 sec Count: 1 Izod Impact, Unnotched 3.86-13.0 J/cm Average value: 8.66 J/cm Grade Count: 12 Izod Impact, Notched 7.80-100 kJ/m.sup.2 Average value: 16.1 kJ/m.sup.2 Grade (ISO) Count: 20 11.0-13.5 kJ/m.sup.2 Average value: 12.5 kJ/m.sup.2 Grade @Temperature 40.0-20.0 C. Count: 6 Izod Impact, Unnotched 61.0-87.0 kJ/m.sup.2 Average value: 74.0 kJ/m.sup.2 Grade (ISO) Count: 5 Charpy Impact Unnotched 1.00-9.50 J/cm.sup.2 Average value: 7.60 J/cm.sup.2 Grade Count: 25 1.40-9.00 J/cm.sup.2 Average value: 6.55 J/cm.sup.2 Grade @Temperature 30.0-30.0 C. Count: 8 Charpy Impact, Notched 0.200-9.00 J/cm.sup.2 Average value: 1.63 J/cm.sup.2 Grade Count: 32 1.10-7.00 J/cm.sup.2 Average value: 2.14 J/cm.sup.2 Grade @Temperature 40.0-30.0 C. Count: 11 Tensile Creep Modulus, 1 10000-14000 MPa Average value: 11700 MPa Grade hour Count: 3 Tensile Creep Modulus, 7500-12000 MPa Average value: 9170 MPa Grade 1000 hours Count: 3 Electrical Properties Metric Comments Electrical Resistivity 1.00e+11-1.00e+17 ohm-cm Average value: 6.20e+15 ohm-cm Grade Count: 23 Surface Resistance 1.00e+12-2.00e+15 ohm Average value: 6.40e+14 ohm Grade Count: 8 Dielectric Constant 3.40-6.10 Average value: 4.30 Grade Count: 17 Dielectric Strength 18.9-40.0 kV/mm Average value: 25.5 kV/mm Grade Count: 16 Dissipation Factor 0.00400-0.0500 Average value: 0.0154 Grade Count: 18 Arc Resistance 125-300 sec Average value: 190 sec Grade Count: 6 Comparative Tracking 325-600 V Average value: 555 V Grade Index Count: 22 Hot Wire Ignition, HWI 120-150 sec Average value: 140 sec Grade Count: 3 High Amp Arc Ignition, 60.0-120 arcs Average value: 77.7 arcs Grade HAI Count: 3 High Voltage Arc-Tracking 4.00-18.0 mm/min Average value: 13.2 mm/min Grade Rate, HVTR Count: 6 Thermal Properties Metric Comments CTE, linear 12.0-500 m/m- C. Average value: 104 m/m- C. Grade Count: 15 8.00-500 m/m- C. Average value: 161 m/m- C. Grade @Temperature 55.0-250 C. Count: 9 CTE, linear, Transverse to 36.0-76.0 m/m- C. Average value: 53.5 m/m- C. Flow Grade Count: 12 53.0-150 m/m- C. Average value: 96.4 m/m- C. @Temperature 55.0-250 C. Grade Count: 8 Melting Point 260-327 C. Average value: 309 C. Grade Count: 34 Maximum Service 140-210 C. Average value: 164 C. Grade Temperature, Air Count: 7 Deflection Temperature at 120-320 C. Average value: 270 C. Grade 0.46 MPa (66 psi) Count: 20 Deflection Temperature at 90.0-302 C. Average value: 268 C. Grade 1.8 MPa (264 psi) Count: 51 Deflection Temperature at 205-250 C. Average value: 229 C. Grade 8.0 MPa Count: 4 Vicat Softening Point 100-295 C. Average value: 241 C. Grade Count: 5 Glass Transition Temp, 135-144 C. Average value: 141 C. Grade Tg Count: 3 Flammability, UL94 HB-V-0 Grade Count: 32 Flame Spread 17.0-29.0 mm/min Average value: 25.0 mm/min Grade Count: 4 Oxygen Index 24.0-49.0% Average value: 31.8% Grade Count: 4 Glow Wire Test 700-960 C. Average value: 836 C. Grade Count: 3 Processing Properties Metric Comments Processing Temperature 79.4-340 C. Average value: 148 C. Grade Count: 7 Nozzle Temperature 320-338 C. Average value: 329 C. Grade Count: 4 Melt Temperature 270-360 C. Average value: 322 C. Grade Count: 51 Mold Temperature 65.6-180 C. Average value: 127 C. Grade Count: 48 Drying Temperature 80.0-130 C. Average value: 110 C. Grade Count: 45 Moisture Content 0.0300-0.200% Average value: 0.0803% Grade Count: 37 0.850-0.850% Average value: 0.850% Grade @Temperature 70.0-70.0 C. Count: 2 Dew Point 31.7-28.9 C. Average value: 30.1 C. Grade Count: 7 Injection Pressure 41.4-124 MPa Average value: 88.2 MPa Grade Count: 9

