Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B66—HOISTING; LIFTING; HAULING
  • B66D—CAPSTANS; WINCHES; TACKLES, e.g. PULLEY BLOCKS; HOISTS
  • B66D3/00—Portable or mobile lifting or hauling appliances
  • B66D3/18—Power-operated hoists
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B66—HOISTING; LIFTING; HAULING
  • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
  • B66C1/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles
  • B66C1/02—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles by suction means
  • B66C1/0212—Circular shape
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B66—HOISTING; LIFTING; HAULING
  • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
  • B66C1/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles
  • B66C1/02—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles by suction means
  • B66C1/0237—Multiple lifting units; More than one suction area
  • B66C1/0243—Separate cups
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B66—HOISTING; LIFTING; HAULING
  • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
  • B66C1/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles
  • B66C1/02—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles by suction means
  • B66C1/0256—Operating and control devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B66—HOISTING; LIFTING; HAULING
  • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
  • B66C1/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles
  • B66C1/02—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles by suction means
  • B66C1/0256—Operating and control devices
  • B66C1/0275—Operating and control devices actuated by lifting action

Definitions

• the present invention relates to material handling devices that lift and lower loads as a function of operator-applied force.
• the device described here is different from manual material handling devices currently used by auto-assembly and warehouse workers. Initial research generally shows three types of material handing devices are currently available on the market.
• a class of material handling devices called balancers consists of a motorized take-up pulley, a line that wraps around the pulley as the pulley turns, and an end-effector that is attached to the end of the line.
• the end- effector has components that connect to the load being lifted.
• the pulley's rotation winds or unwinds the line and causes the end-effector to lift or lower the load connected to it.
• an actuator generates an upward line force that exactly equals the gravity force of the object being lifted so that the tension in the line balances the object's weight. Therefore, the only force the operator must impose to maneuver the object is the object's acceleration force. This force can be substantial if the object's mass is large. Therefore, a heavy object's acceleration and deceleration is limited by the operator's strength.
• the air pressure is set and controlled by a valve to maintain a constant load balance.
• the operator has to manually reach the actuator and set the system to a particular pressure to generate a constant tensile force on the line.
• the LIFTRONIC System machines made by Scaglia also belong in the family of balancers, but they are electrically powered. As soon as the system grips the load, the LIFTRONIC machine creates an upward force in the line which is equal and opposite to the weight of the object being held. These machines may be considered superior to the Zimmerman pneumatic balancers because they have an electronic circuit that balances the load during the initial moments when the load is grabbed by the system. As a result, the operator does not have to reach the actuator on top and adjust the initial force in the line.
• the load weight is measured first by a force sensor in the system. While this measurement is being performed, the operator should not touch the load, but instead should allow the system to find the object's weight. If the operator does touch the object, the force reading will be incorrect. As a result, the LIFTRONIC machine then creates an upward line force that is not equal and opposite to the weight of the object being held.
• balancers do not give the operator a physical sense of the force required to lift the load. Also, unlike the device of this application, balancers can only cancel the object's weight with the line's tension and are not versatile enough to be used in situations in which load weights vary.
• the second class of material handling device is similar to the balancers described above, but the operator uses an intermediary device such as a valve, push-button, keyboard, switch, or teach pendent to adjust the lifting and lowering speed of the object being maneuvered. For example, the more the operator opens the valve, the greater will be the speed generated to lift the object. With an intermediary device, the operator is not in physical contact with the load being lifted, but is busy operating a valve or a switch. The operator does not have any sense of how much she/he is lifting because his/her hand is not in contact with the object. Although suitable for lifting objects of various weights, this type of system is not comfortable for the operator because the operator has to focus on an intermediary device (i.e., valve, push-button, keyboard, or switch). Thus, the operator pays more attention to operating the intermediary device than to the speed of the object, making the lifting operation rather unnatural.
• an intermediary device such as a valve, push-button, keyboard, switch, or teach pendent
• the third class of material handling device use end-effectors equipped with force sensors or motion sensors. These devices measure the human force or motion and based on this measurement vary the speed of the actuator.
• An example of such a device is U.S. Patent 4,917,360 to Yasuhiro Kojima. With this and with similar devices, if the human pushes upward on the end-effector the pulley turns and lifts the load; and if the human pushes downward on the end-effector, the pulley turns and lowers the load. A problem occurs when the operator presses downward on the end-effector to engage the load with the suction cups, the controller and actuator interpret this motion as an attempt to lower the load.
• the actuator causes the pulley to release more line than necessary, creating "slack" in the cable.
• slack should be interpreted as meaning an excessive length of line but should not be construed as including instances where the line is simply not completely taut.
• a slack line may wrap around the operator's neck or hand. After the slack is produced in the line by this or other circumstances, when the operator pushes upwardly on the handle, the slack line can become tight around the operator's neck or hand creating deadly injuries. Because slack can occur even when suction cups are not used as the load gripping means, for safe operation it is important to prevent slack at all times.
• the assist device of this application solves the above problems associated with the three classes of material handling devices.
• the hoist of this invention includes an end-effector to be held by a human operator; an actuator such as an electric motor; a computer or other type of controller for controlling the actuator; and a line, cable, chain, rope, wire or other type of line for transmitting a tensile lifting force between the actuator and the end- effector.
• lifting should be interpreted as including both upward and downward movements of a load.
• the end-effector provides an interface between the human operator and an object that is to be lifted.
• a force transfer mechanism such as a pulley, drum or winch is used to apply the force generated by the actuator to the line that transmits the lifting force to the end-effector.
