CN1812868A - CMM arm with exoskeleton - Google Patents

Abstract

A kind of equipment used for CMM arm with exoskeleton is provided, it comprises internal CMM arm with base end and probe end and exoskeleton driving this internal CMM arm through multiple transmission devices.One or more contact probes, optical probes and tools are installed on the probe end.CMM arm with exoskeleton is provided in the embodiment that can be operated manually and automatically.CMM arm with exoskeleton can be used for accurate measurement or for performing accurate operation.Provide the method for operating this CMM arm with exoskeleton.

Description

CMM Arm with Exoskeleton

technical field

The present invention relates to apparatus and methods for a CMM arm with an exoskeleton for performing precise measurements and manipulations.

Background technique

Existing methods for automated measurements

Automatic measurements of medium to large objects require a measuring machine with an accuracy of 0.05mm (+/-2 Sigma), typically 0.025mm (+/-2 Sigma) or better. 'Sigma' means one standard deviation. It is currently done in two main ways: (i) large, expensive conventional computer numerically controlled coordinate measuring machines (CNCCMMs) with 3 or more axes; (ii) dedicated Rigid structure of the stationary optical probe in the cell. With a conventional CMM, an optical probe is moved in a highly controlled manner around a stationary object in order to generate accurate data. In the second case, both the optical probe and the object are stationary and positioned in a calibrated manner allowing accurate data to be calibrated. Most conventional CMMs are carriage or horizontal arm structures; several companies including Zeiss (Germany), Hexagon Brown & Sharpe (Sweden) and LK (UK) manufacture them. Mechanical tactile probes for mounting on conventional CMMs are supplied by companies including Renishaw (UK). Optical probes for mounting on conventional CMMs are supplied by companies including Metris (Belgium). Automatic probe mounts such as the Renishaw Autojoint are repeatable to high precision and have probe holders for automatic probe changes. The rigid structure of the stationary optical probe was supplied by Perceptron (USA). The rigid structure of conventional CMMs and stationary optical probes both have the following disadvantages: they use up cell space on the production line, they are usually only used for measurement and not production operations, they are usually located at the end of the production line, and cannot feed forward data to downstream processes , and the price is expensive, and it is difficult to guarantee the return on investment. In addition, the rigid structure of the optical probe cannot be bent, making it difficult to quickly change models on the production line. Today, due to these shortcomings of existing high-precision measurement systems, efficient production processes that use faster, better or cheaper than conventional types of processes but require high-precision positioning cannot be deployed on such production lines.

Robot automatic measurement

Since the 1960s, many companies have developed heavy-duty robotic arms for use in applications requiring fast cycle times and reproducibility. However, they have low accuracy mainly due to temperature, wear and vibration issues. Robots have been used to carry probes for automated measurements. These robotic arms are not precise enough to meet most automated measurement needs, especially in the automotive industry. The high reproducibility of the robot arm has made "quasi-static" measurements a solution adopted by the automotive industry. In "quasi-static" measurements, the probe is moved from one location to the next, and data is only taken when stationary or moving slowly. Measurements can be made with contact or non-contact probes. Measurement probes on robotic arms that extract 3D data from object surfaces are not precise when moving at typical speeds of 10mm/sec-200mm/sec (but can be more or less). Companies producing robotic arms include Fanuc (Japan) and Kuka (Germany). Perceptron and LMI-Diffracto (USA) offer solutions using robotic arms and optical probes. 3D Scanners and Kuka presented a solution using real-time optical inspection at the Euromold 2001 exhibition in Frankfurt; with an accuracy of the order of 0.5-1mm. Standard industrial robots project thermal growth of about 10 microns per meter per degree Celsius increase in temperature; errors in excess of 500 microns can be recorded in production line conditions. LMI-Diffracto has automotive production line equipment consisting of four standard industrial robots supplied by Kuka, each carrying an optical probe, where compensation for thermal expansion of the robots reduces thermal errors in production line conditions to less than 100 microns. In US Patent 6,078,846 Greer, assigned to Perceptron, compensation for thermal expansion of the robot is performed by measuring fixed artifacts with an optical probe. Optical probes take measurements while the robot is at rest during motion. Error mapping improves the accuracy of the robot. There are several methods including bouncing the robot through a planar motion program while measuring it with a photogrammetry system such as produced by Krypton (Netherlands) or Northern Digital (Canada). The measurements are then used to generate the error map. Error compensation for load is performed by measuring the power used by the servo system to automatically calculate the load acting on the arm. Even with multiple types of error compensation, this type of robot has achieved an accuracy of only 0.2mm (+/- 2 Sigma) and is heavily used in automotive production lines. A problem with robotic arms with scanning probes that there is relative motion between the probe and the object during scanning is that the system is not precise enough to be useful.

record track

In US Pat. No. 6,166,811 to Long et al., a photogrammetric system for improving the accuracy of scanned objects is disclosed, wherein a photogrammetric target fixed to a probe is tracked in real time by the photogrammetric system. This approach has many disadvantages. First, multiple clear lines of sight need to be maintained between the probe and the photogrammetry camera. In practice, the line of sight from the photogrammetric camera to the photogrammetric target on the probe is often blocked by the programmed robot motion and/or programmed probe orientation changes required to scan the object. This limits the applicability of such systems and makes them unusable for many applications. Second, ambient lighting conditions must remain close to ideal, otherwise the accuracy of the photogrammetry system will decrease or the system will cease to function. In practice, this is difficult to establish and often contradicts other lighting requirements for positioning. Third, in such applications, photogrammetric systems often do not have the resolution and speed required to provide sufficient accuracy for such applications. Fourth, such photogrammetric cameras and robots must be rigidly mounted relative to each other. This usually requires a rigid structure of large dimensions to achieve the required accuracy. The main problem with introducing photogrammetry into a robotic measurement system is that the resulting system is not compact and robust enough to be used.

Leica Geosystems supplies the 6-DOF laser tracker Laser TrackerLTD800. It measures position and orientation at up to 1000 measurements per second within a range of 35m using a single line of sight. For slowly moving targets, the accuracy is on the order of 50 microns. It cost over $130,000. Its limitations for robotic surveying are many similar to those for photogrammetry. The main problems with introducing laser tracker technology into a robotic measurement system are that it is expensive, there are limitations on the orientation of the probe to the recorded trajectory, and the resulting system is not compact and robust enough for use.

Robot controller and program control

Applications for robotic arms are well understood by those of ordinary skill in the art to which this invention pertains; the standard reference is "Robot Manipulators, Mathematics Programming and Control" by Richard P Paul. Adept Technologies (USA) supplies 6-axis robot controllers starting at $8,500. There are a number of products available for the programming of robots which allow motion sequences to be generated off-line and then transmitted to the robot controller for later execution; one example is EmWorkplace produced by Tecnomatix (USA). In patent application GB2036376A Richter assigned to HA Schlatter AG (Switzerland), programming is achieved by manually guiding the robot by means of a device mounted on the robot, which is held by the user and includes strain gauges that detect the user's predetermined commands to the robot .

Manual CMM Arm

Since the 1970s, many companies have been building manually operable CMM arms, which have recently achieved measurements between 0.025mm (+/-2 Sigma) and 0.005mm (+/-2 Sigma) using contact probes. The accuracy of the measurement depends mainly on the extension range of the Manual CMM arm. With further development, the Manual CMM Arm is expected to become even more precise. These Manual CMM Arms are now accurate enough for many measurement requirements and are a growing segment in the measurement market. They have the flexibility to gain access to hard-to-reach areas. Manual CMM Arms have acceptable accuracy for many applications, but they do not work automatically; they are expensive to operate, especially because semi-skilled operators are required; operators are also subject to human error. Manual CMM Arms are manufactured by companies including: Cimcore (USA), Faro Technologies (USA), Romer (France), Zett MessTechnik (Germany) and OGP (UK). For example, U.S. Patent 3,994,798 Eaton, U.S. Patent 5,402,582 Raab assigned to Faro Technologies, U.S. Patent 5,829,148 Eaton, and U.S. Patent 6,366,831 assigned to Faro Technologies disclose background information on Manual CMM Arms. The provision of bearings at the joints of Manual CMM arms is well known and background information on bearings is disclosed in U.S. Patent Application 2002/0087233 Raab assigned to Faro Technologies. Manual CMM arm designs are typically limited to about 2 meters of extension from the center of the joint 1 to the probe tip, since longer it would require two operators to use the arm. The longer the Arm of a Manual CMM, the less accurate it will be. In general, for a Modular Manual CMM Arm, other things being equal, accuracy is just inversely proportional to length. In US Patent 6,366,831 Raab, it is disclosed that in the field to which this invention pertains, manual CMM arms typically have ten times or more absolute positioning accuracy than robotic arms. Some of the sources of inaccuracy in robots include joint misalignment see US Patent 6,366,831. Manual CMM Arms such as those manufactured by Faro Technologies and Romer are typically operated by a single person using two hands. Each hand of the operator provides a different six degrees of freedom to act on the segment of the Manual CMM Arm held by that hand. In some applications, only one hand may be required by some skilled operators. A Manual CMM Arm is a mechanism that is controlled in a closed loop, where the operator closes the loop. This control is a skilled activity; the operator needs to use only two hands to control the 6-axis or 7-axis arm degrees of freedom under the influence of gravity according to various spatial configurations. It is often the case that the operator mishandles the Manual CMM Arm and the Manual CMM Arm is partially or fully accelerated by gravity until a collision occurs or the operator stabilizes it. It is the case during data acquisition that the operator applies variable and sometimes excessive forces and torques to the Manual CMM Arm, which reduces the accuracy of the measurement data output by the Manual CMM Arm.

compensation and holding device

Manual CMM Arms typically have compensation built into the second joint that provides torque to the upper arm that tends to provide a lifting force to the upper arm in order to balance it. Compensation devices for Manual CMM Arms are disclosed in US Patents 6,298,569, 6,253,458 to Raab et al. and US Patent Application 2003/0167647, all assigned to Faro Technologies. This means the operator has less weight to lift the arm and is therefore less tiring to use. It also means that more torque is transmitted through the Manual CMM Arm, and requires that the Manual CMM Arm must be designed heavier than without such compensating means in order to obtain the required accuracy. Compensating robots to reduce robot power consumption and motor power, size and weight is routine practice. In 2003/0167647 the machined spring compensator can be removed, reversed and replaced in order to compensate the arm when used in the down position; this procedure is inconvenient for the user as it has to be done at the factory. Some Manual CMM Arms have a holding device for locking one or more axes of the arm in an arbitrary spatial orientation; this holding device eliminates the need to lower the arm between measurement sets. In the 3000 Series Manual CMM Arms supplied by Cimcore (USA), there is a slip pin fixture mounted on the compensator on axis 2 (the first orthogonal pivot); when the pin slides into the hole, axis 2 The compensating device placed on is locked. Pneumatic brakes on several axes are disclosed in PCT/EP01 01570 Nietz assigned to Zett MessTechnik GmbH, which are provided on axes 1 to 4 of Zett Mess AMPG P manual CMM arm products; the pneumatic brakes can be released by a radio remote control switch; Air brakes act on the discs. Pneumatic brakes and discs are mounted directly on the Manual CMM Arm; they add weight to the Manual CMM Arm and transmit torque through the Manual CMM Arm's bearings, reducing its accuracy and usability.

Optical Probe on Manual CMM Arm

Optical probes on Manual CMM Arms are disclosed in several patent applications including WO9705449 by the inventor of the present invention, Crampton. Optical probes for manual CMM arms are offered or are being developed by, among others, 3D Scanners, Romer, Faro Technologies, Perceptron, Steinbichler (Germany), Pulstec (Japan), and Kreon (France). Optical probes are typically mounted offset to the side of the Manual CMM Arm or mounted on its probe end. There are three generalized types of optical probes: point, line, and area. So far, there is still no measurement accuracy standard defining the measurement accuracy of point-type, line-type and area-type optical probes. The market is failing to perform standard tests to verify accuracy and enable comparisons between optical probe types in a realistic manner. Optical probes have become accurate primarily because of their short measurement ranges. Generally speaking, optical probes collect measurement data over a measurement range of about 20-400mm. This is usually offset from the end of the Manual CMM Arm. The accuracy of the best manual CMM arms combined with the best optical probes has long exceeded 0.050mm (+/-2 Sigma) and can exceed 0.010mm (+/-2 Sigma), even exceeding 0.002mm for short measurement ranges (+/-2 Sigma).

Synchronization and Interpolation of Optical Probes on Manual CMM Arms

In a system that includes a Manual CMM Arm and an Optical Probe, measurements from each are combined to give output measurement data. As disclosed in WO9705449 by the inventor of the present invention, Crampton, the measurement accuracy of a system comprising a Manual CMM Arm and an Optical Probe is improved by synchronizing measurements from the Manual CMM Arm and from the Optical Probe. Additionally, as further disclosed in WO9705449, the measurement accuracy of a system comprising a Manual CMM Arm and an Optical Probe is measured by time-stamping each measurement from the Manual CMM Arm and each measurement from the Optical Probe and then using The method of interpolation of two sets of measurements is enhanced to provide a combined measurement. However, sometimes there is interference in the system and one or more measurements from one device or the other are lost. In this case, the latter interpolation method can be complicated.

Calibration of Robotic and Manual CMM Arms

As disclosed in U.S. Patent 5,687,293 Snell, a robot can be calibrated using a reference sphere and a ball-tipped probe located on the robot by making multiple contacts of the ball-tipped probe with the reference sphere in different spatial layouts of the robot; A 39-parameter motion model for a 6-axis robot embodiment is disclosed. Calibration of an optical probe relative to a robot is disclosed in US Pat. No. 6,321,137 B1 De Smet. A method of manually calibrating the Manual CMM Arm is disclosed in US Patent 5,402,582 Raab assigned to Faro Technologies. Manual CMM Arms are calibrated by the factory prior to shipment. Some vendors, including Faro Technologies, allow the user to perform a simple probe calibration each time the probe is changed, while manual CMM arm calibration remains the same. OGP UK supplies the Polar Manual CMM Arm and allows the user to fully calibrate the Polar arm and probe together following a simple procedure by using a datum artefact with several cones as the arm is exercised through various spatial layouts, where the Polar arm's Spherical probes are placed into these cones; a 39-parameter motion model is used for their 6-axis Polar arms. Adequate and accurate manual calibration of a Manual CMM Arm is a laborious process in which typically 500 separate points are recorded, taking several hours at a time. Each point is susceptible to human error. Different operators hold the Manual CMM Arm in different positions, apply different torques through different gripping forces, and apply different types of loads and bending moments to the arm, resulting in different deflections and tip slopes. A manually calibrated Manual CMM Arm will perform differently depending on how each operator holds and uses it. The required Manual CMM Arm is under repeatable load patterns and bending moments, however applicable for each spatial orientation. A manual method of calibrating a Manual CMM Arm is required with the same load patterns and bending moments that will occur when it is used by different operators. Automated methods of calibrating manual CMM arms need to improve the reproducibility and precision of their calibration, in particular allowing recording of substantially more points than existing manual processes or being more cost effective. Calibration (aka alignment or identification) of an optical probe relative to a manual CMM arm is disclosed in WO9705449 to Crampton, the inventor of the present invention.

