WO2019191729A1

WO2019191729A1 - Manipulator, system and process of operating the same

Info

Publication number: WO2019191729A1
Application number: PCT/US2019/025058
Authority: WO
Inventors: Christopher M. Carpenter; Rodney K. CLARKE; David M. PAUL
Original assignee: Esco Group Llc
Priority date: 2018-03-30
Filing date: 2019-03-29
Publication date: 2019-10-03
Also published as: EP3774208A1; BR112020019290A2; EP3774208A4; US20190360180A1; AU2019245445A1; CL2020002433A1; CA3095419A1

Abstract

A joint secured to a manipulator for movably supporting a tool(s) for conducting operations, particularly those in the field is hydraulic to be robust in varied environmental conditions and/or provide sufficient power. The joint includes a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes.

Description

MANIPULATOR, SYSTEM AND PROCESS OF OPERATING THE SAME FIELD OF THE INVENTION

[01] The present invention pertains to a manipulator and systems for movably supporting a tool(s) for conducting operations and processes for operating the same.

BACKGROUND OF THE INVENTION

[02] Workers are at times called upon to work in hazardous environments and/or to undertake difficult and/or time-consuming activities. Various tools have been developed to help make such operations safer, easier and/or quicker.

[03] As one example, in mining operations, ground-engaging wear parts are provided along the digging edge of a bucket of an excavating machine such as a dragline machine, cable shovel, face shovel, hydraulic excavator, bucket wheel excavator, and the like. The wear parts protect the underlying equipment from undue wear and, in some cases, also perform other functions such as breaking up the ground ahead of the digging edge. During use, the wear parts typically encounter heavy loading and highly abrasive conditions. As a result, they must be periodically replaced.

[04] The wear part may comprise two or more components such as a base that is secured to the digging edge, and a wear member that mounts on the base to engage the ground. The wear membertends to wear out more quickly and is typically replaced a number of times before the base (which can also be a replaceable wear member) must also be repaired or replaced. One example of such a wear part is an excavating tooth that is attached to the lip of a bucket of an excavating machine. A tooth commonly includes an adapter secured to the lip and a point attached to the adapter to initiate contact with the ground. A pin or other kind of lock is used to secure the point to the adapter.

[05] In mining operations, these wear parts tend to be heavy and are not easily lifted, which can make replacement difficult, hazardous and/or time consuming. Such large wear parts when new commonly have lifting eyes to facilitate lifting with assistance from a mobile crane. Nevertheless, though a crane can enable lifting of the wear part, the worker can still be pinched or otherwise injured by using hand tools on the lock or general part handling during removal or installation. Various ways have been used to secure the wear part in place; examples include welding, bolts, or locks in various forms such as pins, wedges, etc. To install, remove and/or operate the lock, the worker needs to be, at times, in close proximity to the wear part when the wear part is not secured to the bucket, i.e., before the lock is installed or operated to secure the wear part and after the lock is removed or released to permit removal of the wear part. In such unsecured conditions, the wear part may experience uncontrolled movement, such as falling from the bucket and/or shifting or swinging, and risk injuring the worker.

[06] The excavating equipment can at times be operated in remote locations. The equipment often cannot be easily moved to a maintenance facility when wear part replacement is needed. As a result, wear parts are generally replaced in the field where the environment is uncontrolled. It may be cold, hot, snowing, sleeting, raining, windy, dusty, etc. Moreover, the ground may be muddy, un-level, and/or unstable. All of which can make wear part replacement difficult, hazardous and/or time consuming.

[07] The lifting eyes on the wear parts tend to wear away during use, which leaves no attachment point for connection to a crane when replacement is needed. As a result, the wear part is sometimes left to simply fall to the ground when the lock is removed. At times, a hammer may be used to separate the wear part from the base if fines prevent the release of the wear part when the lock is removed. The uncontrolled falling of the wear part and/or the use of a hammer subjects the worker to risks. After removal, the wear part still needs to be moved from the ground to a discard pile or bin.

[08] Rigging arrangements are sometimes used to hold the wear part in position during installation prior to securing with the lock and during removal of the wear part from the machine to support the wear part after release of the lock. Such arrangements typically use chains, straps, or other means to wrap around and hold the wear part. However, injuries to the worker can occur if the rigging arrangement is insecure, slips or creates pinch points. Feeding the chains or the like from under the worn detached wear parts can also be problematic when the rigging is removed. There is potential for harm to the worker as the heavy part is rolled or moved off of the rigging. A lifting ring is at times welded to a worn out wear part, but this requires additional welding equipment and, since wear parts are typically composed of very hard steel, a careful and time consuming process to achieve a high quality weld. If the weld is poor, the lifting eye may separate from the wear part causing uncontrolled movement of the wear part that becomes a risk of injury to the worker.