• the controller causes the actuator to rotate the pulley and move the end-effector appropriately so that the human operator only lifts a pre-programmed small proportion of the load force while the remaining force is provided by the actuator. Therefore, the actuator assists the operator during lifting movements in response to the operator's hand force.
• the tensile force in the line is detected or estimated, for example, by detecting the energy or current that is drawn by an actuator.
• load force can be used to roughly approximate tensile force and vice versa.
• tensile force can be estimated using load force and load force can be estimated using tensile force.
• a signal representing the load force or tensile force on the line is sent to the controller, and the controller uses the load force or tensile force signal to drive the actuator effectively in response to the human input. This, for example, can prevent the actuator from releasing line when the load force or tensile force is zero so that although the line may become loose (i.e. not taut), slack (as defined above) will never be created in the line.
• the operator has the sense that he or she is lifting the load, but with far less force than would ordinarily be required.
• the force applied by the actuator takes into account both the gravitational and inertial forces that are necessary to move the load. Since the force applied by the actuator is automatically determined by line force and the force applied to the end-effector by the operator, there is no need to set or adjust the human power amplifier for loads having different weights. There is no switch, valve, keyboard, teach pendent, or push-button in the human power amplifier to control the lifting speed of the load. Rather, the contact force between the human hand and the end-effector handle combined with line force are used to determine the lifting speed of the load. The human hand force is measured and used by the controller in combination with line force to assign the required angular speed of the pulley to either raise or lower the line and thus create sufficient mechanical strength to assist the operator in the lifting task.
• the device follows the human arm motions in a "natural" way.
• a well-defined small portion of the total load force (gravity plus acceleration) is lifted by the human operator. This force gives the operator a sense of how much weight he/she is lifting.
• the actuator does not rotate the pulley at all, and the load hangs motionless from the pulley.
• the device of this application does have the above-identified advantages.
• Fig. 1 illustrates one embodiment of a human power amplifier that includes an end-effector according to this invention.
• Fig. 2 illustrates a cross-sectional view of one embodiment of an end- effector usable in the invention, showing in particular the structure of the force sensor that measures operator force.
• Fig. 3 illustrates a cross-sectional view of one embodiment of another end-effector that includes a displacement detector for measuring the force imposed on the end-effector by an operator.
• Fig. 4 illustrates a perspective view of the end-effector of Fig. 3 when used by an operator to lift a box.
• Fig. 5 is a schematic block diagram showing operator and load forces interacting with elements of the human power amplifier to provide load movement.
• Fig. 6 illustrates the problem of line slack that can occur with prior art devices that use suction cups to grip a box.
• Fig. 7 A illustrates a partially cross-sectioned view of one embodiment of an end-effector that includes a displacement detector for measuring the force imposed on the end-effector by an operator and a force sensor for measuring the line tensile force.
• Fig. 7B illustrates a partially cross-sectioned view of one embodiment of an end-effector that includes a displacement detector for measuring the force imposed on the end-effector by an operator and a force sensor for measuring the force associated with the weight and acceleration of the load only.
• Fig. 8 schematically illustrates how a force sensor can be used to measure the entire force that the human power amplifier imposes on a ceiling or on an overhead crane.
• Fig. 9 schematically illustrates one embodiment of an actuator that contains a mechanism and a motion sensor to measure the line tensile force.
• Figs. 10A and 10B illustrate partially cross-sectioned views of one embodiment of an end-effector that includes a displacement detector for measuring the force imposed on the end-effector by an operator and a mechanism for detecting the line tensile force.
• Figs. 11 A and IIB illustrate one embodiment of an actuator that contains a mechanism and a switch to detect the line tensile force.
• Figs. 12A and 12B illustrate one embodiment of an end-effector that includes a displacement detector for measuring the force imposed on the end- effector by an operator and a switch that transmits a signal when the end- effector is constrained from moving downwardly.
• Fig. 13 illustrates how a clamp-on current sensor can be used to detect the current drawn by the actuator.
• Fig. 14 schematically illustrates operator-applied forces and load forces interacting with elements of a human power amplifier to move a load while slack in the line is prevented.
• Figs. 15A, 15B, 15C, and 15D graphically show values of a control variable K M as a function of the tensile force in a hoist line.
• Fig. 16 illustrates one embodiment of a human power amplifier that prevents slack in the line even when the end-effector is pushed downwardly by the operator while the end-effector is constrained from moving downwardly.
• Fig. 17 schematically illustrates both human force and load force used as feedback signals to provide movement to a load while slack in the cable is prevented.
• Figs. 18A and 18B show flowcharts of software that can be used to drive a controller practicing the invention.
• Fig. 1 illustrates a first embodiment of the invention, showing a human power amplifier 10.
• a take-up pulley 11 driven by an actuator 12, is attached directly to a ceiling, wall, or overhead crane.
• Encircling pulley 11 is a line 13.
• Line 13 is capable of lifting or lowering a load 25 when the pulley 11 turns.
• Line 13 can be any type of line, wire, cable, belt, rope, wire line, cord, twine, string or other member that can be wound around a pulley and can provide a lifting force to a load.
• Attached to line 13 is an end-effector 14, that includes a human interface subsystem 15 (including a handle 16) and a load interface subsystem 17, which in this embodiment includes a pair of suction cups 18.
• an air hose 19 for supplying suction cups 18 with low-pressure air.
• actuator 12 is an electric motor with a transmission, but alternatively it can be an electrically-powered motor without a transmission. Furthermore, actuator 12 can also be powered using other types of energy including pneumatic, hydraulic, and other alternative forms of energy.
• transmissions are mechanical devices such as gears, pulleys and lines that increase or decrease the tensile force in the line.