Connection of robot and measuring device

As disclosed in US Pat. No. 5,392,384 Tounai et al., the tip of a 6-axis articulated measurement device is attached to the tip of the robot to calibrate the robot. As disclosed in US Patent 6,535,794 Raab assigned to Faro Technologies, the tip of a 6-axis articulated measurement device is attached to the tip of a robot to generate an error map. As disclosed in US Patent 6,519,860 Bieg et al., the tip of a 3-axis articulated measurement device is attached to the tip of a robot or machine in order to measure the spatial performance of the robot or machine. None of these disclosures are used to measure objects. As disclosed in WO98/27887 Wahrburg, the surgical robot and branch cannula sensor arm are connected at the base; the branch cannula sensor arm is used manually to measure the patient, a robotic program is generated from those measurements, and the robot performs the surgery. In this disclosure, measurements are not made automatically. Two prior arts disclose devices for measuring the position and or orientation of an end point of a robotic arm affected by deflection due to bending and or thermal expansion. As disclosed in US Patent 4,119,212 Flemming, a simple elbow connection with planar goniometers rigidly connected at both ends is used to monitor the position of the end of the moving segment. Such devices are limited to operation in a plane and thus cannot measure bending out of plane. It is thus capable of measuring position and orientation in three-dimensional space. As disclosed in U.S. Patent 4,606,696 Slocum, the means for measuring the position and orientation of the end of a robot arm includes numerous measuring links and measuring devices connected by rotary and linear bearings for measuring rotational angle and linear motion. In addition to being pinned at both end points of the robot arm, the measuring link is rigidly pinned to the robot arm at least at one intermediate articulation joint. This approach requires 12 accurate rotational and linear measurement devices on a 6-axis robot. The accumulation of errors in these 12 measuring devices casts doubt on whether it can be developed into an accurate three-dimensional measuring device for a 6-axis robot. This requires a simpler, more robust system that does not require additional rotary and linear measurement devices and their associated error accumulation. Both patents 4,119,212 and 4,606,696 require rigid attachment of measurement devices at each end of the robotic arm. A rigid connection at the tip of the probe is essential to accurately measure the position of the tip of the robot arm. When a robotic arm is used to position the CMM arm, a rigid connection at the probe tip is neither necessary nor desirable. Neither patents 4,119,212 nor 4,606,696 provide a mechanism for using the calibration information in the device. Neither of them proposes to use the device as a coordinate measuring machine. Without the use of calibration information, it is questionable whether a device can be located anywhere near as precise as is required in this application.

other background

As disclosed in PCT/GB01/01590 Gooch, the robots are shown with an optical probe and a tool mounted at the end of the robot probe; the robot can be alternately used to take measurements with the optical probe and perform operations with the tool; however, To achieve the measurement accuracy, an optical tracking system is used which has all the disadvantages mentioned earlier. As further disclosed in PCT/GB01/01590 Gooch, the robot may be mobile, e.g. mounted on a track, in order to get close to the larger object being measured; this further disclosure also has the disadvantage of optical tracking. In patent PCT/GB01/03865 Gooch, a manual marking system using a Faro arm and a robotic marking system using an industrial robot from Kuka are disclosed; both systems are either accurate or automatic, but not both. Crampton, the inventor of the present invention, disclosed in patent application WO9705449 the manual scanning of objects on a turntable using a contactless sensor mounted on a manual CMM arm. Milling of larger objects has been performed with standard 5 or 6 axis industrial robots; due to the limitations of the accuracy of standard industrial robots, the objects produced are imprecise and often require manual trimming at different orientations where the cut form is produced. Milling work on larger objects is regularly performed on large 5-axis machining centers such as those manufactured by Mecofspa (Italy) and on large 5-axis horizontal arm CMMs such as those supplied by Zeiss and LK Tool; The kind of machined objects is limited by the Cartesian machining type, eg a horizontal arm cannot bend around a corner. Delcam (UK) provides software called PowerShape which is capable of generating milling programs for 5-axis and 6-axis industrial robots.

need for precision

Users are demanding higher precision from their Manual CMM Arms than ever before. The large amount of error in the Manual CMM Arm comes from over-stressing the Manual CMM Arm by the operator, the variability in the torque applied to the arm through different handle positions, and the built-in counterweights that provide torque across the bearings. This requires a more repeatable Manual CMM Arm, where the load on the CMM Arm is independent of the way it is held, and which is much more accurate. There is also a need to automate a more accurate calibration process that removes human error.

The need for automation

Manual CMM Arms with optical probes are typically used for many hours at a time. During most of this period, the operator holds the Manual CMM Arm at a distance from him, usually in an inconvenient location. For long Manual CMM Arms, the weight supported at some distance may be several kilograms. This is hard work and tiring for many operators, especially smaller ones; operator fatigue is a common problem and this can lead to illness, incapacity or trauma. Most of the work done with the Manual CMM Arm is a unique part that only needs to be visually inspected once. Often the surface being inspected is not directly accessible and a temporary platform needs to be built for the operator to climb on to be able to maneuver the arm. The problem with using Manual CMM Arms that carry scanning probes where there is relative motion between the probe and the object during scanning is that, while they are sufficiently accurate, the systems are tiring to use and may be damaged due to operator error or damage to the Manual CMM Arm. Overstressed to output inaccurate data because it cannot operate automatically.

need for accessibility

The shape of the object to be measured and its accessibility by the probe on the movable member varies with the application. A CMM that is flexible enough to access a larger range of object shapes has greater utility. In fact, it is generally believed that an articulated arm CMM comprising a set of preferably 6 or 7 joints separated by rigid segments has greater flexibility than an orthogonal axis configuration CMM. It is also generally accepted that, in the state of the art, automated orthogonal axis configuration CMMs are several orders of magnitude more accurate than automated articulated robotic arms. It is also generally believed that automated orthogonal axis configuration CMMs are less suitable than automated articulating arm robots for positioning in a manufacturing environment such as on an assembly line. The problem is that there are no articulated, sufficiently accurate automatic CMM machines available.

The need for portability

There is a significant demand for Portable Manual CMM Arms as shown by the approximately 5,000 Portable Manual CMM Arms purchased in the mid-1990's as they became sufficiently accurate. A corresponding need for a portable automated CMM arm still exists today, but it doesn't.

The need for robustness

Manual CMM Arms are becoming more precise and less robust. Existing designs of Manual CMM Arms have sophisticated measurement systems that are susceptible to shocks, moments, and violations of operating procedures during use and transportation. Existing designs of shipping containers are relatively simple and leave the Manual CMM Arm vulnerable to damage, especially from impact. This requires a rugged, portable Manual CMM Arm and shipping container that minimizes the forces and moments on the Manual CMM Arm due to shocks during transport.

Contents of the invention

In the prior art, Flemming discloses a robot arm with a connected measuring arm, which is only usable in-plane and does not take into account out-of-plane bending. Slocum discloses a measurement device for a robotic arm operating in three dimensions. It requires 12 rotary and linear measuring devices for a 6-axis robot, which is complex in structure, expensive to manufacture and limited in accuracy due to error accumulation.

Accordingly, it is an object of the present invention to provide a CMM arm with an exoskeleton and transmission that operates in three dimensions and requires only one measurement device per axis, i.e. 6 angle encoders are required on a 6-axis CMM arm, whereas 7 angle encoders are required on a 7-axis CMM arm. The resulting CMM arm with the exoskeleton is stronger and more precise than Slocum's device, and can operate in three dimensions, a drawback of Flemming's device. Another object of the present invention is to provide a CMM Arm with an exoskeleton having both manually operated and automated embodiments. Another object is to provide a CMM Arm with an exoskeleton that can collect data. Another object is to provide a CMM Arm with an exoskeleton that can perform operations.

In a first embodiment of the invention, the Portable Robot CMM Arm includes an automated exoskeleton supporting and manipulating the Internal CMM Arm through transmissions to enable it to take measurements of objects. The Robot CMM Arm and the Internal CMM Arm are rigidly connected at the base. The Exoskeleton and Internal CMM Arm have the same number of axes and approximately the same joint axis orientation and crosshead. The Robot CMM Arm preferably has 6 or 7 axes. There is a transmission between the Exoskeleton and the Internal CMM Arm so that the Exoskeleton both drives and supports the Internal CMM Arm. The actuator is non-rigid and the probe tip of the Internal CMM Arm can move a small amount relative to the probe tip of the Exoskeleton. This first embodiment differs fundamentally from the devices of Slocum and Flemming, which require a rigid connection between the probe end of the robot arm and the probe end of the measuring device. At least one probe is mounted on the probe end of the Internal CMM Arm. Positioning from the internal CMM arm and measurement from the probe are combined, and a novel systematically changed calibration marker and method is proposed to avoid inaccuracies due to ambiguity in the combination. The Control Box is integrated into the base of the Robot CMM Arm. Slip rings allow infinite rotation on the axial axis. The Robot CMM Arm typically weighs 20-30 kg and is portable allowing it to be brought to the object being measured. Another object of this first embodiment is to provide a method for positioning a Robot CMM Arm for measuring data of an object. This Robotic CMM Arm invention has novel structures and novel capabilities not found in Robots, Manual CMM Arms, or conventional CMMs.

In a second embodiment of the invention, the Industrial Robot CMM Arm includes an Exoskeleton enclosing an Internal CMM Arm. A tool may be mounted on an Industrial Robot CMM Arm for performing operations such as milling. The Exoskeleton and Internal CMM Arm are rigidly connected at the probe end so that the Internal CMM Arm can measure the position of the tool and guide it through space more accurately than any previous robot.

In a third embodiment, the Actively Supported Robot CMM Arm includes an active actuator that supports and moves the Internal CMM Arm from the Exoskeleton for precision measurements. The Exoskeleton supports the Internal CMM Arm in order to lighten it and significantly reduce the forces and moments acting on it. The actuator is non-rigid and the probe tip of the Internal CMM Arm can move a small amount relative to the probe tip of the Exoskeleton. This means that the Actively Supported Robot CMM Arm is more accurate than other types of Robot CMM Arms. In another variant, an air bearing is provided between the Internal CMM Arm and the Exoskeleton.

In a fourth embodiment, methods for measuring quantities, simulating quantities, analyzing quantities, visualizing quantities and feeding back results to a manufacturing process are disclosed. The Quantity Measurement Probe is attached to the probe end of the Robot CMM Arm. Means are provided for combining the measured quantity with a CAD model of the measured object.

In a fifth embodiment, methods and apparatus for a Mobile Robot CMM Arm are disclosed. The Robot CMM Arm is mounted on a tripod with retractable feet built into the motorized vehicle and moves from one measurement position to the next. It is commonly used for automatic scanning of large objects such as vehicles or aircraft and provides a lower cost and more flexible alternative to the large horizontal or bridge CMMs currently in use.

In a sixth embodiment, a Robot CMM Arm with a displaceable exoskeleton embodiment is disclosed. The Internal CMM Arm is displaced from the Exoskeleton and used manually to generate robotic programs. The internal CMM arm is replaced in the exoskeleton and the robot then executes the robot program automatically. Manual manipulation of the Internal CMM Arm for generating robotic programs has the advantage of being faster and more practical than conventional methods such as using a teaching suspension.

In a seventh embodiment, a Robot CMM Arm comprising a coupled CMM Arm and a robot is disclosed. The CMM Arm is supported by the robot in at least two positions: at the probe tip and at an intermediate position. This embodiment has the advantage of removing the heat source from the vicinity of the CMM arm.

In an eighth embodiment, a Manual CMM Arm with an Exoskeleton is disclosed. The Internal CMM Arm is supported and driven by the Exoskeleton, which in turn is supported and moved by the operator. Existing Manual CMM Arms combine the functions of measurement, self-support, and robustness for the operator to manipulate the same arm. This eighth embodiment places the functionality of measurement in the Internal CMM Arm and the functionality of support and robustness for operator manipulation in the Exoskeleton. Regardless of the way the Exoskeleton is held by the operator, during the calibration process the Internal CMM Arm is always supported in exactly the same way at each spatial location so that the loads acting on the Internal CMM Arm are repeatable and identical to the load. This load profile reproducibility means that the Manual CMM Arm with Exoskeleton is a more accurate device than any existing Manual CMM Arm device. A flexible button device is provided for the operator to connect the button unit with the wireless transmitter at any suitable position on the exoskeleton; the wireless receiver is integrated in the system. A bumper arrangement is provided in the Exoskeleton to cushion the Internal CMM Arm from undesirable impacts and loads. A probe cover is provided to protect the probe from impact and to compensate for some loading on the contact probe. A number of Manual CMM Arms with partial exoskeletons are disclosed which are more compact than Manual CMM Arms with exoskeletons and improve maneuverability especially in the wrist and probe area, while still having remarkable precision. A Manual CMM Arm with Exoskeleton and many different measurement methods for contact and non-contact probe use are provided. Automatic calibration apparatus and methods for a Manual CMM Arm with Exoskeleton are disclosed. A transport container with a load spreading mechanism is provided to minimize the magnitude of shock loads on the Manual CMM Arm with Exoskeleton during transport.

In a ninth embodiment, a Manual CMM Arm with a Retaining Exoskeleton embodiment is disclosed. One or more joints in the exoskeleton can be locked with brakes. This means that operators who need to pause in the middle of an operation can lock the arm wherever it is without returning it to its resting position. Previous braking systems act on the CMM Arm and apply loads to the CMM Arm, but this embodiment has the advantage of acting on the Exoskeleton without applying any load to the Internal CMM Arm.

In a tenth embodiment, an embodiment of the Manual CMM Arm with an endoskeleton of the present invention is disclosed. The CMM arm is located on the outside of the supporting endoskeleton. In previous devices, the function of the counterweight was either parallel to and outside the arm as in Romer and Cimcore's device, or inserted into the arm so that the bending moment was across the arm. The present invention not only hides the compensation function inside the CMM arm, but also performs compensation without applying a bending moment across the arm.

In an eleventh embodiment, a Robot CMM Arm with an Endoskeleton is disclosed. The CMM arm is located outside the endoskeleton that supports and drives the robot. A first advantage is that the External CMM Arm hides all the drivers, providing an arm suitable for applications where access is limited. A second advantage is that the External CMM Arm has a larger section and bends less, making it more precise.