SUMMARY OF THE INVENTION

[09] The present invention pertains to a manipulator and systems for movably supporting a tool(s) for conducting operations, particularly those in the field, and processes for operating the same. In one embodiment, the manipulator is hydraulic to be robust in varied environmental conditions and/or provide sufficient power. A manipulator in accordance with the present invention can improve processes that are difficult, hazardous and/or time- consuming.

[10] In one embodiment, a manipulator includes a controller to provide control of the manipulator and/or supported tool(s). In one example, the controller operates a manifold to drive the manipulator and/or operations of a supported tool(s). In one other example, the controller is located at or near a distal end and/or adjacent a supported tool(s).

[11] In another embodiment, the controller may include or be in cooperation with a communication device that receives wireless signals for a variety of purposes. The signals may be usable to direct the actions of the manipulator and/or supported tool(s). In one example, the signals may be transmitted by a remote worker conducting a real-time operation - for example, an installation, an inspection, etc. In another example, the signals may provide directions for an automatic or semi-automatic operation by the manipulator and/or supported tool(s). In another example, signals may be received from sensors contained in the components and/or equipment to be removed, installed, inspected, etc. to, e.g., identify the component and/or equipment, guide the manipulator, or communicate other information about the position, condition or operation of the component and/or equipment. In another example, signals may be received from other manipulators and/or tools working near or in cooperation with the manipulator and/or supported tool(s). Any or all of such signals in the various examples may be collectively used or be available, or they may each comprise the whole of the signals received or available, or may be received in combination with other kinds of signals. The communication device may also and/or alternatively transmit signals for a variety of purposes including in connection with any or all of those noted above.

[12] In another embodiment, a fluid-driven manipulator includes outboard connectors (e.g., hydraulic line connectors) to facilitate and enable operation of the tool(s) and/or modular attachments to expand system functionality.

[13] In another embodiment, a fluid-driven manipulator includes a three-axis joint where at least one axis always intersects the other two axes to facilitate a versatile, easily controlled movement of a supported tool(s). The axes are preferably in close juxtaposition to provide a compact and easily controlled manipulation of the tool(s). In one other embodiment, the three-axes intersect each other at all times.

[14] In another embodiment, a joint for securing a tool to a manipulator includes a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes.

[15] In another embodiment, an apparatus for removing ground-engaging wear parts from earth working equipment includes a manipulator, a joint, and one or more tools. The joint is secured to the manipulator and includes a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes. The one or more tools is secured to the joint to hold the wear part and release a locking element securing the wear part to the equipment. The manipulator in cooperation with the joint and one or more tools can remove the wear part from the equipment. [16] In another embodiment, an apparatus for conducting an in-field operation includes a manipulator, a joint and one or more tools. The joint is secured to the manipulator and includes a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes. The one or more tools is secured to the joint to conduct an in-field operation.

[17] In another embodiment, a process for removing ground-engaging wear parts from earth working equipment includes operating the movements of a manipulator, a joint secured to the manipulator and one or more tools secured to joint to grip a wear part secured to the earth working equipment. The joint includes a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes. Subsequently operating the one or more tools to release a locking element securing the wear part to the earth working equipment. Then, operating the one or more tools to remove the wear part from the earth working equipment after the locking element has been released

[18] In accordance with certain embodiments, a manipulator may be usable to remove and/or install wear parts on equipment in mining, construction, dredge and/or other earth working operations. As examples, such earth working equipment can include, for example, various excavating machines (e.g., excavators, cable shovels, cutter heads, etc.) and/or conveying equipment (e.g., chutes, conveyors, truck trays, etc.). The wear parts can include, e.g., points, adapters, shrouds, runners, wear plate, track components, blades, etc.

[19] In accordance with certain embodiments, a manipulator may be usable to remove and/or install other kinds of components or equipment, particularly those that are heavy, involve a hazard such as high placement, tight quarters, extreme temperatures, hazardous environments (e.g., dust, toxic, caustic, etc.), etc., and/or are time consuming.