• Pulley 11 can be replaced by a drum or a winch or any mechanism that can convert the motion provided by actuator 12 to vertical motion that lifts and lowers line 13.
• actuator 12 directly powers the take-up pulley 11, one can mount actuator 12 at another location and transfer power to take-up pulley 11 via another transmission system such as an assembly of chains and sprockets.
• Actuator 12 is driven by an electronic controller 20, that receives signals from end-effector 14 over a signal cable 21. Because there are several ways to transmit electrical signals, signal cable 21 can be replaced by other alternative signal transmitting means (e.g. RF, optical, etc.).
• controller 20 essentially contains three major components:
• An analog circuit, a digital circuit, or a computer with input output capability and standard peripherals The responsibility of this portion of the controller is to process the information that is received from various sensors and switches and to generate command signals for the actuator.
• a power amplifier that sends power to the actuator based on a command from the computer discussed above.
• the power amplifier receives electric power from a power supply and delivers the proper amount of power to the actuator.
• the amount of electric power supplied by the power amplifier to actuator 12 is determined by the command signal computed within the computer.
• a logic circuit composed of electromechanical or solid state relays, to start and stop the system depending on a sequence of possible events.
• the relays are used to start and stop the entire system operation using two push buttons installed either on the controller or on the end-effector.
• the relays also engage the friction brake in the presence of power failure or when the operator leaves the system.
• one can design many architectures for logic circuit depending on the application, one can design many architectures for logic circuit.
• Human interface subsystem 15 is designed to be gripped by a human hand and measures the human force, i.e., the force applied by the human operator against human interface subsystem 15.
• Load interface subsystem 17 is designed to interface with a load and contains various holding devices. The design of the load interface subsystem depends on the geometry of the load and other factors related to the lifting operation. In addition to the suction cup 18 shown in Fig. 1, hooks and grippers are examples of other means that connect to load interface subsystems. For lifting heavy objects, the load interface subsystem can contain more than two suction cups.
• the human interface subsystem 15 of end-effector 14 contains a sensor (described below) that measures the magnitude of the vertical force exerted by the human operator. If the operator's hand pushes upward on the handle 16, the take-up pulley 11 moves the end-effector 14 upward. If the operator's hand pushes downward on the handle 16, the take-up pulley moves the end- effector 14 downward. The measurements of the forces from the operator's hand are transmitted to the controller 20 over signal cable 21 (or alternative signal transmission means). Furthermore, while the preferred embodiment of my system includes a sensor positioned in proximity to the end-effector 14, other operator-applied force estimating elements can be used to estimate operator-input that are not in proximity to the end-effector 14.
• controller 20 assigns the necessary pulley speed to either raise or lower the line 13 to create enough mechanical strength to assist the operator in the lifting task as required. Controller 20 then powers actuator 12, via power cable 23, to cause pulley 11 to rotate. All of this happens so quickly that the operator's lifting efforts and the device's lifting efforts are for all purposes synchronized perfectly. The operator's physical movements are thus translated into a physical assist from the machine, and the machine's strength is directly and simultaneously controlled by the human operator. In summary, the load moves vertically because of the vertical movements of both the operator and the pulley.
• One of the most important properties of the device of this invention is that the actuator and pulley turn causing the end-effector to follow the operator's hand motion upwardly and downwardly yet the line does not become slack if the end-effector is physically constrained from moving downwardly and the end-effector is pushed downwardly by the operator.
• a dead-man switch with a lever 26 on handle 16 sends a signal to controller 20 via a signal cable 22 (or other alternative signal transmission means).
• the dead- man switch sends a logic signal to the controller 20 causing the end-effector to follow the operator's hand.
• the dead- man switch sends a different logic signal to the controller 20 causing the end- effector to remain stationary.
• a friction brake 24 has been installed on the actuator 12. The friction brake engages whenever the operator releases the dead-man switch or at any time there is a power failure.
• FIG. 2 shows a version of end-effector 30 that measures the vertical human force via a force sensor.
• a force sensor 31 is installed between a handle 32 and a bracket 33 and is connected to controller 20 via signal cable 21.
• Force sensor 31 has a threaded part 34 that screws into an inside bore within handle 32, which is grasped by the operator.
• the other side of the force sensor 31 is connected to bracket 33 via a cylinder 35.
• the outside diameter of cylinder 35 is slightly smaller than the inside diameter of handle 32.
• the force sensor used in embodiments of this invention can be selected from a variety of force sensors that are available in the market, including piezoelectric based force sensors, metallic strain gage force sensors, semiconductor strain gage force sensors, Wheatstone bridge-deposited strain gage force sensors, and force sensing resistors.
• Bracket 33 is connected to cylinder 35 rigidly and it includes hook 36 to interface the load and eyelet 37 to be connected to the line 13.
• a partially cross-sectioned view of one embodiment of an end-effector of the second group is shown in Fig. 3.
• Fig. 4 shows a perspective view of the end-effector of Fig. 3 when used by an operator to lift box 25.
• end- effector 40 includes a human interface subsystem 41 and a load interface subsystem 42.
• Human interface subsystem includes a handle 16 that is grasped by the operator and thus measures the human force, not the load force.
• Load interface subsystem 42 includes a bracket 44 that bolts to a hook 45 or a suction cup or any other type of device that can be used to hold an object.
• An eyelet 46 is mounted in bracket 47 for connecting bracket 47 to a line 13.
• a handle 16 is held by the operator and connected rigidly to the ball-nut portion 49 of the ball spline shaft mechanism securely.