Description of drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

1A is a schematic diagram of a 6-axis robot CMM arm according to a first embodiment of the present invention;

Fig. 1 B is the schematic diagram of 7-axis robot CMM arm;

Fig. 1 C is the layout drawing of robot CMM arm system;

Figure 2 is a schematic diagram of the joints and segments of the Exoskeleton and Internal CMM Arm;

Fig. 3 is the schematic diagram of the extended range of robot CMM arm;

Figure 4 is a schematic diagram of the actual extension range of the robot CMM arm with an optical probe;

Figure 5A is a schematic diagram of the extended range of a long CMM section;

Figure 5B is a schematic diagram of the extension of the short CMM segment;

Figure 5C1 is a schematic diagram of the CMM section 8;

Figure 5C2 is a schematic illustration of the cantilever and series orthogonal junction options;

Figure 5D is a schematic diagram of the base;

FIG. 5E is a layout view of separately mounted split base sections;

FIG. 5F is a layout view of separate base segments mounted on the same surface;

FIG. 5G is a layout diagram of an exoskeleton base mounted on a surface;

Figure 5H is a layout diagram of the public base;

Fig. 6 is the schematic diagram of stand;

Fig. 7 A is the layout diagram of the robot CMM arm installed on the shock absorber;

Fig. 7B is the layout diagram of the robot CMM arm installed on the ground;

Figure 7C is a layout view of the Robot CMM Arm mounted on a platform inserted into the ground;

Fig. 7D is the layout diagram of the robot CMM arm installed on the linear track;

Figure 7E is a layout diagram of two independent robot CMM arms mounted on horizontal rails;

Fig. 7F is the layout drawing of the robot CMM arm installed on the vertical shaft perpendicular to the horizontal line;

Fig. 7G is the layout drawing of two robot CMM arms installed on the mobile multi-arm base;

Figure 7H is a layout view of the Robot CMM Arm mounted on an object;

Figure 71 is a plan view of a Robot CMM Arm mounted adjacent to a processing machine;

Figure 7J is a layout view of a Robotic CMM Arm installed between several processing machines;

Figure 7K is a layout view of a Robot CMM Arm installed between several work areas;

Figure 7L is a layout view of the Robot CMM Arm on the bridge above the object;

7M is a layout view of a Robot CMM Arm adjacent to an object mounted on a turntable;

Figure 7N is a layout view of the Robot CMM Arm adjacent to the object mounted on the linear stage;

Figure 8A is a layout view of a Robot CMM Arm mounted on a wall;

Fig. 8B is the layout diagram of the robot CMM arm installed on the platform;

Fig. 8C is a layout diagram of the robot CMM arm installed on the inclined platform;

Fig. 8D is a layout drawing of the robot CMM arm installed on the horizontal arm CMM;

Fig. 8E is the layout drawing of the robot CMM arm installed on the carriage CMM;

Figure 8F is a layout view of the Robot CMM arm mounted on the rotating wedge;

Figure 9 is a layout diagram of a Robotic CMM Arm with a photogrammetric tracker;

Figure 10 is a detailed layout diagram of the robot CMM arm system;

FIG. 11A is an illustration of the architecture of the Robot CMM Arm;

Figure 1 IB is a diagram of an alternative architecture for a Robot CMM Arm;

Figure 12A is a schematic diagram of an encoder;

Fig. 12B is a schematic diagram of a dual-mode encoder;

12C is a schematic diagram of a dual-mode encoder mapping device;

Figure 12D is a schematic diagram of the axis and mode center;

Figure 13A is a schematic diagram of forced air circulation;

Fig. 13B is the schematic diagram of high inertia and low inertia robot CMM arm;

Fig. 14 is the schematic diagram of the position of all transmission devices;

Figure 15 is a schematic diagram of the position of the section 8 transmission;

Figure 16 is a schematic diagram of a rotation limiting device;

Fig. 17 is two sections of radial transmission device;

Fig. 18 is two cross-sections of the torsion transmission device;

Figure 19 is a schematic diagram of the compensation device;

Figure 20 is a schematic diagram of hard limits and limit switches in an axial joint;

21A and 21B are schematic illustrations of hard limits in orthogonal joints;

Figure 21C is a schematic diagram comparing the axis separation of the Robot CMM Arm and the Manual CMM Arm;

Figure 22 is a schematic diagram of the bearing;

Figure 23 is a view and cross-section of the probe tip of the Internal CMM Arm;

Fig. 24 is a longitudinal sectional view of a trigger probe installed on the end of the probe;

Figure 25 is a longitudinal sectional view of the optical probe mounted on the end of the probe;

Figure 26 is a view of the optical probe and bracket;

Figure 27A is an illustration of the architecture of the probe;

Figure 27B is a schematic diagram of a probe connected to three cables and a probe box;

Figure 27C is a layout view of the probe with a cable connected to the probe box located outside the Robot CMM Arm;

Figure 27D is a layout view of a probe with a probe box attached through the Robot CMM Arm;

Figure 28 is two schematic diagrams of the principle of the streak probe;

Fig. 29 is a schematic diagram of the scanning mode of the fringe probe;

Figure 30 is a schematic diagram of the measurement area of the fringes;

Figure 31 is a schematic diagram of a small piece of stripes;

Figure 32 is a schematic diagram of many overlapping small blocks;

Figure 33A is a schematic diagram of a two-view fringe probe;

33B is a schematic diagram of a two-view fringe probe scanning a stepped object;

Figure 34A is a schematic diagram of a two-stripe probe;

Figure 34B is a schematic diagram of a two-stripe probe scanning a vertical wall of a stepped object;

35 is a schematic diagram of a platform of a laptop computer;

Figure 36 is a schematic diagram of the suspension;

Figure 37 is a schematic diagram of an operator's headset;

Figure 38A is a layout view of the buttons on the Robot CMM Arm;

Figure 38B is a layout diagram of the foot switch;

Figure 38C is a layout diagram of a remote control with a belt;

Figure 39 is a layout diagram of the coordinate system;

Figure 40 is an illustration of the architecture of the control PCB;

FIG. 41A is an illustration of the architecture of a header PCB;

Figure 41B is a graphical representation of positional averaging in a connector PCB;

Figure 41C is a timing diagram of encoder counting and trigger pulses;

Figure 41D is a flow chart of the position averaging process;

Figure 41E is an illustration of a strain gauge system;

Fig. 42 is a flowchart of the calibration process in the case of the probe as the main control unit;

43A, 43B and 43C are timing diagrams of probe measurement;

Figure 44 is a timing diagram showing delays in triggering probe measurements;

Figure 45 is a flow chart of the calibration process with the probe as the slave;

Figure 46 is a flowchart of the time stamp measurement process;

Figure 47 is a schematic illustration of a probe for scanning ridge artefacts;

Figure 48 is an illustration of +X and -X scans of ridge artefacts;

Figure 49 is a layout diagram of the calibration device;

Figure 50 is an illustration of a calibration artifact;

Figure 51A is a schematic diagram of the positioning of positioning calibration artifacts;

Figure 51B is a layout view of a calibration device with a rotating shaft;

Figure 52 is a flow chart of the measurement process;

53 is a schematic diagram of an industrial robot CMM arm according to a second embodiment of the present invention;

Figure 54 is an illustration of a hybrid 6/7 axis industrial robot CMM arm;

55 is a schematic illustration of a global coordinate system artifact in a Multi-Robot CMM Arm unit;

Figure 56 is a flowchart of the feature checking process;

Figure 57 is a flow chart of the surface inspection process;

Figure 58 is a flowchart of the tool operation process;

Figure 59A is a flowchart of the inspection and tool adjustment process;

Figure 59B is a flowchart of the component adjustment process;

FIG. 60 is a schematic diagram of a movable support robot CMM arm according to a third embodiment of the present invention;

Figure 61 is an illustration of a radially movable transmission with movable axial supports;

Figure 62 is a schematic diagram of a torsionally movable transmission with movable axial and radial supports;

Figure 63 is an illustration of a movable transmission with movable radial supports;

Figure 64 is a schematic diagram of the movable support control system;

Figure 65 is a schematic diagram of a control loop with movable supports;

66 is a flowchart of a quantity measurement process according to a fourth embodiment of the present invention;

Figure 67 is a flow chart of the quantity simulation process;

Figure 68 is a flowchart of the Quantitative Analysis, Visualization and Feedback process;

Figure 69 is an illustration of a Mobile Robot CMM Arm according to a fifth embodiment of the present invention;

FIG. 70 is a floor plan of the mobile robot CMM arm device;

Figure 71 is an illustration of the installation of the reference cone;

Figure 72 is the data structure of reference cone position, target position and belt position;

Figure 73 is a flowchart of the preparation process of the Mobile Robot CMM Arm;

FIG. 74 is a flow chart of the CMM arm measurement process of the mobile robot;

75 is an illustration of a Robot CMM Arm with a displaceable exoskeleton according to a sixth embodiment of the present invention;

Figure 76 is an illustration of a slotted tubular robot segment;

Figure 77 is a diagram of the split bearing transmission;

Figure 78 is a flowchart of the Robot CMM Arm measurement process with replaceable exoskeleton;

Fig. 79 is the schematic diagram of connecting robot CMM arm;

Figure 80A is a layout view of the Manual CMM Arm with the Exoskeleton System;

Figure 80B is a schematic illustration of the Manual CMM Arm with Exoskeleton in a stationary state;

Figure 81 is a schematic diagram of a probe cover;

Figure 82A is a schematic diagram of an optical probe cover;

Figure 82B is a schematic diagram of the optical probe cover as a handle;

Figure 83A is a schematic diagram of a part of the exoskeleton;

Figure 83B is a schematic diagram of an extended partial exoskeleton;

Figure 83C is a schematic illustration of a protective extension part exoskeleton with different internal CMM and exoskeleton joint locations;

Figure 83D is a flowchart of a manual contact measurement process;

Figure 83E is a flowchart of the automated contact measurement process;

Figure 83F is a flowchart of a contactless scanning process;

Figure 83G is a flowchart of a contact scanning process;

Figure 83H is a schematic diagram of a modular robotic calibration device;

Figure 83I is a schematic diagram of an external robotic calibration device;

Figure 84 is a schematic illustration of a shipping container;

Figure 85 is a layout view of the Manual CMM Arm with the Exoskeleton System;

Figure 86A is an illustration of an Unsupported Manual CMM Arm showing forces;

Figure 86B is an illustration of the Manual CMM Arm with Exoskeleton showing forces;

Figure 86C is an illustration of the Manual CMM Arm with Endoskeleton showing forces;

Figure 87 is a schematic diagram of the joints and segments of the Robotic Endoskeleton External CMM Arm;

Detailed ways

first embodiment

Portable Robot CMM Arm

A first embodiment of such an Internal CMM Arm with Exoskeleton is a Portable Robotic CMM Arm. This Portable Robot CMM Arm embodiment includes an Internal CMM Arm guided by an Exoskeleton. The Exoskeleton supports and steers the Internal CMM Arm through actuators so that it can be accurately measured. The present invention can be embodied in accordance with many Robot CMM Arm Articulated Arm layouts. The Robot CMM Arm according to the first embodiment of the present invention has two preferred layouts: 6-axis with 6 joints and 7-axis with 7 joints.

Robot CMM Arm Joint and Segment Layout Diagram

1A and 1B are diagrams respectively showing preferred 6-axis and 7-axis layout views of a Robot CMM Arm 1 according to a first embodiment of the present invention. An Articulated Robot CMM Arm 1 has a base end 2 and a probe end 3 and includes a set of segments and swivel joints between these two ends. There are two types of joints: axial and orthogonal. The axial joint (labeled 'A' in Figures 1A, 1B) rotates about the common axis of its two adjoining segments. An orthogonal joint (labeled 'O' in Figures 1A, 1B) rotates as a hinge between its two adjoining segments. In FIG. 1A , the joint types are AOOAOA in order from base end 2 to probe end 3 , referring to joint centers 21 , 22 , 24 , 25 , 26 and 27 , respectively. In Figure 1B, the joint types are AOAOAOA in order from base end 2 to probe end 3, referring to joint centers 21, 22, 23, 24, 25, 26, and 27, respectively. The 6-axis layout diagram has a more cost-effective low pros. The 7-axis layout has the advantage of allowing more flexible access to structurally complex objects.

The preferred 7-axis Robot CMM Arm 1 layout of FIG. 1B is described in this first embodiment of the Robot CMM Arm 1 invention, but the invention is not limited to this joint layout or the preferred 6-axis of FIG. 1A layout and may have more or fewer than seven contacts. For simple applications, 3 connectors may be sufficient. The invention is not limited to rotating axes of motion. As will be disclosed later, it may comprise one or more linear axes of motion to which the base end 2 is preferably connected.

The Robot CMM Arm System 150 shown in FIG. 1C includes a Robot CMM Arm 1 connected to a laptop 151 by a cable 152 . The Robot CMM Arm 1 has a base end 2 and a probe end 3 . It is mounted on the surface 7 . The probe 90 is mounted on the probe end 3 of the Robot CMM Arm 1 . The optical probe 91 is also mounted on the probe end 3 of the Robot CMM Arm 1 . The Robot CMM Arm 1 comprises a Base 4 , an Internal CMM Arm 5 , an Exoskeleton 6 and a Transmission 10 . The object 9 being measured is located on the surface 7 .

FIG. 2 shows the two main parts of the Robot CMM Arm 1 : the Inner CMM Arm 5 and the Exoskeleton 6 , which share a common base 4 and common joint centers 21 , 22 , 23 , 24 , 25 , 26 and 27 . Internal CMM Arm 5 includes segments 32, 33, 34, 35, 36, 37 and 38, which are referred to herein as CMM segments 2-8, respectively. CMM Segment 838 extends to Probe End 3 of Robot CMM Arm 1. The common base 4 is also referred to as the CMM segment 131. The Internal CMM Arm 5 also includes connectors 51, 52, 53, 54, 55, 56, 57, which are referred to herein as CMM connectors 1-7, respectively. Exoskeleton 6 comprises segments 42, 43, 44, 45, 46, 47 and 48, which are referred to herein as exoskeleton segments 2-8, respectively. Exoskeleton Segment 848 does not extend to Probe End 3 of the Robot CMM Arm. Common base 4 is also referred to as exoskeleton segment 141. The exoskeleton 6 also includes joints 61, 62, 63, 64, 65, 66 and 67, which are referred to herein as exoskeleton joints 1-7, respectively. Robot CMM Arm 1 also includes actuators 72, 73, 74, 75, 76, 77, and 78, referred to herein as actuators 2-8, respectively, for connecting the Internal CMM Arm 5 to the Exoskeleton 6 . Gearing 272 connects CMM Segment 232 to Exoskeleton Segment 242. Gearing 3 73 connects CMM Segment 3 33 to Exoskeleton Segment 3 43, and so on for Gearings 4-8 74, 75, 76, 77, and 78.

Internal CMM Arm Connector and Segment Layout Diagram

The segments and joints of the Internal CMM Arm 5 in the Robot CMM Arm 1 are generally named and arranged as follows. part name location description compare length CMM segment 1CMM segment 2CMM segment 3CMM segment 4CMM segment 5CMM segment 6CMM segment 7CMM segment 8 Base Shoulder Upper Arm Elbow Lower Arm Wrist Probe between base end and connector 1 between connector 1 and connector 2 between connector 2 and connector 3 between connector 3 and connector 4 between connector 4 and connector 5 between connector 5 and connector 6 between connector 6 and connector 7 between connector 7 and probe end short long short long short short connector name type to rotate CMM Connector 1CMM Connector 2CMM Connector 3CMM Connector 4CMM Connector 5CMM Connector 6CMM Connector 7 Base Shoulder Elbow Front Elbow Wrist Front Wrist Transducer Axial Orthogonal Axial Orthogonal Axial Orthogonal Axial ＞360degs＞180degs＞360degs＞180degs＞360degs＞180degs＞360degs

Referring now to FIG. 3, the extension range 80 of the Robot CMM Arm 1 is defined from the joint center 222 to the probe end 3 of the CMM segment 838 when the CMM joint 3-7 is rotated so as to maximize this distance. Most of the reach 80 of Robot CMM Arm 1 includes the sum of the lengths of CMM Segment 3 33 and CMM Segment 5 35.