[20] In accordance with certain embodiments, a manipulator may be usable to perform other operations such as inspection and/or repair of components, equipment and/or other things. In one example, the manipulator can support a tool in the form of a camera, scanner, range finder or other means to perform or assist inspections and/or repair, particularly where the component, etc. to be inspected and/or repaired is high, in tight quarters, difficult to access, in a hazardous environment, and/or difficult for a person to manually access, inspect and/or repair. Such inspections and/or repair may, e.g., include runners or wear plate in a chute or truck tray, bridge structures, roofs or other building structures, power or telephone poles and lines, banks and/or other earthen structures, etc.

[21] In accordance with certain embodiments, a manipulator may be usable for varied activities, particularly those involving difficult, hazardous and/or time-consuming processes such as equipment refueling, plane de-icing, tree trimming, elevated agricultural harvesting, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

[22] Figure 1 is perspective view of a manipulator in accordance with the present invention.

[23] Figure 2 is a partially exploded perspective view of the manipulator.

[24] Figure 3 is a perspective view of a manifold of the manipulator

[25] Figure 4 is a perspective view of a controller of the manipulator.

[26] Figure 5 is a perspective view of a sample tool to be supported by the manipulator.

[27] Figure 5A is a perspective view of another sample tool to be supported by the manipulator.

[28] Figure 5B is a perspective view of another sample tool to be supported by the manipulator. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[29] The present invention pertains to a manipulator for movably supporting one or more tools for conducting operations. A manipulator in accordance with the present invention can improve processes that are difficult, hazardous and/or time-consuming. The manipulator can, e.g., be used to assess conditions and/or perform critical operations.

[30] In one embodiment, the manipulator is fluid driven, preferably hydraulic to be robust in varied environmental conditions, though other drives are possible for certain operations and/or conditions. A hydraulically-driven manipulator is less susceptible (e.g., as compared to electric drives) to failure in in-field operations where it may be subject to varied environmental conditions such as heat, cold, precipitation, dirt, fines, dust, smoke, corrosive materials, etc. A hydraulic drive is also able to provide substantial power by compact means (e.g., as compared to electric drives), which is useful for certain applications; one such example includes the removal and/or installation of wear parts in a mining environment - though many other uses are possible.

[31] The term manipulator as used herein refers to an apparatus, device, assembly, sub- assembly or the like for movably supporting a tool(s) for conducting an operation - e.g., removal, installation, inspection, repair, etc. The term manipulator is intended as a general term that may include, e.g., (i) multiple components such as the combination of a base, arm, joint and tool support, (ii) a subassembly such as an articulated arm, a joint, and/or tool support, and/or (iii) other assembly or subassembly that movably supports or works with other assemblies or subassemblies to movably support a tool(s) for conducting an operation.

[32] Likewise, the term tool is also intended as a general term that refers to one or more apparatus, device, component, assembly, sub-assembly or the like that conducts, participates in, assists and/or takes part in an operation, which, e.g., may include removal, installation, inspection, repair, refueling, deicing, harvesting and/or other operations. The tool may consist, e.g., of one component, a plurality of components working cooperatively, and/or a plurality of components performing different operations concurrently or separately. As a few examples, tools may include one or more of grippers, pulling assemblies, cleaning apparatus, unthreading and/or threading assemblies, welding equipment, impact devices, cutting apparatus, dispensing implements, magnets, cameras, range finders, sensors, etc.

[33] Relative terms such as front, rear, top, bottom and the like are used for convenience of discussion. The terms front or forward are generally used to indicate a direction toward the component, equipment, machine, structure, ground, vegetation, etc. that is the subject of the operation to be conducted (such as the removal, installation, inspection, repair, cleaning, refueling, harvesting or other operation). Similarly, the terms upper or top are generally used as a direction or position farther from the ground or other support for the manipulator. Nevertheless, it is recognized that in various operations the manipulators may be oriented in various ways and move in all kinds of directions during use.

[34] In one example embodiment, a manipulator 10 in accordance with the present invention can be used with a tool(s), such as tool 1 1 (Fig. 5) to remove and/or install a ground-engaging wear part 13 from and/or on a bucket (not shown). The manipulator may be used in ways and operations and with tools such as disclosed in U.S. Patent Application 2015/0107075, which is herein incorporated by reference in its entirety, and/or used in ways and operations and with tools such as disclosed in U.S. Patent Application 2017/0356167, which is also herein incorporated by reference in its entirety. These are intended as examples as the manipulator could have many other uses. The tools can be interchangeably secured to the manipulator to enable different operations as desired and/or multiple tools can be concurrently secured to the manipulator to be used cooperatively, independently, simultaneously and/or successively.