• Balls 50 located in grooves of spline shaft 51 allow for linear motion of ball-nut 49 and handle 16 freely along a spline shaft 51, with no rotation relative to spline shaft 51.
• the spline shaft 51 is secured to bracket 47 which is connected to line 13 via an eyelet 46.
• the spline shaft 51 is press fitted into bracket 47.
• Member 44 holding a hook 45 is connected to bracket 47 via bolts 52.
• Member 44 has hole patterns that allow for connection of a suction cup mechanism, a hook, or any device to hold the object.
• a coil spring 53 is positioned around spline shaft 51 between the ball-nut portion 49 of the ball-spline shaft mechanism and a stop 54 and urges handle 16 upward.
• stop 54 can be a clamp ring that is secured to spline shaft 51 rigidly.
• a linear encoder measures the motion of the handle 16 relative to bracket 47.
• the encoder system has a sensor 48 that produces an electric signal on signal cable 21.
• the encoder also has a reflective strip 55 mounted on handle 16 by adhesive. The reflective strip has dark horizontal stripes.
• Fig. 3 shows the end-effector when handle 16 is pushed upwardly to its upper limit (the bull-nut 49 is pushed against the bracket 47). Rather than gluing a reflective strip with dark stripes on handle 16, one can laser mark the handle 16 itself.
• the controller assumes zero position for the handle 16 at this location and calculates the handle displacement by counting the pulses carried over the signal cable 21.
• the linear motion detector used in this embodiment can be a magnetic linear encoder, a linear potentiometer, a LVDT (linear variable differential transformer), a capacitive displacement sensor, an eddy current proximity sensor or a variable-inductance proximity sensor.
• the ball spline shaft mechanism shown in Fig. 3 can be replaced by a linear bushing mechanism, wherein a bushing (slider) and a shaft slide relative to one another with no balls. There should be little friction between the bushing (slider) and the shaft.
• a dead-man switch 56 is installed on handle 16 sends a signal to controller 20 via signal cable 22 (or by alternative signal transmission means).
• a lever 26, pivoting around hinge 58, is installed on the handle 16 and pushes against the switch 56 when the operator holds onto handle 16.
• a friction brake 24 has been installed on the actuator 12. This friction brake engages when the operator releases the dead- man switch and any time there is a power failure.
• the assist device controller can be designed so that when the operator leaves the handle 16, the controller transfers the actuator to position control mode. In position control mode, the controller tries to keep the actuator (and consequently the end-effector) at the position where the operator left the device.
• the actuator moves out of position control mode.
• the position control mode includes a standard feedback system that uses the encoder on the actuator as a feedback signal and maintains the position of the actuator where the operator left the device.
• this optional feature holds the actuator and the end-effector stationary when the operator leaves the handle, I do not recommend that practitioners substitute this feature for the friction brake discussed above.
• the position control feature will not work if there is a sensor, computer or power failure.
• Fig. 3 shows the end-effector using compression springs.
• springs such as cantilever beam springs, tension springs or belleville springs in the end-effector.
• any resilient element capable of bringing the handle back to its equilibrium position will be sufficient.
• a bellow not only to protect the end-effector from dust and moisture, but also to bring back the handle to its equilibrium position.
• the structural damping in the resilient element (e.g. springs) or the friction in the moving elements of the end- effectors (e.g. bearings) provide sufficient damping in the system to provide stability.
• brace 59 can be connected to handle 16 to create stability and comfort for operators. This brace 59 has a hinge 57 and allows for a rotational motion along arrow 43. Because brace 59 transfers all forces imposed on the operator's hand to the operator's lower arm, by-passing the operator's wrist, some operators may find that brace 59 makes operation more comfortable.
• operator-input estimating elements can be used in place of the specific embodiments described above.
• Examples of alternative operator-input estimating elements may include sensors that evaluate energy consumed by the actuator during lifting or sensors that are not in proximity to the end-effector that can estimate load force or tensile force to estimate operator-applied force.
• the block diagram of Fig. 5 shows the basic control technique of the device.
• the force or displacement sensor in the end-effector delivers a signal to controller 20 that is used to control actuator 12 and to apply an appropriate torque to pulley 11. If (e) is the input command to actuator 12 then, in the absence of any other external torque on the actuator, the linear velocity of the outermost point of the pulley or the velocity of the end-effector (v) can be represented by:
• (S) is the actuator sensitivity transfer function which relates the line tensile force (f R ) to the end-effector velocity (v). If a closed loop velocity controller is designed for the actuator such that (S) is small, the actuator has only a small response to the line tensile force. A high-gain controller in the closed-loop velocity system results in a small (S) and consequently a small change in velocity, (v), in response to the line tensile force. Also note that non-back-driveable speed reducers (usually high transmission ratios) produce a small (S) for the system.
• the human force, (f) is measured and passed to the controller 20 that delivers the output signal (e).
• equation (7) represents the load velocity:
• Equation (11) shows that any change in the load weight, ( ⁇ W), and any change in the force imposed by the operator on the end-effector, ( ⁇ f), will result in a variation of the end-effector speed, ( ⁇ v), such that:
• Equation (13) indicates that an increase or a decrease in the load weight ( ⁇ W) will lead to an increase or a decrease in the upward human force, if operational speed is expected to remain unchanged. In other words, if the load weight is increased, the operator needs to increase his/her upward hand force or decrease his/her downward force to maintain the same operational speed.
• the term (GK/S +1) in equation (13) is the force amplification factor. The larger (K) is chosen to be, the greater the force amplification in the system will be. Consequently, if the force amplification is large, the operator "feels" only a small percentage of the change of the load weight. Essentially, the operator still retains a sensation of the dynamic characteristics of the free mass, yet the load essentially "feels" lighter.