Celanese THERMX LED 0201 PCT, 40% Specialty

[0250]

TABLE-US-00002 Physical Properties Metric Comments Density 1.62 g/cc ISO 1183 Linear Mold Shrinkage, 0.0030 cm/cm ISO 294-4 Flow Linear Mold Shrinkage, 0.0090 cm/cm ISO 294-4 Transverse Mechanical Properties Metric Comments Tensile Strength at Break 73.0 MPa 5 mm/min; ISO 527-2/1A Elongation at Break 1.7% 5 mm/min; ISO 527-2/1A Tensile Modulus 6.27 GPa 50 mm/min; ISO 527-2/1A Charpy Impact 3.20 J/cm.sup.2 ISO 179/1eU Unnotched Charpy Impact, Notched 0.320 J/cm.sup.2 ISO 179/1eA Thermal Properties Metric Comments CTE, linear, Parallel to 32.0 m/m- C. ISO 11359-2 Flow CTE, linear, Transverse to 102 m/m- C. ISO 11359-2 Flow Melting Point 285 C. 10 C/min; ISO 11357-1,-2,-3 Processing Properties Metric Comments Processing Temperature 100-150 C. cavity Zone 1 290-305 C Zone 2 285-300 C. Zone 3 285-300 C. Zone 4 285-300 C. Die Temperature 285-295 C. Melt Temperature 290-310 C. Drying Temperature 95.0-100 C. Dry Time 4.00-6.00 hour Moisture Content 0.030%

DuPont Crastin FG6129 NC010 PBT

[0251]

TABLE-US-00003 Physical Properties Metric Comments Density 1.30 g/cc ISO 1183 Melt Density 1.12 g/cc @Temperature 250 C. Water Absorption 0.40% Sim. to ISO 62 @Thickness 2.00 mm Moisture Absorption 0.200% Sim. to ISO 62 @Thickness 2.00 mm Viscosity Test 150 cm.sup.3/g Viscosity number; ISO 307, 1157, 1628 Linear Mold Shrinkage, 0.017 cm/cm ISO 294-4, 2577 Flow Linear Mold Shrinkage, 0.015 cm/cm ISO 294-4, 2577 Transverse Melt Flow 10 g/10 min ISO 1133 @Load 2.16 kg, Temperature 250 C. Mechanical Properties Metric Comments Tensile Strength, Yield 58.0 MPa ISO 527-1/-2 Elongation at Break 50% Nominal; ISO 527-1/-2 Elongation at Yield 5.0% ISO 527-1/-2 Tensile Modulus 2.60 GPa ISO 527-1/-2 Flexural Strength 85.0 MPa ISO 178 Flexural Modulus 2.35 GPa ISO 178 Izod Impact, Notched 4.50 kJ/m.sup.2 ISO 180/1A (ISO) @Temperature 23.0 C. 6.00 kJ/m.sup.2 ISO 180/1A @Temperature 30.0 C. Izod Impact, Unnotched 130 kJ/m.sup.2 ISO 180/1U (ISO) @Temperature -30.0 C. NB ISO 180/1U @Temperature 23.0 C. Charpy Impact NB ISO 179/1eU Unnotched @Temperature 23.0 C. NB ISO 179/1eU @Temperature 30.0 C. Charpy Impact, Notched 0.400 J/cm.sup.2 ISO 179/1eA @Temperature 30.0 C. 0.550 J/cm.sup.2 ISO 179/1eA @Temperature 23.0 C. Tensile Creep Modulus, 1 2600 MPa ISO 899-1 hour Tensile Creep Modulus, 1800 MPa ISO 899-1 1000 hours Electrical Properties Metric Comments Volume Resistivity 1.00e+15 ohm-cm IEC 60093 Surface Resistance 1.00e+12 ohm IEC 60093 Dielectric Strength 26.0 kV/mm IEC 60243-1 Comparative Tracking 600 V IEC 60112 Index Thermal Properties Metric Comments CTE, linear, Parallel to 130 m/m- C. ISO 11359-1/-2 Flow CTE, linear, Transverse to 130 /m- C. ISO 11359-1/-2 Flow Specific Heat Capacity 2.09 J/g- C. melt Thermal Conductivity 0.250 W/m-K Melt Melting Point 225 C. 10 C./min; ISO 11357-1/-3 Deflection Temperature at 115 C. ISO 75-1/-2 0.46 MPa (66 psi) 180 C. Annealed; ISO 75-1/-2 Deflection Temperature at 50.0 C. ISO 75-1/-2 1.8 MPa (264 psi) 60.0 C. ISO 75-1/-2 Vicat Softening Point 175 C. 50 C./h, 50N; ISO 306 Flammability, UL94 HB IEC 60695-11-10 @Thickness 1.50 mm HB IEC 60695-11-10 @Thickness 0.900 mm Oxygen Index 22% ISO 4589-1/-2 Processing Properties Metric Comments Melt Temperature 240 C. 250 C. Optimum 260 C. Mold Temperature 30.0 C. 80.0 C. Optimum 130 C. Ejection Temperature 170 C. Drying Temperature 110 C. @Time 7200-14400 sec 120 C. @Time 7200-14400 sec 130 C. @Time 7200-14400 sec Moisture Content 0.040% Hold Pressure 60.0 MPa