[35] Manipulator 10 includes an articulated arm 12, a joint 14, and an adapter 16 (Fig. 1). As noted above, the term manipulator herein can refer to any, all or some of these components with or without other related components shown and/or not shown (e.g., a base). The arm 12 may include one or more segments 18 pivotally joined together and controlled by hydraulic cylinders (not shown), but could have other constructions and/or drivers. Arm 12 is coupled on a proximate end to a base (e.g., a turntable, mobile unit, vehicle, machine, etc.), which is not shown. The arm can be a crane, a boom and stick of an excavator, a custom component and/or other assembly.

[36] Joint 14, which on its own is also referred to as a manipulator, is preferably secured to the distal end 22 of arm 12, which in this example terminates in a base plate 30. The base plate 30 can be fixed in a single orientation to arm 12 or include a joint to provide a pivotal, universal or other connection. In one embodiment, joint 14 includes movable components in close proximity to define three axes 24, 25, 26 for compound movement of the supported tool(s), such as tool 1 1. Joint components secured together to form more or less than three axes are possible. In one embodiment, one axis always intersects the other two axes. In this example, axis 26 always intersects axes 24 and 25. Alternatively, the joint could be constructed so that the three axes intersect at all times. In one construction, the axes 24-26 are in close juxtaposition to facilitate a controlled motion in a compact space. Joint 14 is secured to the distal end 22 of arm 12 by a first support 28. The first support 28 in this example includes spaced securing plates 32 that are attached (e.g., by bolting) to base plate 30 (Figs. 1 and 2). In the illustrated embodiment, the axes 24-26 are oriented successively from distal end 22 as a pitch axis 24, a yaw axis 25 and a roll axis 26, though they could be oriented in a different order.

[37] In the illustrated embodiment, joint 14 includes a first actuator 34 for movement about a first axis 24. First actuator 34 includes a casing 36 secured to securing plates 32, and a first internal rotatable element (not shown) attached to and movably holding a second support 38. Second support 38 includes a pair of arms 40 that extend around opposite ends of casing 36 to attach to the first internal rotatable element, a base plate 42, and securing plates 44 for holding a second actuator 46. First actuator 34 is, in this example, a hydraulic rotary actuator such as is available from Parker-Helac Corporation. In this embodiment, actuator 34 provides movement about the first or pitch axis 24 of about 100°. The first or pitch actuator 34, in this example, provides a freedom of motion that ranges from -10° to +90° from neutral, which in this case is when base plate 42 is parallel to base plate 30. Other drivers, constructions and freedom of motion are possible. [38] Second or yaw actuator 46 is, in this example, a hydraulic rotary actuator such as is available from Parker-Helac Corporation. Second actuator 46 includes a casing 48 secured to securing plates 44, and a second internal rotating element (not shown) attached to and movably supporting a third support 49. In this embodiment, third support 49 includes arms 52 secured to the second internal rotating element, and a base plate 54 supporting a fourth support 50. In this embodiment, the second or yaw actuator 46 provides movement about the second or yaw axis 25 of about 160°. In this example, actuator 46 provides a freedom of motion that ranges from -80° to +80° from neutral, which in this case is when the base plate 55 of support 50 is parallel to base plate 42. Other drivers, constructions and freedom of motion are possible.

[39] Third or roll actuator 56 is, in this example, a hydraulic cylinder supported by fourth support 50 for moving a turntable 57. In this embodiment, roll actuator 56 provides movement about the third or roll axis 26 of about 40°. In this example, actuator 56 provides a freedom of motion that ranges from -20° to +20° from neutral, which in this case is when the adapter legs 61 extend downward for setting on the ground or other support when not in use. The roll axis 26 intersects the other two axes 24, 25 at all times, i.e., in all orientations. Other drivers, constructions and freedom of motion are possible. In an alternative construction, the yaw joint is shifted rearward to overlie the pitch joint such that the pitch and yaw axes 24, 25 always intersect. In this arrangement, the roll axis 26 also preferably intersects the other two axes 24, 25 such that all three axes intersect at all times (not shown).

[40] Adapter 16 includes a tool mount 62, which in this embodiment is on the front end opposite turntable 55. The tool 1 1 includes a connector 67 to secure the tool to the tool mount 62. In this example, tool mount 62 includes a pin 64 and a supporting plate 65 to which a tool, such as tool 1 1 , is secured. With tool mount 62, the tool connector 67 can have the form of hooks to secure the tool 1 1 to adapter 16. In this example, the tool is a gripper assembly 70 (Fig. 5) that holds wear parts (such as points) when installing or removing them onto or off of earth working equipment (e.g., a bucket). However, other kinds of tool mounts could be used to accommodate tools with different kinds of connections. Additionally, adapter 16 can be provided with various means to attach different kinds of tools, e.g., with holes to permit bolting and/or other common or custom connection devices. Different adapters could also be secured to joint 14 to accommodate different tools and/or operations.