• (K) may not be arbitrarily large. Rather, the choice of (K) must guarantee the closed-loop stability of the system shown in Fig. 5.
• the human force (f) is a function of human arm impedance (H)
• the load force (p) is a function of load dynamics (E), i.e. the weight and inertial forces generated by the load.
• E load dynamics
• (K) also depends on the available computational power; elaborate control algorithms to stabilize the closed system of Fig. 5 while yielding a large force amplification with high speed of maneuvers might require a fast computer and a large memory.
• linear system theory was used here to model the dynamic behavior of the elements of the system. This allows me to disclose the system properties in their simplest and most commonly used form. Since most practitioners are familiar with linear system theory, they will be able to understand the underlying principles of this invention using mathematical tools of linear system theory (i.e. transfer functions). However, one can also use nonlinear models and follow the mathematical procedure described above to describe the system dynamic behavior.
• the actuator and pulley must take up the slack in line 13 before the box 25 is lifted. This impedes the operator since he has to wait while the actuator winds the slack in line 13. Moreover, the sudden change in the line tensile force from zero (i.e. when the line is slack) to a non-zero value (i.e. when the line is not slack), will jerk the end-effector 14. This sudden jerk can cause the box to be dropped. In summary, the operator's motion during the lifting operation is impeded due to unnecessary slack in the line 13; and the box may be dropped due to the sudden change in the line's condition from slack to tight.
• the slack in the line can have far more serious consequences than slowing down the workers at their jobs; the slack line may wrap around the operator's neck or hand. As stated earlier, after the slack is produced in the line, when the operator pushes upwardly on the handle, the slack line may become tight around the operator's neck or hand creating serious or even deadly injuries. It is therefore important to ensure that the line 13 will never become slack.
• the actuator when the operator pushes the end-effector handle 16 downward to ensure tight engagement between the suction cups 18 and the box 25, the actuator does not unwind the line 13.
• the device described here has the "intelligence" to recognize that the operator is simply pushing downwardly to engage the box with the suction cups 18 and he does not intend to move his hand further downward.
• the actuator of this invention will unwind the line 13 to ensure that the downward operator motion is not impeded.
• the assist device described here is able to differentiate between these two cases; in the first case the actuator does not unwind the line 13, while in the second case the actuator does unwind the line 13.
• the pulley speed depends on the signal representing the operator force only. However for the device that will not create slack in the line, the pulley speed depends on the signal representing the line tensile force in addition to the signal representing the operator force on the end-effector handle.
• Two methods are preferred for detecting the rope tensile force. The first method involves the direct detection of the rope tensile force while the second method estimates the rope tensile force based on measurement of the power consumed by the actuator or the electric current used in actuator. Knowledge of line tensile force can then be used to force the actuator and pulley to have zero speed so slack is prevented in the line.
• a force sensor can be used to directly measure the line tensile force.
• FIG. 7A shows an end-effector 60 having a force sensor 61 installed on the end-effector between the end-effector 60 and line 13. Screw 62 is used to install the force sensor 61 to bracket 47 of the end-effector. A set of screws 63 are used to connect bracket 64 to force sensor 61. Eyelet 46 is screwed to bracket 64 and provides an interface to line 13. The force between line 13 and the end-effector 60 passes through the force sensor 61 and therefore the force sensor 61 always measures the line tensile force.
• Signal cable 65 carries a signal representing the line tensile force to the controller 20.
• a force sensor can be installed on the end-effector to measure the force associated with the load only as shown in Fig. 7B.
• Force sensor 61 is connected to part 44 via screw 62.
• a set of screws 63 are used to connect bracket 64 to force sensor 61.
• Suction cups 18 are connected to bracket 64 and provide an interface to box 25.
• force sensor 61 always measures a force that is equal to the weight and inertia force due to acceleration of the load only.
• Signal cable 65 carries a signal representing this force to the controller 20 and therefore the force representing the weight and inertia force of the load (labeled as ⁇ L ) will be identified in the controller.
• Measurement of p L and f in conjunction with calculation (or direct measurement) of end-effector acceleration leads to calculation of the line tensile force, (f R ), according to equation (16):
• W E is the weight of the end-effector itself and is known in advance.
• the force measured by the sensor is always a tensile force (e.g. a positive value) as long as the line is not slack.
• the sensor shows a compressive force (e.g. a negative value).
• This change of sign during the measurement of p L flags the existence of zero line tensile force.
• the load force (p L ) is typically greater than operator-applied force (f)
• f R operator-applied force
• the line tensile force is approximately equal to the sum of the weight of the end-effector and the weight of the load.
• equation 16 is truly satisfied in using any signal in flagging the zero line tensile force.
• a force sensor suitable for use in this invention can be selected from a variety of force sensors that are available in the market, including piezoelectric based force sensors, metallic strain gage force sensors, semiconductor strain gage force sensors, Wheatstone bridge-deposited strain gage force sensors, and force sensing resistors. Regardless of the particular type of force sensor chosen and its installation procedure, the design should be such that the force sensor allows an estimation of load force or line tensile force with reasonable accuracy.
• Force sensor 71 measures the entire force being imposed on the rail 72 by the lifting device.
• a signal representing the measured force is sent to the controller 20 via a signal cable 73.
• the force sensor output signal represents the weight of the actuator, pulley, brake and all the components connected to the rail 72. This value can be measured and saved in the controller memory in advance.
• the force sensor output signal increases to include the line tensile force. Therefore, by subtracting a constant value (saved value in the memory) from the force sensor output signal, one can detect the line tensile force.