DuPont Performance Polymers Zytel HTN54G35HSLR NC010 PA-IGF35

[0252]

TABLE-US-00004 Physical Properties Metric Comments Density 1.42 g/cc DAM; ISO 1183 Linear Mold Shrinkage, 0.0020 cm/cm DAM; ISO 294-4, 2577 Flow 0.0060 cm/cm DAM; ISO 294-4, 2577 Mechanical Properties Metric Comments Tensile Strength at Break 180 MPa DAM; ISO 527-1/-2 Elongation at Break 3.0% DAM; ISO 527-1/-2 Tensile Modulus 10.0 GPa DAM; ISO 527-1/-2 Flexural Modulus 9.00 GPa DAM; ISO 178 Poissons Ratio 0.38 DAM; ISO 527-1/-2 Charpy Impact 7.50 J/cm.sup.2 DAM; ISO 179/1eU Unnotched @Temperature 23.0 C. Charpy Impact, Notched 0.900 J/cm.sup.2 DAM; ISO 179/1eA @Temperature 40.0 C. 1.10 J/cm.sup.2 50% RH; ISO 179/1eA @Temperature 23.0 C. 1.20 J/cm.sup.2 DAM; ISO 179/1eA @Temperature 23.0 C. Tensile Creep Modulus, 1 11000 MPa 50% RH; ISO 899-1 hour Tensile Creep Modulus, 10000 MPa 50% RH; ISO 899-1 1000 hours Electrical Properties Metric Comments Surface Resistance 1.00e+14 ohm 50% RH; IEC 60093 Dielectric Strength 42.0 kV/mm 50% RH; IEC 60243-1 43.0 kV/mm DAM; IEC 60243-1 Comparative Tracking 600 V DAM; IEC 60112 Index Thermal Properties Metric Comments CTE, linear, Parallel to 20.0 m/m- C. DAM; ISO 11359-1/-2 Flow 20.0 m/m- C. DAM; ISO 11359-1/-2 @Temperature 40.0-23.0 C. CTE, linear, Transverse to 72.0 m/m- C. DAM; ISO 11359-1/-2 Flow 75.0 m/m- C. DAM; ISO 11359-1/-2 @Temperature 40.0-23.0 C. Thermal Conductivity 0.350 W/m-K Solid Melting Point 300 C. first heat; DAM; ISO 11357-1/-3 Deflection Temperature at 285 C. DAM; ISO 75-1/-2 0.46 MPa (66 psi) Deflection Temperature at 255 C. DAM; ISO 75-1/-2 1.8 MPa (264 psi) Processing Properties Metric Comments Melt Temperature 320 C. 325 C. Optimum 330 C. Mold Temperature 85 C. 135 C. Drying Temperature 100 C. @Time 21600-28800 sec Moisture Content 0.10%

[0253] Some of the above specified plastics are suitable for 3D printing or injection moulding as fabrication methods. Some of the parts may be generic parts that are readily obtainable (such as the motors and screws and belts) and others may be manufactured specifically for the robot arm (casing parts such as the shell parts and covers and caps; drive transmission parts such as gear parts and pulley parts; bearing parts; strengthening parts such as flanges and brackets; and mounting parts such as retainers and mounts). By providing most of the parts of the robot arm in plastic an overall weight of 2 to 6 kg can be achieved for the example described above, and typically approximately 5 kg. By providing most of the parts of the robot arm in plastic the cost of a robotic arm can be kept relatively low.