[41] Adapter 16 could also mount a series of tools 1 1 secured together. In one embodiment, the manipulator includes a base tool mount (such as tool mount 62), and each tool includes a connector (such has hooks 67), an operating device (such as a gripper 70) and a tool mount (such as mount 62). In one example, a first tool 1 1A (Fig. 5A) can be secured to adapter 16 and a second tool 1 1 (Fig. 5) can be secured to the first tool 1 1A. In this illustrated embodiment, tool 1 1A has hooks 67A on a rear end to secure tool 1 1A to adapter 16, and a tool mount 62A on a front end to support tool 1 1. As can be seen, tool mount 62A has a pin 64A for securing hooks 67. In one embodiment, tool 1 1 A is a vibrator 74, which can cooperate with gripper 70 in removing ground-engaging wear parts 13 from earth working equipment. Wear parts (such as points 13) can become stuck on the base on which it is mounted on account of friction, impacted fines, bent components, corrosion and the like. The use of a vibrator in connection with the tool for removing the wear parts (e.g., gripper 70) can reduce the force needed to remove the wear part and thereby ease and/or shorten the removal process. While using a vibrator 1 1 A secured seriatim with gripper 70 is one possible construction, a vibrating device could be otherwise provided, such as one or more vibrators included as part of tool 1 1 that vibrates the arms gripping the wear part. The tools could be operated selectively as needed to remove the wear parts; for example, the vibrator and gripper could be controlled by an operator, the vibrator could operate for a set time when pulling force is applied, the vibrator could activate when a certain pulling force is applied, etc.; other operations are possible.

[42] Other tools could be secured in a series in lieu of or in addition to tools 1 1 , 11 A. As one example, a tool in the form of a sensor module 1 1 B could be mounted in series with tool 1 1 and/or tool 1 1 A. As examples, the sensor module could detect the applied pulling force to remove the wear part, the level of applied vibration, signals from sensors in the wear parts, etc. The sensor module 1 1 B could be similar to the vibrator and include a connector in the form of hooks 67B and a tool mount 62B, though other arrangements are possible. In one embodiment, vibrator 74 is secured to adapter 16, sensor module 1 1 B is secured to vibrator 74, and gripper 70 is secured to the sensor module. Each tool could be operated as needed, continuously, when certain events occur, etc. depending on what is needed or desired. Other tools including, for example, sprayers for cleaning out fines, welding equipment, cameras, etc. could be secured in a series from adapter 16. The various tools can be secured and removed as needed for the desired operation. Although tool mounts and hooks are illustrated, other securing arrangements are possible. Additionally, though examples with two or three tools in a series have been discussed other numbers of tools could be secured together.

[43] Couplers 68 are secured to adapter 16 outboard of adapter housing 72 to facilitate hydraulic, pneumatic and/or electrical connection to the tool(s), i.e., to drive and/or control the various mechanisms and operations the tool(s). They could be otherwise secured. In this embodiment, two six port hydraulic couplers 68 are included to provide an easy and quick hydraulic source for the tool(s); other arrangements are possible. Electrical connectors (not shown) can also be provided for use by the tool(s).

[44] In one embodiment, arm 12 and joint 14 are operated together by the same control whether manual, automatic or semi-automatic. For example, operation of joint 14 can be joined with the operation of a crane or other base manipulator so they work together. In such cases, the manipulator or joint 14 can include a controller 71 and a multi-valve manifold 73 (Figs. 2-4) to operate the supported tool(s) 1 1 through couplers 68. In an alternative embodiment, arm 12 can be operated by the controls of a crane or other manipulator, and the controller 71 and manifold 73 are used to operate actuators 34, 46 and 56, and the supported tool(s). In other alternatives, the arm 12, joint 14 and tool(s) could each have separate controls or all be operated by a single control. Hoses and/or internal ducts provide hydraulic fluid or the like from a source to the components of manipulator 10, joint 14 and/or the supported tool(s). The hoses and/or ducts are omitted from the drawings; they could have virtually any arrangement. Similarly, electrical lines may be provided to manipulator 10, joint 14 and/or the supported tool(s); the electrical lines are also not shown in the drawings. A battery may be provided in addition to or in lieu of such electrical lines. Hydraulic fluid (and electrical power if needed) for the joint 14 and/or tool(s) can be supplied by a crane, excavator, vehicle, or other device supporting the joint, or from a separate drive unit(s).