Referring now to FIG. 4, with the optical probe 91 mounted on the CMM section 838, the extension range 80 varies with the actual distance between the probe end 3 of the CMM section 838 and the optical measurement midpoint of the measurable depth of measurement. Extended range 81 increases.

Each CMM segment has high stiffness. Any loads on the Internal CMM Arm 5 that cause the segments to bend or twist will reduce the Internal CMM Arm 5 accuracy. Gravity is a continuous load source and acts differently for different spatial orientations of the Robot CMM Arm 1 . Typical maximum angular torsional slope in the long CMM segment of the Robot CMM Arm in normal use is 0.25 rad-seconds, but could be more or less, depending especially on the length of the CMM segment. A typical maximum angular bend slope in the Long CMM Segment of the Robot CMM Arm in normal use is 0.5 arc seconds, but could be more or less, depending inter alia on the material, length and diameter of the Long CMM Segment.

Each CMM segment includes one or more important items: part item connector illustrate CMM segment 1CMM segment 2CMM segment 3CMM segment 4CMM segment 5CMM segment 6CMM segment 7CMM segment 8 Base Shoulder Housing Rod Housing Elbow Housing Linkage Housing Wrist Probe 11, 22033, 44055, 66, 77 Machining aircraft aluminum machining aircraft aluminum machining aircraft aluminum weaving carbon fiber machining aircraft aluminum machining aircraft aluminum machining aircraft aluminum weaving carbon fiber machining aircraft aluminum machining aircraft aluminum machining aircraft aluminum machining aircraft aluminum

Referring now to FIG. 5A, a CMM segment 3, 5 33, 35 includes a linkage member 102 having a diameter 108 and a wall thickness 109 between two end shells 100, 101 each housing a joint. . Referring now to FIG. 5B, CMM segments 2, 4, 6, and 7 32, 34, 36, and 37 include a double housing 103 housing two connectors, one at each end. Referring now to FIG. 5C1 , the CMM section 838 includes a probe head housing 105 housing the CMM connector 757 at one end and the CMM probe mount 39 at the other end, the probe 90 terminating in the probe tip 3 is connected to the CMM probe Mounting device 39. It should be understood that there are different options for providing orthogonal junctions for the CMM junctions 2, 4, 6 52, 54, 56. Referring now to FIG. 5C2, the cantilever selection and the series selection for the CMM joint 252 are shown. The preferred option for use with CMM connectors 2, 4, 6 52, 54, 56 is the serial option. The scope of the Robot CMM Arm 1 is not limited to any of these joint options, but may include orthogonal joints of any other design.

Exoskeleton Joint and Segment Layout Diagram

The joint and segment layout diagrams of the Exoskeleton 6 in the Robot CMM Arm 1 are named and arranged broadly as follows. part name location description compare length Exoskeleton Segment 1 Exoskeleton Segment 2 Exoskeleton Segment 3 Exoskeleton Segment 4 Exoskeleton Segment 5 Exoskeleton Segment 6 Exoskeleton Segment 7 Exoskeleton Segment 8 Base Shoulder Upper Arm Elbow Lower Arm Wrist Probe between base end and connector 1 between connector 1 and connector 2 between connector 2 and connector 3 between connector 3 and connector 4 between connector 4 and connector 5 between connector 5 and connector 6 Between joint 6 and joint 7 extends from joint 7 short long short long short short connector name type to rotate brake Exoskeleton joint 1 Exoskeleton joint 2 Exoskeleton joint 3 Exoskeleton joint 4 Exoskeleton joint 5 Exoskeleton joint 6 Exoskeleton joint 7 Base Shoulder Elbow Front Elbow Wrist Front Wrist Transducer Axial Orthogonal Axial Orthogonal Axial Orthogonal Axial ＞360degs＞180degs＞360degs＞180degs＞360degs＞180degs＞360degs No brake Brake brake Brake brake Brake brake

Each exoskeleton segment consists of one or more important items: part item connector illustrate Exoskeleton Segment 1 Exoskeleton Segment 2 Base shoulder 11, 2 Machined aircraft aluminum Machined aircraft aluminum

Exoskeleton segment 3 Exoskeleton segment 4 Exoskeleton segment 5 Exoskeleton segment 6 Exoskeleton segment 7CMM segment 8 Housing Link Housing Elbow Housing Link Housing Wrist Probe 2033, 44055, 66, 77 Machining aircraft aluminum aluminum tube machining aircraft aluminum machining aircraft aluminum machining aircraft aluminum aluminum tube machining aircraft aluminum machining aircraft aluminum machining aircraft aluminum machining aircraft aluminum

Base layout

Referring now to FIG. 5D , the base 4 includes a CMM segment 31 that houses the CMM connector 151 by screwing the connector center 21 into the mounting plate 8 using standard 3.5″ heavy-duty threads 116 and by attaching the connector center 21 to the mounting plate 8 using bolts 106. Exoskeleton Segment 141 houses Exoskeleton Joint 161 on CMM Segment 131. Mounting plate 8 is attached to surface 7 by mounting means 104 such as mounting bolts 107. Both Internal CMM Arm 5 and Exoskeleton 6 are There are respectively base sections 31, 41. In this first embodiment, the exoskeleton section 1 41 is rigidly connected to the CMM section 31 using countersunk bolts 106. Referring now to Fig. In another embodiment, the CMM segment 31 can be installed on the first surface 7a, and the exoskeleton segment 141 can be installed on the second surface 7b, and the CMM segment 31 is not connected to the exoskeleton segment 141. See now Fig. 5F, in another embodiment of the invention of the robot CMM arm 1, the CMM segment 31 and the exoskeleton segment 141 can be mounted independently on the same surface 7. By providing a base extension between the surface 7 and the base 2 Sections, CMM joints 151 can be raised higher above the surface 7. Such base extension sections are preferably based on lightweight tubes made of braided carbon fibers with a low coefficient of thermal expansion typically 0.075ppm/degC. This means that Measurements on the Robot CMM Arm 1 with the Base Extension Tube are not significantly affected by temperature variations relative to the Surface 7. Referring now to Figure 5G, in another embodiment of the present Robot CMM Arm 1 invention, the CMM Segment 31 It can be rigidly or flexibly connected to the exoskeleton segment 141, which is mounted on the surface 7. Referring now to Figure 5H, in another embodiment of the present Robotic CMM Arm invention, the CMM segment 131 is connected to the outer Skeleton segment 1 41 can be mounted on the same base item 4 on surface 7 to which both CMM segment 2 32 and exoskeleton segment 2 42 are connected via CMM joint 1 51 and exoskeleton joint 1 61 respectively. One of the goals of the invention of the Robot CMM Arm is to allow any form of base mounting.

Robot CMM Arm Extension Range

In this first embodiment, the present Robot CMM Arm 1 invention is provided as a series of portable Robot CMM Arms with different extension ranges. The Portable Robot CMM Arm Reach 80 varies from 0.6m to 3m. The scope of the present invention is not limited to the extension within this range, the extension 80 may be lower than 0.6m or more than 3m.

Internal CMM Arm Structure

stiffness and mass

It is an object of the invention to minimize the mass of the Internal CMM Arm 5 . This in turn allows the Portable Robot CMM Arm 1 mass to be minimized as it requires less stiffness and motor power to move the Internal CMM Arm 5 and thus the Robot CMM Arm 1 is more portable.

Experience has shown that there will be a double benefit and for every 100g of mass removed from the Internal CMM Arm 5 approximately 250-400g can be removed from the Robot CMM Arm 1 design. The typical weight of the moving parts of the Medium Reach Inner CMM Arm 5 is 2.5-4 kg. The Exoskeleton 6 supports and drives the Internal CMM Arm 5 so as to minimize the stress on the Internal CMM Arm 5, particularly on the Internal CMM Arm Joints 51-57. In use, the only load acting on the exoskeleton 6 should be gravity and the load is transmitted through the transmission 10 . The Exoskeleton 6 always supports the Internal CMM Arm 5 at the same location, providing repeatable loads at the same spatial orientation. In comparison, modern Manual CMM Arms are designed for additional stresses placed on them by the operator which are significantly higher than those acting on the Internal CMM Arm 5 and also depend on the operator holding it The location and manner of application of different loading locations and directions. This means that the Internal CMM Arm 5 does not need to be as stiff and is lighter than a Manual CMM Arm of similar reach.

Connecting rod member diameter and thickness

The larger the linkage member diameter 108, the stiffer and more accurate it is. As materials science advances, the stiffness-to-weight ratio of the arms increases day by day as stiffer, lighter materials become available. The Internal CMM Arm 5 has two long linkage members 102 in the upper and lower arms: CMM Segment 3 33, CMM Segment 5 35. The linkage member diameter 108 of the Internal CMM Arm 5 is in the range of 40mm-70mm. The scope of the present Robot CMM Arm 1 invention is not limited to such link member diameters; link member diameters above 70mm or below 40mm may be used. During handling by the operator, the forces and torques acting on the current Manual CMM Arm come from gravity, compensating devices, acceleration and operator induced forces and torques related to the combination of joint angles at that time. The operator can apply a bending force on either link. For this reason, the Manual CMM Arm typically has the same linkage diameter for both segments. Exoskeleton 6 supports all segments 32-38 of Internal CMM Arm 5 approximately equally. To this end, the Internal CMM Arm 5 of this first embodiment has the same linkage member diameter 108 for both segments 33 and 35 . The scope of the present Robot CMM Arm invention is not limited to uniform link member diameters and link member diameters may vary. The linkage member 102 is essentially a simple beam supported at either end by a joint or transmission. When horizontal, the primary deflection mode is under gravity. Assuming there is no undesirable moment on the link member 102 , the deflection of the link member 102 is substantially independent of the link member thickness 109 . The link member thickness can then be small, and this is consistent with the goal of minimizing the mass of the Internal CMM Arm 5 . The link member thickness 109 of the Inner CMM Arm is preferably 1 mm to 1.5 mm for both segments 33 and 35 . For longer reach arms, the link member thickness 109 and/or link member diameter 108 typically increases in order to maintain stiffness. The connecting rod member diameter and thickness are parameters that are optimized during the design process for different design specifications and manufacturing constraints.

shape

During assembly, the Exoskeleton Segments 2-8 42-48 sequentially pass over the Internal CMM Arm Segments. The shape of the CMM Segments 32-38 of the Inner CMM Arm has to be such that the maximum radial dimension is as small as possible. Any reduction in the maximum radial dimension enables the size of the Exoskeleton Segments 2-8 42-48 to be reduced, and this makes the Robot CMM Arm invention smaller in size and more flexible in its application.

exoskeleton structure

performance

One purpose of this first embodiment is to make the Robot CMM Arm 1 portable and minimize its weight. This aim is at odds with the requirement for period minimization and correspondingly high angular acceleration at the joint. The performance in terms of maximum angular velocity and acceleration is higher for the Short Reach Robot CMM Arm 1 than the Long Reach Robot CMM Arm 1 . The maximum joint angular velocity is typically in the range of 20deg/sec to 400deg/sec. Exoskeleton joint 1-4 61-64 has a lower maximum angular velocity than exoskeleton joint 5-7 65-67 because of the higher torque. With a long reach 80 of 3m and a Robot CMM Arm weight of 35kg or less, the Joint 2 may typically have a maximum angular velocity of 20deg/sec. With a short reach 80 below 1 m and a Robot CMM Arm weight above 20 kg, the Joint 7 may typically have a maximum angular velocity of 400 deg/sec. The scope of the present Robot CMM Arm invention is not limited to this maximum angular range, but the maximum angular velocity of the joint can be higher than 400 deg/sec or lower than 20 deg/sec.

mass and stiffness

The exoskeleton structure is less rigid than the internal CMM arm because high stiffness is not required for support and actuation functions. Therefore, the weight of the exoskeleton structure is light, so that the Robot CMM Arm is lighter. A virtuous circle exists because, for a given performance standard, a reduction in mass in any movable segment requires a less powerful drive system, which in turn reduces weight. Typical masses for a Portable Robot CMM Arm range from 18 kg at a 1 m reach to 35 kg at a 3 m reach. The scope of the present Robot CMM Arm invention is not limited to this mass range and the maximum mass may be higher than 35 kg or lower than 18 kg.

shape

The exoskeleton is compact and located close to the internal CMM arm. This means that the Robot CMM Arm can access difficult-to-measure areas such as interiors. The Robot CMM Arm can therefore be used in applications that cannot be handled unless the object is extensively prepared, such as when a car seat cannot be measured on site but must first be removed from the car. The Exoskeleton Segments 42-48 form a sealed shape to protect the Inner CMM Arm Segments 32-38 from exposure to damaging solids, liquids or gases during use. Exoskeleton segments 42-48 are hollow to fit over Inner CMM Arm segments 32-38. The Exoskeleton shape also serves to allow the Robot CMM Arm to be used manually and to protect parts of the Internal CMM Arm in case of a collision. For aesthetic reasons, exoskeleton structural parts have non-functional surface shapes. One of the many factors that determine the shape of the exoskeleton is the size and location of the motor and gearbox drive elements.

Material

Internal CMM Arm Material

The housings 100, 101, 103, 105 are constructed of aircraft aluminum; the aluminum is anodized. Link member 102 comprises a thin walled tube made of a braided carbon fiber-epoxy composite such as Toray T700, which provides a near zero coefficient of thermal expansion, high stiffness and low density. The linkage member 102 may be attached to the end housings 100, 101 by an adhesive such as epoxy while being supported in a precision jig, as will be clearly understood by those of ordinary skill in the art to which the present invention pertains.

exoskeleton material

The connectors that hold the items are made of aircraft aluminum. Aluminum is anodized. Linkage items include precision molded carbon-fiber. The link items are attached by an adhesive such as epoxy to the joints housing the items while being supported in precision fixtures.

Robot CMM Arm Installation

It is an object of the present invention that the Robot CMM Arm can be mounted on many different structures in different orientations using many different mounting devices to suit the application in which it is used.

installation device

Mounting the Robot CMM Arm 1 to the surface 7 can be done by a number of means 104 including bolting with bolts 107, magnetic mounting, vacuum mounting and clamps. It is important that the mounting arrangement 104 used is sufficiently rigid so that no motion is introduced between the mounting plate 8 and the surface 7 during operation of the Robot CMM Arm 1 such that the Robot CMM Arm 1 is less accurate.

