Robotic end-effector with active system compliance and micro-positioning capability

A robotic end-effector system, comprising:

• a) a mounting bracket assembly attached to a manipulator arm of a robot;
• b) a dual shaft motor attached to said mounting bracket assembly, said motor having first and second rotatable output shafts, said first shaft for mounting an encoder, for providing position data;
• c) a mechanical drive mechanism comprising a bar linkage assembly connected to said motor and to said mounting bracket assembly, said bar linkage assembly, comprising:
• i) a crank attached to said second output shaft;
• ii) a drag link connected to said crank;
• and,
• iii) a plurality of hinges connected to said mounting bracket assembly;
• d) a passive compliance system connected to ends of said plurality of hinges and to an end of said drag link;
• e) a load sensor system supported by said compliance system for providing force data;
• f) an end-effector end piece connected to said load sensor system;
• and
• g) a closed loop computer control system in communication with said motor for processing said position data and said force data for providing micro-positioning of said end-effector end piece and for providing an active system compliance, thereby achieving the desired end-effector function.

A robotic end-effector system, comprising:

• a) a mounting bracket assembly attached to a manipulator arm of a robot;
• b) a dual shaft motor attached to said mounting bracket assembly, said motor having first and second rotatable output shafts, said first shaft for mounting an encoder, for providing position data;
• c) a mechanical drive mechanism comprising a rack and pinion assembly connected to said motor and to said mounting bracket assembly, said rack and pinion assembly, comprising:
• i) a gear head attached to said second output shaft;
• ii) a rack in cooperative engagement with said gear head;
• and,
• iii) a linear bearing/track/guide wheel assembly in cooperative engagement with said mounting bracket assembly;
• d) a passive compliance system connected to said ends of said rack and to an end of said linear bearing/track/guide wheel assembly;
• e) a load sensor system supported by said compliance system for providing force data;
• f) an end-effector end piece connected to said load sensor system;
• and
• g) a closed loop computer control system in communication with said motor for processing said position data and said force data for providing micro-positioning of said end-effector end piece and for providing an active system compliance, thereby achieving the desired end-effector function.

A robotic end-effector for use with a robotic end-effector system of the type utilizing a closed loop computer control system which processes position and force data from said robotic end-effector for providing micro-positioning of an end-effector end piece and an active system compliance thereof, said robotic end-effector, comprising:

• a) a mounting bracket assembly attached to a manipulator arm of a robot;
• b) a dual shaft motor attached to said mounting bracket assembly, said motor having first and second rotatable output shafts, said first shaft for mounting an encoder, for providing position data;
• c) a mechanical drive mechanism connected to said motor and to said mounting bracket assembly, said mechanical drive mechanism for converting rotational motion of said second output shaft to translational motion;
• d) a passive compliance system connected to said mechanical drive mechanism;
• e) a load sensor system supported by said compliance system for providing force data;
• and,
• f) an end-effector end piece connected to said load sensor system for providing the desired end-effector function.

A robotic end-effector system for the automated re-waterproofing of spacecraft thermal protection systems, comprising:

• a) a mounting bracket assembly attached to a manipulator arm of a robot;
• b) a dual shaft motor attached to said mounting bracket assembly, said motor having first and second rotatable output shafts, said first shaft for mounting an encoder, for providing position data;
• c) a mechanical drive mechanism connected to said motor and to said mounting bracket assembly, said mechanical drive mechanism for converting rotational motion of said second output shaft to translational motion;
• d) a passive compliance system connected to said mechanical drive mechanism;
• e) a load sensor system supported by said compliance system for providing force data;
• f) an end-effector end piece connected to said load sensor system, said end-effector end piece comprising:
• i) an adapter plate connected to said load sensor system;
• and,
• ii) a suction cup assembly mounted on said adapter plate, said suction cup assembly comprising:
• a dual port suction cup element;
• a needle mounted to said suction cup element;
• and,
• a flexible nozzle attached to said needle;
• and,
• g) a closed loop computer control system in communication with said motor for processing said position data and said force data for providing micro-positioning of said end-effector end piece and for providing an active system compliance, thereby achieving the desired end-effector function.