• Fig. 9 shows how a motion sensor or estimator can be used to measure the line tensile force.
• Rope 13 is wound on pulley 11, and actuator 12 is connected to trolley 81 via bolts 82.
• Bar 83 is free to rotate around point 84 on the actuator body and holds an idler pulley 85 on one end and connects to a tensile spring 86 on its other end.
• the tensile spring 86 is anchored to the actuator body at point 87.
• the idler pulley 85 is pushed against line 13 via the force of spring 86.
• the rotation of bar 83 is measured by angular motion sensor 88.
• One can use variety of motion sensors such as optical encoder, resolver, or a potentiometer to measure the rotation of bar 83 relative to the actuator body.
• Signal cable 89 carries the motion sensor output to the controller.
• Figs. 10A and Fig. 10B show an end-effector 90 having a tensile force detector comprising a momentary switch 91, mounted on bracket 47, for generating a binary signal.
• Rope 13 is firmly connected to bracket 47, plate 92 is able to rotate along hinge 93.
• Tensile spring 94 is connected between plate 92 and bracket 47 causing plate 92 to rotate along the direction of arrow 95.
• Plate 92 also has a hole that allows the rope 13 to pass through.
• a signal cable 96 carries the momentary switch output to the controller.
• Stop 97 preferably a plastic sphere is rigidly connected to rope 13. Stop 97 does not allow plate 92 to rotate along the arrow direction 95 when the line tensile force is non-zero (Fig. 10 A). In fact in the presence of a non-zero tensile force in the line 13, stop 97 causes plate 92 to be at the position shown in Fig. 10 A not pressing against switch 91. When the line tensile force is zero (as shown in Fig. 10B), plate 92 pushes against switch 91 by the force of a spring 94.
• this limited force detecting device detects that tensile force exists in the rope, but is not able to measure the magnitude of the rope tensile force.
• this method uses the tensile force in the line to create a binary electric signal, representing the presence or absence of line tensile force for the controller; one signal when the line tensile force is non-zero and another signal when the line tensile force is zero.
• Fig. IIA and Fig. IIB where line tensile force, at the top of the device near the actuator 12, is employed to generate a binary signal for the controller.
• Line 13 is wound on pulley 11, and actuator 12 is connected to trolley 81 via bolts 82.
• Bar 83 is free to rotate along point 84 on the actuator body and holds an idler 85 on one arm and connects to a tensile spring 86 on its other arm.
• the tensile spring 86 is anchored to the actuator body at point 87.
• the idler 85 is pushed against rope 13 via the force of spring 86.
• the idler pulley is in contact with the line 13 and the tensile force in the line causes transnational movement for the bar.
• the movement of the bar, in return, causes a switch 98 to be activated.
• Switch 74 is preferably installed on a horizontal section of bracket 44. Bracket 75 holding two suction cups 18 is free to slide in the vertical direction relative to part 44. Slots 76 are provided in part 44 as bearing surfaces for sliding motion of part 75 relative to part 44.
• Fig. 12A shows the end-effector 79 where the end-effector is not constrained by any object from moving downwardly and switch 74 is not pressed.
• Optional compression springs 78 are installed between bracket 75 and part 44 to maintain a distance between part 44 and bracket 75. When the end-effector is lowered (Fig.
• This signal is carried to the controller 20 by the signal cable 77 and can be used to declare the zero tensile force in the line.
• part 75 is lowered either by its own weight or by the force of compression springs 78 releasing switch 74. Therefore, this end-effector is able to create a binary signal, one when the force in the line is zero and another one when the force in the line is not zero.
• a second preferred method estimates the line tensile force based on the current or energy consumed by the actuator to support the end-effector and any load connected to it on the line.
• the energy consumed by the system to support the end-effector and a load connected to it can include many different types of energy including electric, pneumatic, hydraulic, and other alternative types of energy. If pneumatic or hydraulic actuators are used in the system, then the load pressure in the actuator can be used to estimate line tensile force.
• line tensile force can be determined by measuring the current in the electric actuator, since the current in the electric actuator is related to the tensile force in the line.
• measuring the current used in the electric actuator is a cost-effective approach in estimating the line tensile force since measurement of electric current is usually available in many of the electronic amplifiers that drive the electric actuators. Even if the current measurement is unavailable in the electronic amplifier for the motor, one can use a clamp-on current sensor to measure the current that is used by the motor.
• the clamp-on current sensor can be installed on any part of the cable that powers the electric actuator 12.
• the clamp-on current sensor is essentially a Hall effect sensor that detects the magnetic field strength around a wire, which is proportional to the electric current flow.
• the amplifier that powers the electric motor has a built-in sensor to measure the current drawn by the electric motor of the actuator 12 and thereby estimates line tensile force.
• Fig. 13 shows the inventive assist device with a clamp-on current sensor 100 used to detect the current used in the actuator.
• the current from the power supply in controller 20 to actuator 12 is carried by a cable 23 and the signal representing the measure of the electric current used by the motor is sent to the controller via signal cable 101.
• I will explain later how the current measurement can be used to detect or estimate the line tensile force, but I will first explain how the knowledge about the rope tensile can be used to prevent slack in the line.
• Equation 19 G K(f - ) + S(f R ) (19) Equation 19 is similar to equation 6, and therefore it states that the behavior described previously by three experiments are still valid.
• K M is detected to be zero via any of the methods described above, (K M ) must be changed to a zero value.
• Substituting zero for (f R ) and (K M ) in equation (18) results in a zero value for line speed (v).