Orientation to Horizontal Plane with Vertical Robot CMM Arm

Referring to Figure 6, the Robot CMM Arm 1 is typically mounted on a horizontal mounting surface 112 of a portable stand 110 using standard 3.5" x 8 threads 116. The stand 110 has three wheels 111 that can be locked. The stand 110 has retractable feet 113 The gantry 110 has a larger footprint to avoid it tipping over. The footprint is larger than the corresponding Manual CMM Arm, because the operator receives part of the arm load of the Manual CMM Arm through his feet, which reduces the load on the gantry. Torque on 110. The mass of the stage 110 is greater than that of the corresponding Manual CMM Arm stage because the Robot CMM Arm 1 is heavier than the corresponding Manual CMM Arm. The stage 110 has an extendable vertical member 115 for raising or lowering The base of the Robot CMM Arm. The Table 110 must be used on a rigid floor surface rather than a carpet or compressible floor covering. The Table 110 is preferably heavy so that the dynamic characteristics of the Robot CMM Arm do not cause it to vibrate; Control of a Portable Robot CMM Arm mounted on a stage limits angular acceleration and velocity to avoid vibrating the stage 110 and loss of accuracy. An example of a stage 110 for a short reach Robot CMM Arm is stage number 231-0 A frame, which weighs about 100kg, is manufactured by Brunson Instrument Company (U.S.) and is suitable for short and medium reach. A counterweight can be rigidly attached to the base of the stand 110 to increase its stability. The long reach robot CMM arm A larger and stronger platform is required. Referring to Fig. 7A, the Robot CMM Arm 1 can be rigidly mounted on a stable table 120 such as an optical bench or a granite block, which can be connected to the wearer by a shock absorber 121 positioned above the support 122. Vibration isolation through the ground 119. Referring to Figure 7B, the Robot CMM Arm 1 can be mounted directly on the ground 119. Referring to Figure 7C, the Robot CMM Arm 1 can be mounted on a platform 123, and the platform 123 is installed on the ground 119. See Fig. 7D, the Robot CMM Arm 1 is mounted on an orbital axis 124 on which it travels across the ground 119. The Robot CMM Arm 1 is shown in three different positions along the orbital axis 124 A, B, C. The Robot CMM Arm 1 can measure much larger objects 9. The second Robot CMM Arm 1 is mounted on the second track axis 124 and has two positions D and E as shown. The two tracks The axes are preferably parallel. This means that the two Robot CMM arms can move independently and measure both sides of a large object 9 such as a motorcycle, car or large vehicle. The track axis 124 is preferably linear. The track axis 124 is preferably ground mounted 119 so that it can be removed and reinstalled at a different location; Motor driven, or preferably CNC driven. When translating along the orbital axis 124, the Robot CMM Arm 1 is not as stable as it is at rest. Preferably, the Robot CMM Arm 1 does not take measurements while translating along the Orbital Axis 124, instead the Orbital Axis 124 is used to move the Robot CMM Arm 1 from one measurement position to another, e.g. from A to C via B sports. However, the Robot CMM Arm can take measurements during translation along the Orbital Axis 124, but the accuracy will generally be reduced; this is most likely to occur when the Orbital Axis 124 is part of a larger machine on which the Robot CMM Arm 1 is mounted . Referring now to Figure 7E, two Robot CMM Arms 1 can be mounted on the same orbital axis 124 and move independently. The movement of each Robot CMM Arm 1 along the orbital axis 124 may be manually driven, preferably motor driven via a button in response to manual actuation, or preferably CNC driven. A suitable application is the measurement of automotive prototypes in design studios. This means that the throughput of a measurement setup with four Robot CMM Arms 1 can be double that of a measurement setup with only one Robot CMM Arm on each track axis 124, two on each of the two tracks 124 move independently. Referring now to FIG. 7F , the Robot CMM Arm 1 is mounted on a vertical shaft 133 that allows the base of the Robot CMM Arm 1 to move vertically up and down. The vertical shaft 133 is movable horizontally on the orbital shaft 124 . Vertical shaft 133 may be manually driven, preferably motor driven via a button in response to manual actuation, or preferably CNC driven. Vertical axis 133 may be provided for one or both of the Robot CMM Arms 1 in the paired opposing Robot CMM Arm configuration shown in FIG. 7D, or may be for one or both of the Robot CMM Arm configurations shown in FIG. 7E Each arm provides a vertical shaft 133. Referring now to FIG. 7G , two Robot CMM Arms are mounted on a mobile multi-arm base 134 that moves on orbital axis 124 . The two Robot CMM Arms are separated by an appropriate distance S so that the job overlap is sufficient to eliminate any inaccessible gaps between the robots in the work volume. This means that high productivity can be achieved with reduced cost and simpler equipment involving only one mobile multi-arm base 134 instead of two independent Robot CMM Arms 1 . As previously disclosed, shorter Robot CMM Arms are more accurate than longer CMM Arms. One purpose of this embodiment is that the horizontal rail 124 and vertical shaft 133, whether used separately or in combination, will mean that shorter Robot CMM Arms can be used. This means that by using the horizontal track 124 and vertical axis 133, either separately or in combination, the overall accuracy of the measurement device will increase, since the horizontal track 124 and vertical axis 133 are more accurate over long distances than the Robot CMM Arm. One of ordinary skill in the art to which this invention pertains can optimize the dimensions of the Robot CMM Arm Length, Horizontal Axis, and Vertical Axis to maximize accuracy. Referring now to FIG. 7H , the Robot CMM Arm 1 is mounted on the object 9 to be measured. Adapter 136 is used. An example of such an object 9 is a pipe section of a gas pipeline, which is measured around a surface area that has corroded; in this example, mounting the Robot CMM Arm 1 on the pipe is more stable than building it close to the pipe Temporary buildings are easier and less expensive. Adapter 136 may be magnetically mounted to facilitate mounting and demounting of Robot CMM Arm 1, or any other mounting means may be used. For some objects 9, the adapter 136 is not needed, and the Robot CMM Arm 1 can be directly mounted on the object 9. Referring now to FIG. 71 , the Robot CMM Arm 1 is mounted close to the processing machine 137 on which the object 9 is mounted. The processing machine 137 is surrounded by an enclosure 138 with a self-operating sliding door 139 . Robot CMM Arm 1 may measure Object 9 in Machine 137 . Enclosures 138 and sliding doors 139 are required for processing machines 137 that contain environmental contamination that may be harmful to the Robot CMM Arm 1 within the enclosure during processing. Certain processing machines 137 do not generate environmental pollution harmful to the Robot CMM Arm 1 and thus do not require enclosures 138 and sliding doors 139 . A smaller Robot CMM Arm 1 with a short reach 80 can be mounted directly on the machine 137 in order to bring the Robot CMM Arm 1 closer to and within reach of the object 9; A sliding door is required to protect the Robot CMM Arm 1 mounted on the processing machine 137 . Referring now to FIG. 7J , the Robot CMM Arm 1 is mounted between four processing machines 137 so that the Robot CMM Arm 1 can measure an object 9 mounted on each of the four processing machines 137 . Any number of processing machines 137 may be arranged around the Robot CMM Arm 1 . Referring now to FIG. 7K , the Robot CMM Arm 1 is mounted between three work areas 142 . Each working area can contain an object 9 . At any one time, the work area 142 may contain one of the following: no objects 9 , objects 9 to be measured, objects 9 being measured, objects 9 already measured, objects 9 being passed into or out of the work area 142 . There may be any number of work areas 142 around the Robot CMM Arm 1 . The object 9 in the work area 142 can be accurately positioned in the fixture in a known position and orientation relative to the Robot CMM Arm coordinate system 363; alternatively, it can be roughly positioned in some way, such as by aligning the human eye to a ground marker Object 9. The object 9 may be positioned in the work area by any method known to those of ordinary skill in the art. Each object 9 in each work area 142 may be a different part with a different part number, or each object may be the same part with the same part number. One advantage of having several work areas 142 around the Robot CMM Arm 1 is that jobs can be loaded for automatic measurements overnight, thus increasing the utilization of the Robot CMM Arm 1 . A second advantage resides in maintaining the Robot CMM Arm 1 by replacing the measured object 9 with an unmeasured object 9 at the first work area 142 when the Robot CMM Arm 1 is measuring another object 9 at the second work area 142. 1's full use. Referring now to Figure 7L, the Robot CMM Arm 1 is mounted on a lower, solid bridge 118 across the work area 142 where the object 9 is located. The Robot CMM Arm 1 and the bridge 118 are designed such that the entire upper side of the object 9 can be manipulated by the probe 90 mounted at the probe end 3 of the Robot CMM Arm 1 . Object 9 must be relatively flat in order to fit under bridge 118 and still perform operations on any area thereof. The bridge 118 is rigid, solid and securely mounted on the ground 119 so that there is no significant deflection when the Robot CMM Arm 1 moves. The main field of application of this embodiment of the Robot CMM Arm 1 mounted on a bridge is the optical inspection of sheet metal. In a first step, the object 9, which may be a sheet metal item, is subjected to an upstream process, for example forming under pressure. In a second step, the object 9 is manually transferred and placed in the work area 142 . Alternatively, a mechanism such as an automated conveyor or material handling robot may automatically place the sheet metal in the work area 142 . In a third step, the object 9 is inspected by at least one probe 90 mounted on the Robot CMM Arm 1 . In the fourth step, there is data output from the inspection process. The data can be generated from an automatic comparison of the data obtained during the inspection with the CAD model of the ideal object 9 . Data output can be statistical data or full inspection data. In a fifth step, the object 9 is manually or automatically removed from the working position. In an optional step, the data output is used to make changes to parameters controlling the upstream process, either directly or through the collection and analysis of process statistics. In an alternative optional step, the data output is used to physically alter the tool for the upstream process. In another embodiment, a linear track 124 is provided above the bridge 118 for moving the Robot CMM Arm 1 to inspect larger objects 9 . In an alternative embodiment, instead of being mounted on the bridge 118, the Robot CMM Arm 1 is mounted on the end of an overhang support and the Robot CMM Arm 1 is positioned over the middle of the work area 142, and the overhang support is mounted on One side of the work area 142 .

displaceable and moving objects

Another object of the invention is that the Robot CMM Arm 1 can perform an operation on an object 9 located on the object displacement device and that the object 9 is displaced at least once during the operation. Referring now to FIG. 7M , the Robot CMM Arm 1 is mounted adjacent to the turntable 820 on which the Object 9 is rotated about axis A. The turntable 820 can be manually rotated and locked in a new position with a clamp 822 . Alternatively, the turntable 820 may be rotated by a mechanized device 821 such as a motor or servo drive. The automatic rotation of the carousel 820 may be controlled by the Robot CMM Arm System 150 or any other means, such as manual actuation by buttons or slave controls. An angular position recording device 823 such as an encoder is usually connected to the axis A of the turntable 820 . In a typical procedure, the object 9 is displaced four times by moving the turntable to four positions at 90 degree intervals in order to enable the Robot CMM Arm 1 to approach to perform operations on all quadrants of the object 9 . In this embodiment, the Robot CMM Arm 1 does not perform operations such as measurements while the object 9 is in motion. One advantage of rotating the object 9 on the turntable 820 is that operations can be performed on the object 9 which is larger than the reach 80 of the Robot CMM Arm 1 ; it is particularly suitable for wide and tall objects. A second advantage of rotating the object 9 on the turntable 820 is that in the case of complex objects 9 different approach orientations can be obtained for the Robot CMM Arm 1 in order to access parts of the object 9 that are difficult to access. Referring now to FIG. 7N , the Robot CMM Arm 1 is mounted close to the linear table 824 on which the Object 9 is positioned for linear displacement along the axis B. Referring now to FIG. The linear stage 824 has similar position measurement capabilities, control capabilities, and advantages as the turntable 820 . In other embodiments, a multi-axis table with 2 or more axes may be used to displace the object. It will be appreciated by those skilled in the art that each type of table axis or combination of axes will have different advantages for use with different kinds of object sizes and shapes. In another embodiment, the Robot CMM Arm 1 is stationary and performs operations such as non-contact measurements or contact operations with the tool while the object 9 is in motion. In another embodiment, the Robot CMM Arm 1 and the object 9 move simultaneously while performing operations with the tool, such as non-contact measurements or contact operations. When both the Robot CMM Arm 1 and the object 9 are moving relative to the ground, another control algorithm is needed to convert the coordinate system into a common coordinate system such as the object coordinate system. In all embodiments, the object 9 may or may not be clamped or otherwise attached to the table so as to eliminate relative movement between the object 9 and the table. In all table embodiments where the object 9 moves during operation, the table must be precise and the object must not be movable relative to the table to enable accurate operations to be performed. A workbench of the required size and accuracy is usually an expensive item.

Other Robot CMM Arm Orientation

For some applications, the orientation in which the Robot CMM Arm 1 is mounted is not horizontal, and where the Robot CMM Arm 1 is not standing approximately vertically. Referring to FIG. 8A , the Robot CMM Arm 1 is mounted orthogonally to the wall 125 . Referring to Figure 8B, the Robot CMM Arm 1 is supported by a stand 126; alternatively it may be supported from a top plate. Referring to Figure 8C, the Robot CMM Arm 1 is mounted on a Platform 127 having a surface at 60 degrees from vertical. Referring to Figures 8D and 8E, the Robot CMM Arm 1 is mounted on a large, 3-axis conventional CMM such as used in automotive companies. There are many types of 3-axis conventional CMMs, including the Horizontal Arm CMM128 and Carriage CMM129. The Robot CMM Arm 1 has significant mass, it is typically expected to weigh 18-32 kg depending on its accuracy and arm reach, but it could be heavier or lighter. A lightweight Robot CMM Arm according to the invention can be designed with a mass substantially below 12 kg for mounting on a conventional CMM. For automotive applications where the Robot CMM Arm 1 is mounted on a conventional CMM, as shown in FIG. In this mode, by combining the movement of the Carriage CMM 129 and the movement of the Robot CMM Arm 1, the Robot CMM Arm 1 is able to access all parts of the Object 9 being measured. The scope of the present invention is not limited to Robot CMM Arm 1 extending vertically from Vertical Column 130 of a Bridge Conventional 3-Axis CMM 131 with 3 linear axes or from Horizontal Arm 132 of a Horizontal Arm CMM 128 also with 3 linear axes. Next install. The Robot CMM Arm 1 can be mounted from any comparable conventional CMM with any number of axes and in any orientation. Referring now to FIG. 8F , the Robot CMM Arm 1 is mounted on a rotating wedge base 135 at an angle A to the vertical axis of rotation B. Referring now to FIG.

The scope of the present invention is not limited to the embodiments of the Robot CMM Arm device shown in Figures 7A-G and Figures 8A-F. It is an object of the invention that the Robot CMM Arm 1 can be mounted in any orientation in free space. Another object of the invention is that the Robot CMM Arm 1 can be mounted from a fixed or movable structure. Another object of the present invention is that the Robot CMM Arm 1 can be mounted on any kinematic structure for translational orientation of the Robot CMM Arm in 6 degrees of freedom. The moving structure can be moved at any time during or between measurements. Another object of the present invention is that the Robot CMM Arms 1 can be provided in the equipment in any number and in any arrangement.