[0254] The robotic arm may be manufactured by assembling pre-manufactured components such as polymeric plates which may be glued or otherwise bonded together. Other methods of manufacture may also be used. For example, the robotic arm (or parts thereof) may be manufactured by way of 3D printing whereby a three-dimensional model of the robotic arm (or parts thereof) is supplied, in machine readable form, to a 3D printer adapted to manufacture the robotic arm (or parts thereof). This may be by additive means such as extrusion deposition, Electron Beam Freeform Fabrication (EBF), granular materials binding, lamination, photopolymerization, or stereolithography or a combination thereof. The machine readable model comprises a spatial map of the object to be printed, typically in the form of a Cartesian coordinate system defining the object's surfaces. This spatial map may comprise a computer file which may be provided in any one of a number of file conventions. One example of a file convention is a STL (STereoLithography) file which may be in the form of ASCII (American Standard Code for Information Interchange) or binary and specifies areas by way of triangulated surfaces with defined normals and vertices. An alternative file format is AMF (Additive Manufacturing File) which provides the facility to specify the material and texture of each surface as well as allowing for curved triangulated surfaces. The mapping of the robotic arm (or parts thereof) may then be converted into instructions to be executed by 3D printer according to the printing method being used. This may comprise splitting the model into slices (for example, each slice corresponding to an x-y plane, with successive layers building the z dimension) and encoding each slice into a series of instructions. The instructions sent to the 3D printer may comprise Numerical Control (NC) or Computer NC (CNC) instructions, preferably in the form of G-code (also called RS-274), which comprises a series of instructions regarding how the 3D printer should act. The instructions vary depending on the type of 3D printer being used, but in the example of a moving printhead the instructions include: how the printhead should move, when/where to deposit material, the type of material to be deposited, and the flow rate of the deposited material.

[0255] The robotic arm (or parts thereof) as described herein may be embodied in one such machine readable model, for example a machine readable map or instructions, for example to enable a physical representation of said robotic arm (or parts thereof) to be produced by 3D printing. This may be in the form of a software code mapping of the robotic arm (or parts thereof) and/or instructions to be supplied to a 3D printer (for example numerical code).

[0256] To give sufficient strength to the robotic arm where it is substantially made of plastic, internal brackets may be designed to strengthen certain portions of the arm. Ribbing may be integrated in the casing parts to increase the strength. The wall thickness may be up to 12 mm in parts that require extra strength, such as the base. Parts that require less strength (such as the tool segment) may be thinner, for example as thin as 2 mm.

[0257] The maximum payload of the robotic arm made of plastic and dimensioned as described above is in the range of 0.3 to 3.0 kg, and typically 0.5 to 2.0 kg or approximately 1.5 kg.

[0258] The robot arm may be mounted at the base 18 to a table, wall, ceiling or an inclined surface. At or near the base a data port is provided for connection of the robot arm to a controller such as a suitably programmed computer. The data port may for example be a USB 2.0/3.0/4.0 port, CAN port or a wireless connection port. At or near the base a power port is provided for supplying power to the motors in the robotic arm. A typical power requirement of the motors may be DC 24V 10A; the base may include a switched-mode power supply to ensure the motors are provided with suitable power.

[0259] FIG. 5 shows the tool interface 16 in more detail. The tool interface 16 is presented at the end of the tool segment 12-4. The tool segment 12-4 presents a surface 34 into which the interfacing components are embedded. The surface 34 is approximately 80 mm by 40 mm. The surface 34 can help stabilise a tool attachment to the robotic arm.

[0260] The interfacing components embedded in the surface 34 include an electronically controllable tool attachment 30. The attachment 30 serves to physically affix a tool to the tool segment 12-4. In the illustrated example the attachment 30 is disc-shaped with approximately 38 mm outer diameter and embedded in the centre of the surface 34. In the illustrated example the electronically controllable tool attachment 30 can be an electromagnetic attachment where a permanent magnet presented by a tool is either attracted to the interface 16 and affixed there, or not, depending on electric actuation of the electromagnetic attachment. By enabling electronically controllable tool attachment the robot arm can be controlled to exchange tools without requiring any human assistance. This can widen the scope of tasks a robot arm can perform and hence increase its usefulness.