[45] Including a separate and independent controller 71 for operation of the tool(s) enables the positioning of the tool to be performed by one control (such as a crane control operating arm 12 and joint 14), and the tools to be operated independently for the various tools and/or operations possible using the manipulator. Including a separate and independent controller for the tool(s) and the manipulator 14 enables control and operation of the joint independent of the articulated arm 12 or other components. Such independence enables the joint 14 to be secured to virtually any crane, stick, arm or other support without a need for incorporation of the controls into crane, stick, arm, etc. The controller includes or cooperates with a communication device to receive wireless signals to control the manipulator and/or supported tool(s). The controller could be powered by an electrical source from a crane, excavator, vehicle, power unit, etc. and/or by a battery in the adapter or elsewhere.

[46] The signals may be usable to direct the actions of the manipulator 14 and/or supported tool(s). The signals may be transmitted by a remote worker conducting a real-time operation - for example, operations of removal, installation, inspection, repair, refueling, tree trimming, harvesting, etc. The remote worker may have a joy stick or other kind of controls to use to signal the controller and operate the manipulator and/or tool(s). Alternatively, the signals may provide directions for an automatic or semi-automatic operation by the manipulator and/or supported tool(s). In such a system, the instructions for the automated operations are preferably pre-stored in a database (remote or in the adapter) and used to carry out the desired operation(s). In an automated operation, the manipulator can be provided with encoders (linear or rotary) and/or position sensors at the joints to identify their positions and/or orientations. Automated and manual controls may work together cooperatively, successively or separately. Signals may alternatively or additionally be received from sensors contained in the components and/or equipment to be removed, installed, inspected, etc. to, e.g., identify the component(s) and/or equipment, guide the manipulator, or communicate other information about the position, condition or operation of the component and/or equipment. Examples of sensors that could be included are disclosed in U.S. Patent 9,670,649, U.S. Patent Application 2016/0237657 and/or U.S. Patent Application 2016/0237640, each of which is herein incorporated by reference in its entirety. Signals may be received from other manipulators and/or tools working near or in cooperation with the manipulator and/or supported tool(s). Any or all of such signals in the various embodiments may be collectively used together or be available for use together. Alternatively, they may each be used on their own or in various combinations with others of the kinds of signals and operations. Further, whether they are used together or on their own, they may be received in combination with other kinds of signals. The communication device may also or alternatively transmit signals for a variety of purposes including any or all of those noted above. The signals may be any of a variety of different kinds, with radio being one example.

[47] In one example, the manipulator 10 with an appropriate tool(s) may be used to inspect and/or replace a wear part on an excavating bucket. A camera or other tool could be coupled to adapter 16 to conduct an inspection of the condition of the wear parts. A tool such as tool 1 1 could be used to replace the wear part. The camera or other inspection tool could be provided as part of tool 1 1 , could be a tool separately attached to adapter 16, or could be secured to adapter 16 in lieu of tool 1 1 for the inspection.

[48] In addition to other hazards and difficulties, the bucket position can make assessing the condition of the wear parts and/or replacing the wear parts difficult and/or hazardous. It is common for mining machines to be shut down with lock-out/tag-out safety precautions prior to workers approaching the machine for inspection and/or replacement of the wear parts. At times the bucket is not situated prior to shutting down in a position that is convenient or permissible for a worker to assess and/or replace the wear parts either because the bucket was oriented to perform other maintenance (e.g., welding) or inadvertence by the operator. In such cases, particularly with the increased emphasis on ergonomics and safety for workers, authorized personnel has had to untag, unlock and restart the machine, and adjust the bucket to a suitable position - all of which leads to longer machine downtime and less production. By using a manipulator with appropriate tools, the inspection and/or replacement of wear parts can be achieved even when the bucket is not suitably positioned, e.g., the digging edge may be too high off the ground, tilted too far upward, oriented beneath the equipment, etc. for manual inspection and/or work.

[49] At other times, multiple operations need to be done on a bucket when the machine is shut off. As one example, the bucket may need welding repair as well as wear part replacement. At times, these operations are scheduled successively instead of concurrently because of the risk associated to one or more of the workers. For example, a welding operation may require a portion of a bucket to be isolated and shielded as a safety precaution, which could prohibit the inspection and/or replacement of wear parts on the bucket. Use of the manipulator with the appropriate tools may enable concurrent operations as it removes the otherwise additional worker from the isolated area. Further, manipulators 10 with appropriate tools may be able to perform both operations concurrently without risk of harm to a worker. Use of manipulator 10 with such tools also eliminates the additional time that may otherwise be needed following safety precautions such as erecting safety barriers.