Rigid and non-rigid mounts

The Robot CMM Arm 1 is preferably mounted on a surface 7 that is rigid relative to the object 9 being measured. Occasionally there may be continuous relative motion between the Robot CMM Arm 1 and the object 9 being measured, for example caused by a large machine operating nearby that transmits vibrations through the ground. Alternatively, there may be occasional relative motion between the Robot CMM Arm 1 and the object being measured 9, for example caused by a passing truck or an accidental collision with the object being measured. Alternatively, there may be slow relative motion between the Robot CMM Arm 1 and the object 9 being measured, for example caused by thermal expansion of the structure on which the Robot CMM Arm and object are mounted. Referring to Figure 9, which illustrates the relative motion between the base end 4 of the Robot CMM Arm 1 and the object 9 being measured by the Robot CMM Arm 1, the 6 degrees of freedom relative motion can be measured by a separate measurement device. Examples of such stand-alone measurement devices are the laser tracker supplied by Leica and preferably the photogrammetric tracker 140 supplied by Krypton. The Robot CMM Arm 1 and the Photogrammetric Tracker 140 are mounted on the platform 123 . The object 9 is mounted on a ground 119 subject to motion so that there is significant relative motion between the object 9 and the platform 123 . The photogrammetric targets 141 are attached to the object 9 such that a minimum of 3 targets and preferably more targets are visible to the photogrammetric tracker 140 at any time during the surveying process. It is important that the photogrammetric tracker 140 measurements of relative motion are synchronized in time with the Robot CMM Arm 1 measurements. Time alignment can be achieved by any method familiar to experts in the field, including simultaneous triggering of measuring devices, time stamping of all measurements with a common clock for subsequent processing. This processing may include temporal interpolation when the relative motion measurements are not taken at the same instant as the Robot CMM Arm measurements. The process of calibrating the photogrammetric tracker 140 measurements with the Robot CMM Arm 1 measurements is well known to those of ordinary skill in the art to which the present invention pertains. The result is a measurement of the object 9 that is corrected for the measured relative motion between the Robot CMM Arm 1 and the object 9 .

Robot CMM Arm Range

The reach 80 of the Robot CMM Arm 1 depends on the application. The provided Robot CMM Arm 1 of this first embodiment is a series of portable Robot CMM Arms 1 with different extension ranges 80 . For example reasons only, these extensions 80 may be from 0.5m to 5m, where 1m and 1.5m extensions 80 may be most requested by component customers, 2m to 3.5m extensions 80 are most requested by automotive customers, and 2.5m to The 5m reach of the 80 is the most requested by aerospace and aerospace customers. The extension range 80 of the Robot CMM Arm 1 invention is not limited in this disclosure; the Robot CMM Arm can be longer or shorter than said range. Using the Robotic Exoskeleton to support the Internal CMM Arm means that the Robotic CMM Arm can have a longer reach than the Manual CMM Arm which is effectively limited by 2m. This means that applications requiring a reach longer than 2m (for which a Manual CMM Arm is not practical) can be performed by a Robotic CMM Arm. This first embodiment of the Robot CMM Arm 1 is a portable system and is not designed for high angular velocities and accelerations in order to limit the weight of the Robot CMM Arm 1 . Other embodiments of the Robot CMM Arm 1 can be designed for much higher angular velocities and accelerations. In order to keep the same drive system components across the reach of the Robot CMM Arm 1 , lower maximum angular velocities for longer reach are accepted in this first embodiment. The key difference across the range is the various lengths of the link 102 . The Portable Robot CMM Arm can also have two or more ranges, such as 0.6-1.2m and 1.5m-3m extension ranges 80 .

Overview of Robotic CMM Arm System

Referring now to FIG. 10, the architecture of this first embodiment of the Robot CMM Arm System 150 is described. The Control Box 159 is mounted on the Base 4 of the Robot CMM Arm 1 . Power is supplied using a power cable 155 connected to a power connector 195 . A power switch 156 and a power feed 157 are provided. Therein, an interface connector 194 is provided for connecting the probe box 295 to the arm cable 296 through the probe box. Laptop 151 is connected to laptop connector 197 using laptop communication cable 152 . Pendant 153 is connected to pendant connector 198 by pendant communication cable 154 . The network 200 is connected through a network connector 199 . Both the pendant 153 and the laptop 151 can be powered by the batteries 163, 164 to operate for a certain period of time. The suspension battery 163 is recharged by placing the suspension in the recharging point 158 with the electrical contacts 328; when the suspension is properly seated in the recharging point, a power connection is automatically made. The laptop battery 164 is recharged by mains power. When mounted on the Robot CMM Arm 1 , the Trigger Probe 92 makes automatic power connection 160 and trigger connection 161 . When mounted on the Robot CMM Arm 1 , the optical probe 91 forms an automatic power connection 160 , trigger connection 161 and probe communication connection 162 .

Referring now to FIG. 11A , the internal architecture of the Robot CMM Arm 1 is described. Control PCB 172 is connected to ground 165 and +5 volt power rail 166 . One of the seven motors 176 drives each of the exoskeleton joints 1-7 61-67, which are connected by motor cables 196 to seven amplifiers 175 and are controlled by seven +/- 10v outputs from the control PCB 172 to the amplifiers 175 signal driven. The control PCB 172 is connected to seven connector PCBs 173 via the serial bus 169 . The control PCB 172 has two other communication connections 152 and 154 for communicating with the laptop 151 and the pendant 153 respectively. +24 volt power rail 167 provides power to amplifier 175 . The power supply unit 171 is connected to the power cable 155 , the battery 170 , the ground 165 and the power rails 166 , 167 . At least one connector PCB 173 connects to probe 90 using power 160 , trigger 161 and where applicable communication 162 . All seven motors 176 have brakes 177 which are driven by signals from connector PCB173. The Internal CMM Arm 5 includes seven CMM Encoders 178 connected to a connector PCB 173 . Seven encoders 179 mounted on seven motors 176 driving the exoskeleton 6 are connected to the connector PCB173. A thermocouple 180 mounted on the Internal CMM Arm 5 is connected to each connector PCB 173 . Strain gauges 181 mounted on the Internal CMM Arm 5 are attached to each connector PCB 173 . Two limit switches 182 are connected to each connector PCB 182 . Two operator buttons 183 are connected to the connector PCB 173 of the seventh connector. A touch sensor 184 is connected to each connector PCB 173 . Each connector PCB 173 is connected to ground 165 and +5 volt power rail 166 . A trigger bus 174 is connected to each header PCB 173 and control PCB 172 ; it is used to latch seven CMM encoders 178 .

Referring now to FIG. 11B , an alternative system embodiment is described for the internal architecture of the Robot CMM Arm 1 , which has fewer cables, allows infinite rotation of the axial joint and is lighter, less costly and more robust. The control PCB 172 and the four joint PCBs 173 are connected in series with a bus 193 which passes through four slip ring units 188 located at each axial CMM joint 1,3,5,7 51,53,55,57. One to three contacts are driven by each contact PCB 173 and the control PCB 172 may also drive one or more contacts. Each slip ring unit 188 has a capacity of 28 wires, but the number of wires may be more or less than 28. The bus 193 also has 28 wires. These 28 wires in the bus 193 carry power voltage, ground, serial bus, control bus and signal lines for all component functions located after the joint center 21 in the internal CMM arm 5, exoskeleton 6 and any probe 90. The control bus 394 merges into the bus 193 and uses 5 wires. The control bus 394 can be a proprietary or can be a standard bus such as a CAN bus. The CAN bus is a high-speed and low-latency control bus. The CAN bus and associated circuitry have drawbacks when driving 7 axes. A faster control solution is to use two CAN buses and drive 4 axes with the first CAN bus and 3 axes with the second CAN bus. Using two CAN buses with an extra 5 wires allows a fast 1 ms servo. Smart power amplifiers 175 are located next to each motor 176 and are connected to connector PCB 173 or control PCB 172 via control bus 394 and 24v power and 0v ground. Examples of smart power amplifiers 175 are the EPOS 24/1 and 24/5 offered by Maxon Motor of the USA. In addition, the intelligent power amplifier function can be integrated in the connector PCB173 and the control PCB172. This control function, including turning off the servos, takes place in the controller 395. Controller 395 is a PCI208 supplied by Trio Motion Technology, UK. PCI 208 has two control bus 394 outputs that allow for fast servo control; these control bus 394 outputs are CAN bus standard. Instead of about 10 wires for each of the seven motor/encoders, the 5 or 10 wires of the CAN bus are usually routed directly all the way from the motor 176 to the controller 395 . Since the number of wires in the slip ring 188 is limited by practical factors such as size and weight, the use of a control bus 394 that reduces the number of wires in the arm by approximately 60 wires allows the use of the slip ring 188 to allow for axial CMM joints 1, 3, 5, 7 Unlimited spins are available in 51, 53, 55, 57. The bus 193 provides power, signals and communications to one or more probes 90, which may be contact or non-contact, of which a stripe probe 97 is commonly used. In order to connect the third-party dedicated probe 90 to the Robot CMM Arm 1 , the purpose of the present invention is to provide a channel from the probe 90 to the interface connector 194 through the bus 193 . In this way, suppliers of third-party probes 90 can use desired channels for any combination of power, ground, signal, and bus within the wiring specification constraints of such a Robot CMM Arm system 150 . A typical number of lines provided in a channel is 9, but there may be less than 9 or more than 9. Interface connector 194 may also provide a calibration signal connection for calibrating Robot CMM Arm 1 and Probe 90 .

The scope of the present invention is not limited to the architecture of the Robot CMM Arm System 150 disclosed in the first embodiment, but includes all architectures having the technical effect of the Robot CMM Arm System 150 . For example, in another embodiment, the Control Box 159 is separate from the Robot CMM Arm 1 and connected to the Base 4 of the Robot CMM Arm with a cable. This architecture is required for the Robot CMM Arm if it is portable, where the items in the Control Box 159 need the Control Box 159 to be very large to easily fit in the Base 4 perceptually. Using the architecture of the first embodiment is preferred because the Portable Robot CMM Arm is a single unit without increasing the manufacturing cost and footprint of the separate control box 159 location. In another embodiment, a full size personal computer is used instead of the laptop 151 and the controller PCB 172 is mounted in the personal computer via a standard bus such as the PCI bus; instead a network of several computers in a rack is used. In another embodiment, no suspension is provided and the Robot CMM Arm 1 is controlled using the Laptop 151 . In another embodiment, connectors are provided to connect one or more external axes to the Robot CMM Arm 1 , which are driven by the Controller 395 . Examples of such external axes are linear tracks or turntables.

Internal CMM Arm Encoder

The Internal CMM Arm 5 includes an Angle Encoder 178 at each CMM Joint 51-57. The scope of the invention is not limited to angle encoders or any specially designed angle encoders but any precise form of angle measuring device may be used. The resolution and accuracy of an angle encoder is limited by several factors including: the diameter of the encoder, the number of printable edges, the linearity of the edge, the linearity of the read head, the amount of interpolation and irregularities in the encoder. To optimize the accuracy of the Robot CMM Arm 1 , it is desirable that the angle encoder towards the Base End 2 is more accurate than the angle encoder towards the Tip 3 of the Inner CMM Arm 5 . This is because a small rotation at the base end fittings such as 21 , 22 will cause a large movement at the tip 3 . However a small rotation at the tip 3 joint such as 25 , 26 or 27 will cause a small movement at the tip 3 . If all other factors are controlled, for a given joint rotation, the motion at the tip is proportional to the distance from the tip 3 to the joint. The Internal CMM Arm 5 uses a CMM Encoder 178 such as a CMM Encoder manufactured by Renishaw or Micro-E Systems, USA. The CMM Connectors 21 , 22 towards the base end 2 of the inner CMM Arm 5 have larger diameter encoders because there is a longer distance from the CMM encoder 178 to the probe end 3 . The intermediate joint 23 - 24 at the elbow of the Inner CMM Arm 5 has an encoder of intermediate diameter because there is an intermediate distance from the CMM Encoder 178 to the Probe Tip 3 . The Distal Heads 25 - 27 at the wrist of the Inner CMM Arm 5 have small diameter encoders because there is a small distance from the CMM Encoder 178 to the Probe Tip 3 . The smaller encoder diameter reduces the weight of the arm carried by the best effort of the operator, making it compact and easy to maneuver. In the case of a larger effective reach 81 produced by the optical probe 91, it may be important to have a higher resolution encoder at the joint 23-27 towards the probe end of the arm. It can be expected that the technology behind angle encoders will improve and angle encoders with a given accuracy will decrease in diameter and weight. Referring now to FIG. 12A , the Internal CMM Arm encoder 178 comprises a Renishaw RESR angle encoder 185 with a 20 micron metric pitch, used with one or more Renishaw RGH20 read heads 186 per joint. When two or more read heads 186 are mounted per encoder 185, they are mounted either at 90 degrees to each other as shown in Figure 12 or preferably at 180 degrees to each other, although the read heads may be at any other angle to each other. A 52mm diameter RESR with 8192 counts was used on each of the CMM joints 23-27, providing a calling accuracy of +/- 5.6 arc seconds per joint. A 150 mm diameter RESR with 23,600 counts was used on each of the CMM joints 23-27, providing a calling accuracy of +/- 1.9 arc seconds per joint. The output of each Renishaw readhead 186 goes to a Renishaw RGE interpolator 187. The output from each Renishaw interposer 187 is fed into header PCB 173 . The advantage of using two or more read heads is twofold. First, errors from any of the following can be boosted or compensated for by simple averaging: off-centre mounting of the encoder, poor calibration of the read head, edge print non-linearity, read head non-linearity, irregularities, and others Mechanical/installation errors. Second, in operation, averaging of readings from two or more interpolators 187 of the same encoder 185 can be done in connector PCB 173, giving some improvement in encoder accuracy. In an alternative embodiment, the angle encoder system may be provided as a whole, including the encoder, one or more read heads, interpolators, averaging and error maps, with one connection from the angle encoder system to the header PCB 173. It is expected that companies such as Renishaw will in the future offer such angle encoder systems having a diameter of approximately 50mm with 0.1 arc second accuracy.

Dual Mode Encoder

The accuracy of this encoder provided on the present Robot CMM Arm 1 invention is an important factor in the accuracy of the Robot CMM Arm. It is an object of the present invention to provide a novel dual-mode encoder with one read head for each mode which is more accurate than a single-mode encoder with two read heads. Referring now to FIG. 12B, a dual-mode encoder 860 includes an encoder disk 861 having an edge pattern 862 printed around the perimeter of each of its two sides A, B, a read head 186 that reads the pattern 862 on side A. and a second read head 186 that reads pattern 862 on side B, the two read heads are separated by approximately 180 degrees. Referring now to FIG. 12C , a dual-mode encoder mapping device 863 is provided which includes a precision turntable 864 such as the ABR1000 provided by Aerotech Inc, US, a rotating portion such as for clamping a disk 861 to the precision turntable 864 Rotary clamping mechanism 865 such as specially shaped bolts on the , two fixed read heads 186 and a mapping system 866 connected to a precision rotary table 864 and a read head 186 with a cable 868 , wherein the two fixed read heads 186 about 180 degrees from each other and on opposite sides of the disc 861 so that when the pattern 862 moves relative to the fixed read head 186, the first read head 186 can read the first pattern 862 on the A side, while the second read head 186 can read the second pattern 862 on the B side. The precision rotary table 864 is more accurate than the dual mode encoder 860 can be expected to perform. The mapping system 866 (a) controls the motion of the precision rotary table 864, (b) reads the signal from the read head 186 and (c) outputs the mapping 867. Referring now to FIG. 12D , there is shown a disk 861 on which the center of mode A 869, the center of mode B 870, and the axis of rotation 871 of the joint carrying the dual mode encoder 860 are indicated. The map 867 is a digital file and contains map information to provide (i) the magnitude M of the misalignment of the two modes 862 relative to each other, (ii) the orientation 872 of the misalignment, (iii) the exact rotation stage 864 and the position on each mode 862 The angular error between printed edges and covers at least an error map of the printed non-linearity of the edges on each pattern 862 . The two patterns 862 are printed in a reasonable axial alignment with a typical axial misalignment M of 10 microns, but such misalignment M can be much greater or much less than 10 microns. The orientation 872 of the misalignment M is manually marked on the disc 861 . Sides A and B were manually marked on disc 861 . Typically, the orientation 872 of the misalignment is known with reference to an absolute reference mark on the pattern 862 read by the readhead 186 . The process of generating map 867 is well known to those of ordinary skill in the art to which the present invention pertains. Reference marks located on each pattern 862 are provided for reference to the error map.