• An alternative method in detecting the slack in the line during quasi static operation involves simultaneous evaluation of operator-applied force (f) and tensile force (f R ) to detect whether or not the end-effector is supported by the line.
• the first step is to calibrate the system before operation to evaluate the tensile force on the line derived solely from the weight of the end-effector (W E ).
• W E weight of the end-effector
• the controller can isolate load force (p) using equation (3). Finally, by comparing the value of (p) to the stored value (W E ) the controller can determine whether or not the end- effector is being supported by the line. As long as the load force (p) is approximately equivalent to the weight of the end-effector (W E ), the system will know that the end-effector is neither engaged with a load nor supported by an obstruction and that it is safe to pay out line.
• Fig. 15B when the signal representing the operator force indicates upward motion and plot of Fig. 15A when the signal representing the operator force indicates downward motion.
• the plot of Fig. 15B has a non-zero value of C x for (K M ) when the line tensile force is zero.
• the non-zero value of (K M ) results in a non-zero, but small value for the actuator speed when the upward motion is initiated by the operator. This causes the system to come out of slack control and results in the end-effector being lifted when the operator initiates an upward motion.
• a force detection device gives a complete measurement of the line tensile force (e.g. Fig. 7A, Fig. 7B, Fig. 8, Fig. 9, and Fig. 13)
• Fig. 15C can be used to represent variation of (K M ) as a function of line tensile force when the signal representing the operator force on the end-effector indicates a downward motion.
• the smooth transition between the two values of (K M ) as a function of rope tensile force leads to less jerky motion for the device.
• Fig. 15D shows the variation of (K M ) as a function of line tensile force when the signal representing the operator force on the end-effector indicates an upward motion.
• Equation (20) results in the plot of Fig. 15C if Ci is chosen to be zero.
• C 2 can be chosen to yield an appropriate slope for the plot. Large values for C 2 result in a larger slope for the plot of equation (20).
• Ci and C 2 were chosen to be 0.4 and 600, respectively.
• the variation of (K M ), as shown in Figs. 15A, 15B, 15C, and 15D, can be programmed in controller 20.
• Slack prevention upon detection of zero line tension can be used to prevent only pay out or unreeling of line without effecting reeling in of line. Then an upward force signal from an operator can be acted on by winding line upward even though line force is zero when the upward signal occurs.
• Fig. 16 illustrates an embodiment of the invention that offers slack prevention and can be used for depalletizing.
• the line does not become slack if the end-effector is pushed downwardly by the operator while the end-effector is constrained from moving downwardly.
• End-effector 14 is connected to electric actuator 12 mounted on the ceiling or on an overhead crane. As the shaft rotates the pulley, the pulley's rotation winds or unwinds the line 13 and causes the line 13 to lift or lower the end- effector 14 and box 25. Two suction cups 18 are used to engage the box 25 to the end-effector 14.
• the actuator 12 is controlled by the electronic controller 20.
• the computer located in controller 20 receives two signals: one signal from end-effector 14 over signal cable 21, representing the operator force, and a second signal from a current sensor, representing electric current drawn by the actuator 12.
• the signal representing the current drawn by the actuator 12 is not shown in Fig. 16 since in this embodiment of the invention the available current sensor is in the power amplifier (located in controller 20) that powers the electric actuator 12.
• the computer in controller 20 sets the speed that pulley 11 has to turn, based on two signals representing the operator force on the end-effector 14 and the tensile force in line 13.
• the controller 20 powers the actuator 12 via cable 23.
• actuator 12 and pulley 11 The resulting motion of actuator 12 and pulley 11 is enough to either raise or lower the line 13 the correct distance that creates enough mechanical strength to assist the operator in the lifting or lowering the task as required. If the operator's hand pushes upward on handle 16, the pulley 11 rotates so as to pull line 13 upward, lifting box 25. If the operator's hand pushes downward on the handle 16, the pulley rotates so as to move line 13 downward, lowering box 25. However, as shown in Fig. 16, the line does not become slack if the end-effector is pushed downwardly by the operator while the end-effector is constrained from moving downwardly.
• (T ⁇ ) is the total torque generated by actuator 12
• (I) is the current used in actuator 12
• (K ⁇ ) is a proportionality constant.
• the value of (K ⁇ ) is usually supplied by the actuator manufacturer.
• (K ⁇ ) can also be measured experimentally by measuring current drawn by the actuator for some known loads on the actuator.
• equation (21) is widely reported as the true relationship between the torque generated by the actuator and electric current drawn by the actuator, depending on the quality of the power amplifier that powers the actuator, there might be some residual current measurement when no torque is generated. The power amplifier must be calibrated to take into account this residual biased current measurement.
• the amount of torque available to lift the load and end-effector, T L is equal to the difference between the total torque generated by actuator 12 and the torque required to rotate pulley 11 and all rotating components of the actuator. This is presented in equation (22):
• T P is the torque required to turn pulley 11 and all rotating components of actuator 12.
• Ip moment of inertia of all rotating components of the actuator (motor and transmission) and pulley as reflected on the motor shaft
• ⁇ angular acceleration of the electric motor shaft
• ⁇ angular velocity of the electric motor shaft
• T 0 constant torque due to coulomb friction in the system
• Both ( ⁇ ) and ( ⁇ ) (the angular acceleration and angular velocity of the motor shaft) can be estimated by measuring the motor shaft angle using many standard estimation techniques.
• (Ip) and (B P ) are two parameters associated with the actuator and can be measured experimentally.
• (B P ) represents the proportionality of the torque with the motor speed during steady state behavior (i.e. constant actuator speed). Practitioners must measure the required torque to turn the motor shaft at constant speeds.