[50] The manipulator and tool may be fully manually controlled by a remote worker to grip, release the lock, and remove the wear part. Alternatively, a remote worker may manually adjust the manipulator to place the tool in proximity or engagement with the wear member, and a programed sequence of instructions are used to operate the manipulator and/or tool to carry out one or more of gripping the wear member, releasing the lock and/or removing the wear member. Alternatively, the entire operation may be controlled by a sequence of programmed instructions. Cameras and/or sensors may be used in manual, automatic and/or semi-automatic operations. The controller 71 may receive information from such camera (or the like) and/or sensors, and/or sensors in the wear members or equipment supporting the wear members. As an example, the controller may receive information to identify the type of wear members installed on the bucket, the position of the wear member on the bucket, the orientation of the wear member, the condition of the wear member, etc.

[51] A manipulator 10 or 14 as disclosed herein may be used to remove and/or install wear parts on equipment in mining, construction, dredge and/or other earth working operations. As examples, the earth working equipment can include various excavating machines (e.g., excavators, cable shovels, etc.) and/or conveying equipment (e.g., chutes, conveyors, truck trays, etc.). The wear parts can include, e.g., points, adapters, shrouds, runners, wear plate, track components, blades, etc. The above descriptions of manipulators 10 or 14 in a mining environment (e.g., to replace wear parts) are provided as examples of possible constructions, operations and uses of the manipulators. Manipulators in accordance with the invention can have many other uses.

[52] In other examples, the manipulator 10 or 14 may be used to remove and/or install other kinds of components or equipment, particularly those that are heavy or involve a hazard such as high placement, tight quarters, extreme temperatures, hazardous environments (e.g., dust, toxic, caustic, etc.), etc. The manipulator may also be used to perform other operations such as inspection and/or repair of components, equipment and/or other things. In one example, the manipulator can support a tool in the form of a camera, scanner, range finder or other means to perform or assist inspections and/or repair, particularly where the component, etc. to be inspected and/or repaired is high, in tight quarters, difficult to access or otherwise hazardous or difficult for a person to manually access and/or inspect. Such inspections and/or repair may, e.g., include runners or wear plate in a chute or truck tray, bridges structures, roofs or other building structures, power or telephone poles and lines, banks and/or other earthen structures (such as to inspect for bank stability), etc. The manipulator may be used to hold and control a nozzle for cleaning (e.g., using water and/or abrasive), changing blades on earth working equipment, rail car coupling changing, etc. The manipulator may be used for varied activities, particularly those involving difficult, hazardous and/or time-consuming processes such as equipment refueling, plane de-icing, tree trimming, elevated agricultural harvesting, etc.

Claims

1. A joint for securing a tool to a manipulator comprising a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes.

2. The joint of claim 1 wherein the three axes include a pitch axis, a yaw axis and a roll axis for maneuvering the adapter supporting the tool.

3. The joint of claim 1 or 2 including a manifold to direct the flow of the hydraulic fluid to the actuators.

4. The joint of claim 3 including a controller to control the manifold and a communication device to receive wireless signals for the controller.

5. The joint of any of claims 1-4 including hydraulic couplers secured to an exterior of the adapter to provide hydraulic fluid to a tool supported by the adapter.

6. An apparatus for removing ground-engaging wear parts from earth working equipment comprising:

a manipulator;

a joint secured to the manipulator and including a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes; and

one or more tools secured to the joint to hold the wear part and release a locking element securing the wear part to the equipment, wherein the manipulator in cooperation with the joint and one or more tools can remove the wear part from the equipment.

7. The apparatus of claim 6 wherein the three axes include a pitch axis, a yaw axis and a roll axis for maneuvering the adapter supporting the tool.

8. The apparatus of claim 6 or 7 wherein the manipulator is movably about multiple axes by hydraulic actuators.

9. An apparatus for conducting an in-field operation comprising:

a manipulator;

a joint secured to the manipulator and including a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define at least two nonparallel axes of movement for the adapter, and hydraulically-driven actuators to selectively move and hold the components about the axes; and

one or more tools secured to the joint to conduct an in-field operation.

10. The apparatus of claim 9 wherein the joint has three axes including a pitch axis, a yaw axis and a roll axis for maneuvering the adapter supporting the tool.