Up to seven mapped dual-mode encoders 860 can be provided in the Robot CMM Arm 1 . A mapping 867 is provided for each dual-mode encoder 860 . During encoder calibration, the joint of the Robot CMM Arm 1 with the Dual Mode Encoder 860 is stepped from one rotational axis to the other in steps of typically 5 degrees, but the steps may be more or less than 5 degrees. A read is taken from each read head 186 at each rung to form a set of readings. The set of readings is corrected using the error map of map 867 to provide corrected readings. The corrected readings are processed using the misalignment and misalignment orientation information in map 867 to calculate the location of joint center 871 relative to the centers of pattern A 869 and pattern B 870 in a manner well understood by those of ordinary skill in the art. After the calibration process, when the Robot CMM Arm 1 is in use, the calibrated position of the Joint Center 871 relative to Mode A 869 and Mode B 870 is used to correct the readings from the Dual Mode Encoder 860 and make the Robot CMM Arm 1 more accurate . A calibrated dual-mode encoder 860 provides more accurate angles than an equivalent single-mode encoder with two read heads because (a) there are effectively two independent error-mapping encoder systems instead of one, and this The results of the two systems provide a better average than that of the encoder system with one mode, (b) errors due to non-perpendicularity of disc 861 with respect to the joint axis are automatically averaged. Such a dual-mode encoder 860 has the same number of parts, weighs the same and occupies the same volume as an equivalent single-mode encoder with two read heads. In an alternative embodiment, the two modes 862 of the dual mode encoder 860 may be located on the same side of the disc 861, in the form of inner and outer diameter modes. In another embodiment of the lower cost dual-mode encoder 860, if the mode 862 is aligned with a sufficiently small misalignment M during the manufacture of the disc 861, then it will The extra process of mapping the dual-mode encoder 860 is not required, while still gaining the benefit of having any axial misalignment automatically balanced. In an alternative embodiment of the more precise Robot CMM1, two dual mode encoders 860 are provided at each joint, preferably on either side of the center of the joint.

Exoskeleton transmission system structure

environmental pollution

It is an object of the present invention that the Portable Robot CMM Arm operates quietly and can be used in an office environment. It is important to keep the level of audible noise emitted to a minimum in the design. The use of an inherently low noise drive train including motor and gearing methods was chosen to minimize emitted audible noise. Basically, the level of audible noise output increases with the velocity and acceleration of the driving Robot CMM Arm. In many applications, reductions in velocity and acceleration have little effect on cycle time. This is because usually 90% of the cycle is used for measurement, this process is very slow, and only 10% of the cycle can be reduced by the acceleration method. When minimizing the level of emitted audible noise is a key usage criterion, the control system can be set by the user to scan quietly at low speeds and accelerations. The Robot CMM Arm minimizes the emitted electromagnetic radiation by introducing drive train components with low electromagnetic radiation and providing shielding around the components that emit the highest electromagnetic radiation.

heat transfer

It is an object of the present invention to minimize heat transfer from the motor 176 and other transmission components in the Exoskeleton 6 to the Internal CMM Arm 5, thereby making the Internal CMM Arm 5 more accurate due to a more stable, uniform temperature. made public:

- No significant direct thermally conductive connection from Exoskeleton Motor 176 to Internal CMM Arm 5 to eliminate heat transfer by conduction; Actuator 10 is small and its material has low thermal conductivity; no direct connection to Robot CMM in Control Box 159 Thermal items on the base 4 of the arm; this means that there is no conduction between the thermal items in the control box 159 and the base 4 of the Robot CMM Arm;

- Internal CMM Arm Sections 32-38 are coated to minimize radiation transfer from Motor 176 to Internal CMM Arm 5;

- The motor is well ventilated and finned to maximize convective heat transfer and minimize its operating temperature; the angular velocity of the joint is programmed during operation to avoid overheating of the motor 176;

- Referring now to Figure 13A, there is a duct 189 between the Internal CMM Arm Segments 32-38 and the Exoskeleton Segments 2-8 42-48; a low capacity fan 190 with a larger filter 191 in the base 4 sucks air 192 And blow air along the duct 189 between the Internal CMM Arm 5 and the Exoskeleton 6; This forced air circulation provides effective cooling through convection. The fan 190 was chosen for quiet operation in an office environment. The filter 191 is relatively large; in the case of operation in an office environment, the filter 191 should not require replacement or cleaning for 5 years. A portion of the air 192 drawn in by the fan 190 passes through the control box 159 and is expelled through the air vent 353 in the control box; this air circulation removes heat from the control items including the control PCB 172, PSU 171 and amplifier 175.

Exoskeleton drive system

The robot CMM arm 1 is driven by a motor 176, which is a brushed DC servo motor with an encoder. The drive system of the present invention is not limited to any kind of electric motor, but can be driven by different power systems including hydraulic or pneumatic. Hydraulics and pneumatics introduce less vibration into the Robot CMM Arm than motors with encoders. The motor 176 can be an AC or DC servo motor, a stepper motor or other types of motors; the motor 176 can be brushed or brushless. A high speed control loop is provided where the motor 176 and encoder 179 close the loop; this high speed loop is adapted to traverse the Robot CMM Arm 1 transversely. When making a contact measurement, the hard probe located at the end of the Internal CMM Arm 5 will stop moving while the Robot CMM Arm continues on contact. A high precision control loop is provided for tactile measurements where the CMM encoder 178 is used to close a slower high level loop outside the high speed control loop. To reduce manufacturing costs, reduce the weight of the Robot CMM Arm and create a more compact design, the CMM Encoder 178 can be used for position feedback; the Exoskeleton Encoder 179 is not required. To further reduce manufacturing costs, stepper motors can be used in an open-loop format without any position sensing in the control loop. Certain applications require only low acceleration of the Robot CMM Arm and require a lower power drive train. Other applications require high acceleration and require a more powerful drive train. Application on an automotive production line requires a robust Robot CMM Arm 1 that can withstand the impact of the vehicle body. Due to the presence of this Internal CMM Arm 5, low backlash in the drive train unit is not necessary for most applications. Low cost and low mass drive train components such as belt drives can be used. In this embodiment, one motor 176 is used to drive each joint 61-67.

Robot Dynamics

Those of ordinary skill in the art to which this invention pertains will appreciate that it is beneficial to minimize the moment of inertia of the Robot CMM Arm as much as possible. For a given performance specification defining the angular acceleration and maximum angular velocity of the joint, a Robot CMM Arm with a lower moment of inertia than another Robot CMM Arm will use less energy to perform the process. Drive units such as motors are usually heavy, with a concentrated mass. It is beneficial to (a) position the Drive Unit as close as possible to the base end of the Robot CMM Arm; (b) reduce the mass of the Drive Unit; (c) reduce the mass of the segments of the Robot CMM Arm. In moving the drive unit closer to the base end of the Robot CMM Arm, it is possible to reduce the size of the drives located between the moving drive and the base because the former drives do not have to be moved as they have been. The drive close to the base end moves that hard. Each reduced-gauge drive unit is lighter and, in turn, may require other lower-performance drive units elsewhere. Another benefit of moving the drive unit closer to the base end comes from the reduced stress on certain exoskeleton segments allowing them to be designed to be lighter. It can thus be seen that moving only one of the drive means closer to the base end achieves the combined advantages. It is an object of the present invention to optimize the Robot CMM Arm to minimize its weight and power consumption for a defined size, by methods including positioning the drive as close as possible to the base end.

Referring now to FIG. 13B , in the high inertia embodiment of the Robot CMM Arm 1, the joint centers 3, 5 [23, 25] and their motors 176 are farther from the base end 2 than in the low inertia embodiment of the Robot CMM Arm 1. In a low inertia embodiment of the arm 1, the joint center 3, 5 23, 25 and its motor 176 are closer to the base end 2. The motor does not have to be adjacent to the center of the joint; in an alternative embodiment, the center of the joint 3,5 23,25 is farther away from the base end 2, the motor 176 is closer to the base end 2 and the torque transmission is along the exoskeleton segments 3,5 43, 45 transfers motor torque from motor 176 to joint centers 3,5 23,25. Typical savings due to positioning the drive closer to the base end can be Robot CMM Arm mass savings of greater than 1 kg and power consumption savings of more than 10%.

transmission

In this first embodiment, the base 41 of the Exoskeleton 6 is rigidly connected to the base 31 of the Internal CMM Arm 5 so that there is no significant relative movement between the two bases 41 and 31 and Forces and torques are transmitted through this rigid connection. A number of actuators 72-78 are provided, each CMM section 32-38 may have none, one or more than one actuator. Each of the actuators 72-78 is in direct contact with a respective exoskeleton segment 42-48 and a respective CMM segment 32-38. During operation, the centers and axes of CMM joints 51-57 and joints 61-67 are substantially in the same position. Factors that can cause these joints to be slightly misaligned from the center of the axis include:

- CMM segment 2-8 32-38 has different strain than exoskeleton segment 2-8 42-48

- The actuators 2-8 72-78 are elastically deformed; in this first embodiment all actuators 2-8 72-78 comprise elastic means and are not rigidly connected to the Internal CMM Arm 5 and the Exoskeleton 6. In this first embodiment, the only rigid connection between the Internal CMM Arm 5 and the Exoskeleton 6 is at the Base End 2; rigid connection

-Segment rotation, which will be discussed shortly

- Misalignment due to accumulation of manufacturing and assembly tolerances

Preferred configuration of the transmission

Those of ordinary skill in the art will appreciate that many factors should be considered when selecting and designing the number, location and type of discrete or continuous transmissions 10 . The arrangement of the transmission 10 will be different for 6-axis and 7-axis Robot CMM Arms 1 . The arrangement of the transmission 10 will be different for short reach and long reach Robot CMM Arms 1 . The arrangement of the transmission 10 will be different for different joint arrangements including different positions and sequences of the joints.

Number of transmissions

Any number of actuators can be used, from one discrete actuator to a continuous contact zone along the entire length of the Robot CMM Arm.

One actuator: In order to position and orient the probe 90, if there is only one actuator, it must be the actuator 878 located between the CMM segment 838 and the exoskeleton segment 848. However, a 6 or 7 axis arm has redundancy and the elbow is then free to move under gravity or inertial acceleration. When the CMM joint 454 impacts the exoskeleton joint 464, this free movement will result in a second 'inadvertently achieved' actuator.

Two transmissions: As previously stated, the first transmission must be transmission 8 78. The second actuator must be located between the Joint Center 2 22 end of CMM Section 3 33 and the Joint Center 6 26 end of CMM Section 6 36 in order to control the elbow. If the second transmission was towards the center of the joint 222, the drives on the exoskeleton 6 would need to transfer a lot of power all the way to the first transmission, which supports most of the weight of the arm; 1 is much heavier. If the second actuator is far from the center of the joint 424, then a large bending moment will be required through the inner CMM Arm 5 in order to lift the weight of the elbow; this will reduce the accuracy of the Robot CMM Arm or require large additional weight to strengthen the CMM Paragraph 333.

Three actuators: Three actuators in addition to the rigid base connection is the preferred number of actuators for the first embodiment of the Robot CMM Arm 1 . These three actuators are located: near and in front of the joint center 4 24, near and in front of the joint center 6 26, and the actuator 8 78 in front of the probe end. This arrangement of the transmission has the following advantages:

- The long CMM sections 3, 5 33, 35 are simply supported near either end and this reduces the deflection of the beam under gravity

- The power and weight of the motor and gearbox are minimized to provide a minimum weight Robot CMM Arm 1

- The number of transmissions is optimized; any more will increase cost, weight and complexity

Four to seven actuators: The design complexity of a Robot CMM Arm 1 with 4-7 actuators 10 increases with each additional actuator. The likelihood of the actuators getting in each other's way and applying an undesirable moment to the Internal CMM Arm 5 increases.

Continuous Transmission: A continuous elastic medium can be provided between the Internal CMM Arm 5 and the Exoskeleton 6 . The intermediate volume between the CMM Arm 5 and the Exoskeleton 6 may be filled with small rubber balls coated with adhesive so that they adhere to each other and do not run down or around the intermediate volume in different spatial orientations . The intermediate volume may be filled with a material such as foam-pack, where pockets of air are trapped in a plastic film. The media can be specified in order to minimize the forces and torques delivered to the Internal CMM Arm 5 . Media can also be specified to minimize misalignment of the joints of the Internal CMM Arm 5 and the joints of the Exoskeleton 6 . The media can be specified so that it exhibits the desired elasticity in three sub-directions: radial, axial and torsional. The medium may be continuous throughout the intermediate volume or may be discontinuous so as to resemble a discrete transmission. A continuum can exhibit discontinuous properties; for example, the radial, axial, and torsional elasticity can vary, perhaps greatly, in different regions of the intermediate volume.

Undriven segment autorotation

Referring again to FIG. 2 , there are four situations in the 7-axis Robot CMM Arm 1 when one or more segments automatically rotate under gravity without motive force from the transmission elements. This automatic rotation of the CMM segment is undesirable because if the joint could be oriented at 90 degrees to the angle required for subsequent drive rotation, this could result in damage to the CMM arm or loss of alignment in the CMM arm due to joint locking.

Case 1: Auto-rotation may occur if the orthogonal articulation joint 222 is straight. Automatic rotation involves the CMM Segments 2,3 32,33 rotating together between the CMM Joints 1,3 51,53. This is not possible since the Robot CMM Arm is usually mounted in a vertical orientation and has no eccentric mass accelerated by gravity.

Case 2: Auto-rotation may occur if the orthogonal hinge joint 424 is straight. Automatic rotation includes the co-rotation of CMM Segments 4,5 34,35 between CMM Joints 3,5 53,55. This is possible if there is an off-axis center of gravity accelerated by gravity in the CMM segments 4,5 34,35 and the orthogonal hinge joint 4 24 is not in a vertical orientation.