[0261] The interfacing components also include ports such as a data port, a power port and a pressure port. In the illustrated example a data and power port are combined in a circular male connector 32, and the tool presents a connectable female port that can be mated for connection. In the illustrated example the connector 32 for the data and power port is cylindrical with approximately 15 mm diameter and 8 mm height (and the corresponding female connector on the tool is similarly cylindrical) such that angular orientation of a tool about the connection axis does not affect the connection. This can allow attachment of a tool in an arbitrary angular orientation. This is convenient for a tool such as a screw head attachment, where a specific axial orientation of the tool is not crucial. For other tools such as a mechanical gripper the tool can include a sensor (such as a gyroscope) for sensing tool orientation; following attachment of the tool to the robotic arm the tool orientation is determined and the tool rotated by the robot arm in the connection axis to a desired angular orientation of the tool. By permitting attachment of a tool in an arbitrary angular orientation the exchange of tools by the robotic arm is facilitated and lower dependence on human assistance can be enabled.

[0262] Some examples of tools are a mechanical gripper; a pneumatic gripper; a screw head attachment; and a machine specific attachment (such as a claw designed to fit into a handle of a particular device the robotic arm is to manipulate). In order to identify a tool each tool can have an identification that can be transmitted to the robot arm and controller via a data connection. The controller can then identify the tool. The software for controlling the robot arm allows for tool identifiers (universal global unique identifiers) to enable this.

[0263] In an alternative example the electronically controllable tool attachment 30 is not an electromagnetic attachment but an interlocking attachment that is electronically controllable, for example with a disc-shaped orifice that can receive a disc-shaped protrusion of a tool and a number or electronically controllable catches that clamp the protrusion in the orifice. The electronically controllable catches may be pneumatically actuated or electrically actuated, for example.

[0264] FIGS. 6 and 7 show the base segment 12-1 of the robotic arm in more detail. The waist integrated planetary gear 208 is integrated into the internal circumference of the waist shell 210. The waist integrated planetary gear 208 meshes with four waist planetary gears 202. Each of the four waist planetary gears 202 has a bearing outer raceway 240 integrated into the internal circumference of the gear 202. Bearings are contained by a bearing cage 204. A bearings inner raceway 242 is integrated in a waist planetary gear retainer 206. The four bearing cages 204 are held in place by a combined cage retainer 200. A waist drive gear ring 244 that is attached to a drive motor 246 meshes with the four waist planetary gears 202.

[0265] Each bearing is composed of three parts: a plurality of rolling elements, two side track (or raceway) parts and a bearing cage (spacer). The two track parts are integrated into the casing of the robot, so each track is fabricated simultaneously with the casing part it is integrated within. The bearing cage is inserted separately.

[0266] The gears 202 208 244 shown in FIGS. 6 and 7 are of a polymer. Conventionally polymers are not selected for gears where a non-negligible torque is transmitted as polymers can deform under strain. The consequence of such a deformation is backlash in the gearing, causing unintended motion of the robot arm. Backlash occurs in particular when the gears change direction, because of existing gaps between the trailing face of the driving tooth and the leading face of the tooth behind it on the driven gear. In order to provide the gears in plastic for inexpensive and lightweight parts for a robot while avoiding problems with backlash the gears are sized larger than an ordinary gear meshing would dictate. Plastic gears are designed with a 0.05 mm to 0.3 mm increase in size relative to a conventional just touching dimension choice. During initial operation the slightly oversized plastic gears are worn in by forcing their operation despite the gear meshing being excessively compressed. The selection of a planetary gear is favourable for the wearing in period as the gear axes are not subject to undue shear stress due to the oversizing. A wearing in period may for example be a few hours of operation. Following wearing in of such oversized plastic gearing repeatability of tool positioning in the range of 0.05 to 2 mm can be achieved, and typically 0.2 to 1 mm repeatability can be achieved.

[0267] The precise optimum size increase depends on the stiffness of a material, and may be greater for a very soft material or smaller for a very stiff material. Typically both gears are oversized by the same amount, even if the diameters of the gears are not the same. In an example a first gear with a nominal 1000.0 mm diameter meshes with a second gear with a nominal 10.0 mm diameter. The first gear is oversized to 1000.2 mm, and the second gear is oversized to 10.2 mm.

[0268] It will be understood that the present invention has been described above purely by way of example, and modifications of detail can be made within the scope of the invention.

[0269] Each feature disclosed in the description, and (where appropriate) the claims and drawings may be provided independently or in any appropriate combination.

[0270] Reference numerals appearing in the claims are by way of illustration only and shall have no limiting effect on the scope of the claims.