Note: Descriptions are shown in the official language in which they were submitted.
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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 member tends 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
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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
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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
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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.
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[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,
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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.
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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
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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 11 (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,
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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 11. 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.
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[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 11 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 11, is secured. With tool mount 62, the tool connector 67
can have the form
of hooks to secure the tool 11 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
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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 11 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 11A (Fig.
5A) can be
secured to adapter 16 and a second tool 11 (Fig. 5) can be secured to the
first tool 11A. In
this illustrated embodiment, tool 11A has hooks 67A on a rear end to secure
tool 11A to
adapter 16, and a tool mount 62A on a front end to support tool 11. As can be
seen, tool
mount 62A has a pin 64A for securing hooks 67. In one embodiment, tool 11A 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 11A 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 11 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 11, 11A. As
one example, a tool in the form of a sensor module 11B could be mounted in
series with tool
11 and/or tool 11A. 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 11B could be similar to the vibrator and include a
connector in the
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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 11B 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) 11 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,
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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
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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 11 could be used to replace the wear part. The camera or other
inspection tool could
be provided as part of tool 11, could be a tool separately attached to adapter
16, or could be
secured to adapter 16 in lieu of tool 11 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.
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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
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
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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
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.
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