• (B P ) is a proportionality constant between the motor steady state speed and the required torque.
• (Ip) represents the proportionality of the torque with the motor acceleration during high acceleration maneuvers.
• (T 0 ) is a small constant torque due to dry friction in the actuator (in particular in the transmission part of the electric actuator.)
• (T 0 ) is a small quantity and can be neglected, otherwise it can be measured experimentally.
• T L K ⁇ I -(I P ⁇ + B P ⁇ + T (24)
• R is the radius of pulley 11.
• the motor torque that supports the line tensile force is usually small in comparison with the motor torque that accelerates (or decelerates) the rotating parts of the actuator.
• the current used to provide torque to maintain the line tensile force only constitutes a small portion of the current drawn by the electric motor if high transmission ratios are used.
• actuators having low transmission ratios will yield a larger range for the current reading due to tensile force variation than of the actuators with high transmission ratios.
• g( ⁇ ) The structure of g( ⁇ ) can be estimated experimentally using standard system identification techniques. Again, the Extended Kalman Filter is a well- known approach in parameter estimation and can be found in the control sciences literature.
• the slack control methods described here were motivated based on an application of the device using the suction cups. Even if the human power amplifier device is not employed for use with the suction cups, the slack control described above is preferably implemented in the device. There are many situations when the operator can inadvertently push the load interface subsection onto various surrounding objects including the objects to be maneuvered. The downward residual force of the operator will cause slack in the line if the end-effector is prevented from moving downward. Therefore, it is important to prevent slack in the line at all times.
• (Q) is a controller transfer function operating on the load force (p). Throughout this application (Q) might also be referred to as a force feedback transfer function since it feeds the load force back to the controller.
• a comparison of equation 17 with equation 27 indicates how both operator force and load forces are used as feedback signals in equation 27, but only operator force is used in equation 17.
• Fig. 17 shows the implementation of equation 27.
• Equation (29) shows that any change in load weight ( ⁇ W) and any change in the force imposed by the operator on the end-effector ( ⁇ f) will result in a variation of the end-effector speed ( ⁇ v) such that:
• equation (29) can be re-written as:
• Equation (31) is similar to equation (11), but the system sensitivity to load force is increased from (S) to (S'). Moreover all characteristics previously described in the three experiments are still valid. For example, the effect of this optional load feedback in Experiment 1. Equation (13), when the load feedback transfer function (Q) is used can be rewritten as equation (32):
• Figs. 18A and 18B show a flowchart of a computer program that can be used in controller 20.
• the control program initializes all input and output hardware in the system first. This includes analog-to-digital, digital-to-analog and quadrature counters in addition to any other peripherals in the controller. After calculation of all constants needed in the controller, the controller disengages the frictional brake on the actuator and will energize a green light on the controller indicating that the system is ready to be operated. The controller then enters the main control loop; it reads the actuator position, human force, current in the actuator, and the dead-man switch. The software then implements the transfer function (K) on the signal representing the human force. The transfer function (K) should be chosen to guarantee the closed-loop system stability.
• the controller will estimate the line tensile force using equation (17) above.
• the software will determine if the human force is downward (+) or upward (-).
• the software calculates a value for K using plots similar to Figs. 15B and Fig. 15C. Since the value of K M is obtained from the plot of either Fig. 15B or Fig. 15C, there will be a discontinuity in calculation of magnitude of K M -
• the jump among the various values of K M can be smoothed by using a digital filter. Therefore a digital filter is designed to filter high frequency components associated with KM- In this embodiment, a digital low-pass filter was written in the software to smooth the value of K M .
• the software then checks to see if the dead-man switch is pressed or not. If the dead-man switch is pressed, then the software sends the modified value of (e) to the actuator. If the dead-man switch is not pressed the software keeps the actuator in its current position using a position controller and engages the friction brake. This friction brake engages and prevents the actuator from rotating when the dead-man switch is released. This friction brake adds more rigidity to the system when the operator is not attending the device. As an additional safety feature, I prefer to have the friction brake engage any time there is a power failure.
• the switches and sensors described here can be used with these devices to send the controller information about the line tensile force (e.g. the magnitude of the line tensile force or lack of line tensile force).
• the line tensile force can also be estimated from current measurement as described above.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manipulator (AREA)
• Electric Cable Installation (AREA)
• Emergency Lowering Means (AREA)
• Invalid Beds And Related Equipment (AREA)

Applications Claiming Priority (9)

Publications (2)

Family

ID=27495069

Family Applications (1)

Country Status (7)

Cited By (2)

Families Citing this family (6)

• 2000
  • 2000-02-17 CA CA002373247A patent/CA2373247C/fr not_active Expired - Lifetime
  • 2000-02-17 MX MXPA01011489A patent/MXPA01011489A/es active IP Right Grant
  • 2000-02-17 AT AT00910217T patent/ATE412605T1/de not_active IP Right Cessation
  • 2000-02-17 EP EP00910217A patent/EP1183206B1/fr not_active Expired - Lifetime
  • 2000-02-17 KR KR10-2001-7014403A patent/KR100473093B1/ko active IP Right Grant
  • 2000-02-17 KR KR1020047017109A patent/KR100545695B1/ko active IP Right Grant
  • 2000-02-17 DE DE60040663T patent/DE60040663D1/de not_active Expired - Lifetime
  • 2000-02-17 AU AU32346/00A patent/AU762907B2/en not_active Expired
  • 2000-02-17 KR KR10-2004-7017110A patent/KR100478396B1/ko active IP Right Grant

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events