1 1. The apparatus of claim 9 wherein the joint has three axes, and two of the axes always intersect the third axes.

12. The apparatus of any of claims 9-1 1 wherein the one or more tools includes one or more of grippers, pulling assemblies, cleaning apparatus, unthreading and/or threading assemblies, welding equipment, impact devices, cutting apparatus, dispensing implements, magnets, cameras, range finders and sensors.

13. The apparatus of any of claims 6-12 including a manifold to direct the flow of the hydraulic fluid to the actuators.

14. The apparatus of claim 13 including a controller to control the manifold and a communication device to receive wireless signals for the controller.

15. The apparatus of any of claims 6-14 including hydraulic couplers secured to an exterior of the adapter to provide hydraulic fluid to a tool supported by the adapter.

16. The apparatus of any of claims 6-15 wherein the manipulator is movably about multiple axes by hydraulic actuators.

17. The apparatus of any of claims 6-16 wherein the tool includes a gripper to grip a ground-engaging wear part for earth working equipment for removing and/or installing the wear part from or on the equipment.

18. An apparatus for conducting an in-field operation comprising a manipulator with an first tool mount, a first tool secured to the first tool mount to conduct an in-field operation, the first tool including a second tool mount, and a second tool secured to the second tool mount to conduct an in-field operation, the second tool being secured in a series with the first tool and first tool mount.

19. The apparatus of claim 18 wherein the manipulator includes a joint supporting the first tool mount, the joint including a base to secure the joint to the manipulator, and components movably joined together in close proximity with each other between the base and the first tool mount to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes.

20. The apparatus of claim 19 wherein the joint includes a pitch axis, a yaw axis and a roll axis for maneuvering the adapter supporting the tool.

21. The apparatus of claim 19 or 20 wherein the first tool is a vibrator and the second tool is a gripper to grip a ground-engaging wear part for earth working equipment for removing the wear part from the equipment.

22. The apparatus of claim 19 or 20 wherein the tools include two or more of grippers, pulling assemblies, cleaning apparatus, unthreading and/or threading assemblies, welding equipment, impact devices, cutting apparatus, dispensing implements, magnets, cameras, range finders and sensors.

23. An apparatus for removing a ground-engaging wear part from earth working equipment comprising a gripper for gripping the wear part to be removed, a vibrator for vibrator at least a portion of the gripper contacting the wear part, and a manipulator supporting the gripper and the vibrator.

24. The apparatus of claim 23 wherein the vibrator is secured to the manipulator and the gripper is secured to the vibrator.

25. The apparatus of claim 23 or 24 wherein the manipulator includes a joint supporting the first tool mount, the joint including a base to secure the joint to the manipulator, and components movably joined together in close proximity with each other between the base and the first tool mount to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes.

26. A system for conducting in-field operations comprising:

a manipulator with base tool mount; and

a plurality of tools each having a connector, a tool mount and an operating device to conduct an in-field operation, the connector of each of the tools can be releasably secured to the base tool mount and the tool mount of the other tools so that one or more of the tools can be interchangeably secured in a series to the manipulator.

27. The system of claim 26 wherein the manipulator includes a joint supporting the first tool mount, the joint including a base to secure the joint to the manipulator, and components movably joined together in close proximity with each other between the base and the first tool mount to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes.

28. The system of claim 27 wherein the joint includes a pitch axis, a yaw axis and a roll axis for maneuvering the adapter supporting the tool.

29. The system of any of claims 26-28 wherein a first tool is a vibrator and a second tool is a gripper to grip a ground-engaging wear part for earth working equipment for removing the wear part from the equipment.

30. The system of any of claims 26-28 wherein the tools include two or more of grippers, pulling assemblies, cleaning apparatus, unthreading and/or threading assemblies, welding equipment, impact devices, cutting apparatus, dispensing implements, magnets, cameras, range finders and sensors.

31 . A process for removing ground-engaging wear parts from earth working equipment comprising:

operating the movements of a manipulator, a joint secured to the manipulator and one or more tools secured to joint to grip a wear part secured to the earth working equipment, wherein the joint includes a base to secure the joint to the manipulator, an adapter to secure a tool to the joint, components movably joined together in close proximity with each other between the base and the adapter to define three non-parallel axes of movement for the adapter wherein two of the axes always intersect a third of the axes, and hydraulically-driven actuators to selectively move and hold the components about the axes;

subsequently operating the one or more tools to release a locking element securing the wear part to the earth working equipment; and

operating the one or more tools to remove the wear part from the earth working equipment after the locking element has been released.