Case 3: Auto-rotation may occur if the orthogonal hinge joint 626 is straight. Automatic rotation includes the co-rotation of the CMM Segments 6, 7 36, 37 between the CMM Joints 5, 7 55, 57. This is possible if there is an off-axis center of gravity accelerated by gravity in the CMM segments 6, 7 36, 37 and the orthogonal hinge joint 6 26 is not in a vertical orientation. Cases 1, 2 and 3 are prevented by rotation limiting elements built into the superimposed drive transmission or by a separate rotation limiting device 940 .

Case 4: If the center of gravity of the CMM segment 8 is off axis and it is not driven by a transmission, autorotation may occur. However, transmission 878 is necessary and produces torsional drive, so case 4 can be ignored.

Orthogonal Articulated Joint Lock

There are many spatial orientation situations for the Robot CMM Arm 1 where the Orthogonal Articulation Joints lock and may apply undesirable forces, moments or torques to the Internal CMM Arm 5 due to gravity, misalignment and violation of protocol loading. The three instance lock situations are:

Locking situation 1: Orthogonal hinge joints 2, 4, 6 22, 24, 26 are straight and their axes are horizontal. If the base axis is vertical, then the arm is vertical. Misalignment may cause bending moments to be applied to the Internal CMM Arm 5 through the transmission. Loading against the protocol may cause bending moments to be applied to the Internal CMM Arm 5 through the transmission. Careful design of the transmission and stiffness of the exoskeleton can minimize or eliminate this effect.

Locking situation 2: the orthogonal hinge joints 4, 6 24, 26 are straight, and their axes are vertical. If the segment of the Robot CMM Arm 1 behind Joint 2 22 is horizontal, there are CMM Segments 3-8 33-38 forming a single rigid "lock" beam that is horizontal by gravity and supported in two or more positions Case. When supported at each end, the "lock" beam will deflect significantly in the middle. When supported in 3 or more positions, bending moments will likely be generated and greater deflections will be exhibited. Misalignment may cause bending moments to be applied to the Internal CMM Arm 5 through the transmission. Loading against the protocol may cause bending moments to be applied to the Internal CMM Arm 5 through the transmission. This situation is the worst spatial orientation situation to be considered in terms of undesirable forces and moments acting on the Internal CMM Arm 5 . Careful design of the transmission and stiffness of the exoskeleton can minimize or eliminate this effect. Alternatively, when measuring, steps can be taken so that the Robot CMM Arm 1 is not moved into this Locked Situation 2 spatial orientation. For example, a 90-degree rotation at joints 3, 7 23, 27 places the arms in the same spatial orientation, unlocks the two orthogonal hinge joints 4, 6 24, 26 with respect to gravity, removes any undesirable moments and makes the arms fit Take measurements.

Locking case 3: Orthogonal hinge joint 626 is straight and its axis is vertical. This is a subcase of locking case 2. Deflection is less. Locking case 3 can be decomposed into locking case 2 in a similar manner.

In the above example locked situation, or any other locked situation, the locking of any of the CMM joints 2, 4, 632, 34, 36 can be avoided by any of the following methods: 1. Placing hard stoppers in the exoskeleton 6 so as to prevent the joint from reaching 180 degrees; 2. Do not move the Robot CMM into the spatial orientation where the lockup occurs.

Preferred configuration of the transmission

Referring now to Figure 14, a preferred arrangement of the transmissions for the Robot CMM Arm 1 will be described. Robot CMM Arm 1 is at rest in a horizontal spatial orientation forward from Joint 2 . Three transmissions 3, 5, 8 73, 75, 78 are provided. The transmission 373 is located just before the joint center 323. The transmission 575 is just before the joint center 525. The transmission 878 is located behind the joint center 727. Rotation limiting means 940 is provided adjacent to joint centers 2, 4, 6 22, 24, 26.

Referring now to Figure 15, the position of the transmission 878 is described. The CMM section 838 and standard probe 90 rigidly mounted on the CMM section 838 are supported by the transmission 878 at the center of gravity CG8 so that the resultant force or torque acting on the CMM joint 757 is negligible. The center of gravity CG8 is the center of gravity of the CMM section 838 plus the standard probe 90 rigidly mounted on the CMM section 838. This is ideal since one of the goals of the Robot CMM Arm 1 invention is to maximize accuracy by reducing the forces and torques acting on the joints of the Inner CMM Arm 5 . In practice, a probe 90 comprising an optical probe 91 of various masses, center of gravity positions and moments of inertia will be attached to the probe end 2 of the Robot CMM Arm 1 . Ideally, all probes 90 would be designed such that when mounted on the CMM section 38, the center of gravity position of the combined probe 90 and CMM section 838 would be centered on the axis of the CMM section 38 at the center of the transmission 878. In this way, attaching a high quality probe 90 centered on the center of gravity CG8 does not reduce the accuracy of the Robot CMM Arm, because the extra mass is fully supported by the exoskeleton 6 through the transmission 878.

Referring now to FIG. 16, the rotation limiting device 940 will be described. The rotation limiting device 940 includes a pin 941 and an insert rubber O-ring 942 . Pin 941 is rigidly connected to Internal CMM Arm 5 and extends from the axis of CMM Joint 252 . The O-ring 942 is rigidly inserted into the exoskeleton 6 and aligned with the axis of the exoskeleton joint 262. The outer diameter of the pin 941 is significantly smaller than the inner diameter of the O-ring 942 so that when the CMM joint 252 and the exoskeleton joint 262 are aligned, there is a uniform radial air gap between the pin 941 and the O-ring 942. The purpose of the rotation limiting device 940 is to prevent the automatic rotation R of the CMM segments 2, 3 when the CMM joint 252 is straight. If the automatic rotation R starts, it will shortly be stopped under the action of the pin 941 which swings around the axis of the joint center 222 and collides with the O-ring 942. The air gap is maintained during normal motion of the Robot CMM Arm and prevents undesirable forces or torques from being exerted on the Internal CMM Arm 5 through the O-ring 942 and pin 941 .

Referring now to Figure 17, the principle of the transmission 373 is shown in longitudinal section AA and axial section BB. The driving transmission of transmission device 373 is radial. CMM Segment 333 is moved by radial force applied from Exoskeleton Segment 343 through transmission 373. The transmission device 373 includes three transmission blocks 201, which are rigidly connected to the inside of the exoskeleton segment 343 at intervals of 120 degrees; the transmission blocks 201 are made of lightweight materials such as aluminum. Two layers are bonded to the inner surfaces of the three drive blocks 201, namely a layer of elastic material 203 such as neoprene rubber and a layer of low friction material 202 such as PTFE in contact with the CMM segment 333. The transmission 373 will not transmit axial forces because in axial mode the layer of low friction material 202 allows slip between the CMM segment 333 and the exoskeleton segment 343. When the actuator 373 is assembled in place, the layer of elastic material 203 is in constant compression. The cross-sectional area, thickness and stiffness of the elastic material layer 203 combine to enable it to remain within its designed elastic range without rapidly increasing stiffness during normal use or compression over significant distances. The elastic material layer 203 is much wider than the misalignment that would result if the Internal CMM Arm 5 and Exoskeleton 6 were loaded against the protocol at this location; this prevents the Internal CMM Arm from high forces or torques. The layer of elastic material 203 has a low stiffness so that it undergoes significant compression when it supports maximum weight. Those skilled in the art will understand that the specification of cross-sectional area, thickness and stiffness is a known procedure that requires accurate modeling of many factors, including misalignment tolerance build-up and deflection of the exoskeleton under off-spec loading . The benefit of using a low friction material 202 is that no heat is generated through friction; this means that the driving force required is minimized and the precision of the Internal CMM Arm 5 is maintained by eliminating thermal deformation due to frictional 'hot' spots. Two bumpers 209 are provided to prevent autorotation. The buffer block is connected to CMM segment 333. Under normal operation, there is an air gap between the buffer block 209 and the drive block 201 . The bumper 209 has a rubberized surface to reduce impact. If automatic rotation is started, the collision transmission block 201 by the buffer block 209 will stop the automatic rotation very soon. Similarly, transmission 575 is provided for radial drive transmission.

The driving transmission of transmission device 878 is torsion and radial mode. The transmission 87 (?8 78) consists of two adjacent units, a torsional drive and a radial drive. The radial drive is similar to that of FIG. 17 . Referring now to FIG. 18, there is shown the torsional drive of the transmission 878 viewed along longitudinal section AA and axial section BB. CMM segment 838 is rotated by torque applied from exoskeleton segment 848 through transmission 878. Transmission 878 includes collar 204 bonded to CMM Segment 838. Collar 204 also includes three drive flanges 209 spaced 120 degrees apart, extending radially outward and longitudinally. Three grooved transmission blocks 205 with a spacing of 120 degrees drive the transmission flange. Each slotted drive block 205 includes two pads made of elastic material 203 bonded to the two drive faces of the slot of the slotted drive block 205 . The grooved drive block 205 is attached to the exoskeleton segment 848 with the bolt 206 using the washer 207 . The grooved drive block 205, collar 204 and washer 207 are made of a lightweight material such as aluminum. The resilient material 203 has an outer layer 202 of low friction material, such as PTFE, in contact with the drive flange 209 . The transmission 878 does not transmit axial forces because the layer of low friction material 202 allows slippage between the CMM segment 838 and the exoskeleton segment 848 in the axial mode. The transmission 878 partially transmits the radial force because in radial mode the transmission flange 209 is positioned at 120 degrees and act together to provide a correcting force for any radial movement between the CMM segment 838 and the exoskeleton segment 848. When the actuator 878 is assembled in place, the layer of elastic material 203 is in constant compression. The cross-sectional area, thickness and stiffness of the elastic material layer 203 combine to enable it to remain within its designed elastic range without rapidly increasing stiffness during normal use or compression over significant distances. Those skilled in the art will appreciate that an integrated torsional and radial drive can be provided as a lighter and more compact unit than the previously described separate two adjacent torsional and radial drives, thereby better disclosing the present invention principle.

review

Those skilled in the art to which the present invention pertains will understand that the Exoskeleton 6 can transmit forces and torques to the Internal CMM Arm 5 using a variety of actuators 10 that can achieve the desired effect on the Internal CMM Arm 5. The purpose of minimizing forces and torques to maximize the accuracy of the Robot CMM Arm 1 . The scope of the present Robot CMM Arm 1 invention is not limited to the disclosed preferred arrangement of the transmission 10, but is applicable to all transfers of forces and torques from the Exoskeleton 6 to the Internal CMM Arm 5 in order to automatically drive and make the Robot CMM Arm 1 Accurate gearing10. For example, in alternative embodiments, the number of splitter transmissions 10 may be two or more; continuous transmissions may be used; combinations of splitter and continuous transmissions may be used. The scope of the present invention of the Robot CMM Arm 1 is not limited to elastic actuators. In other embodiments, transmission 10 may rigidly couple Internal CMM Arm 5 to Exoskeleton 6 at one or more locations such that forces and torques transmitted from Exoskeleton 6 to Internal CMM Arm 5 do not affect Accuracy of the Robot CMM Arm 1. Experts in the field to which this invention pertains will further appreciate that it appears that future marketed devices may have a combined Internal CMM Arm and Exoskeleton, and may be referred to as a conventional robot rather than a Robot CMM Arm. The scope of the invention covers all devices having the technical effect of reducing the forces and torques acting on the bearings and segments of the CMM.

Robot CMM arm compensation method

Compensation of the internal CMM arm

If a compensating device is used in the Internal CMM Arm 5, the stresses in the joints it utilizes will increase and may also generate bending moments, both of which lead to reduced accuracy or require increased weight for balancing. The joints of the Internal CMM Arm 5 of this Robot CMM Arm 1 invention are typically used for more cycles than the Manual CMM Arm because the Robot CMM Arm can be used up to 24 hours a day, 365 days a year, with fewer maintenance cycles and downtime. If the joint is under high stress and is used continuously, the compensating means will generate more heat and the temperature of this joint in the arm will be higher than under low use conditions. This may increase the inaccuracy of the arm. The bearings on that joint of the Internal CMM Arm 5 need to be designed to be very stiff in order to have a much greater life cycle. Loose bearings are a significant cause of inaccuracies in the Internal CMM Arm 5 and cannot be compensated for. It is an object of the present invention that the Exoskeleton 6 carries the Internal CMM Arm 5 so as to be an external compensating device. This external compensation minimizes most of the forces and torques acting on the Internal CMM Arm 5 during motion and eliminates the disadvantages of internal compensating devices. This means that the internal CMM Arm 5 does not need a compensating device and without the compensating device, the manufactured Robot CMM Arm 1 will be lighter in weight, simpler in structure and lower in cost. The scope of the present invention is not limited to the Robot CMM Arm 1 without the compensation device on the Internal CMM Arm 5 , but also includes the Robot CMM Arm 1 with the compensation device on the Internal CMM Arm 5 .

Exoskeleton compensation device

The Robot CMM Arm 1 can be installed with its base 4 in any orientation. In a vertically up or down base orientation, the Exoskeleton 6 preferably has compensation means located in the Exoskeleton Joint 262 for compensating the weight of both the Exoskeleton 6 and the Internal CMM Arm 5, the compensation means being A device that does not directly consume power from a power source such as electrical voltage, pneumatic or hydraulic pressure. This means that the drive train located in the exoskeleton joint 262 can make less power, weigh less, and consume less energy in most work cycles. In a typical design of the Robot CMM Arm 1, the presence of the compensating means can reduce power consumption by 10-25% and reduce the weight of the Robot CMM Arm by 5-12%.

Referring now to FIG. 19 , the base 4 of the Robot CMM Arm 1 is installed vertically upwards and the application direction A of the compensating device 210 is used to lift the exoskeleton 6 exoskeleton segment 3 43 upwards against the force of gravity towards a vertical position. The compensating device 210 is located at one end of the shaft of the exoskeleton joint 262. Since the base 4 of the Robot CMM Arm 1 is installed vertically downwards, for example when hanging from the column of the carriage 3 axis CMM 129, the application direction of the compensating device 210 is used to lift the exoskeleton 6 upward against the force of gravity towards a horizontal position Paragraph 343. Preferably, a single compensating device 210 acts to provide torque through the exoskeleton joint 262. The compensating means 210 is preferably a machined coil spring. The compensation device 210 is set to an optimum value so as to minimize the maximum torque required to rotate the exoskeleton joint 262 in any orientation of the exoskeleton joint 262. This compensating device 210 means that a smaller and lighter drive train can be provided to drive the exoskeleton joint 262. Ideally, the compensating device 210 should act directly through the center of the exoskeleton joint 262 in order to avoid applying bending moments to the exoskeleton joint 262. In this robot CMM arm invention, the CMM joint 2 of the internal CMM arm 5 is located in the middle of the exoskeleton joint 262. Therefore, the position of the compensating device 210 is off-center and it applies a bending moment to the exoskeleton joint 262. The structure of the exoskeleton 6, particularly the parts around the exoskeleton joint 262, is sufficiently rigid to balance the bending moments from the compensating means 210 and keep the bending of the exoskeleton 6 within desired limits. For the orientation of the Robot CMM Arm Base 4 that is vertically upward or vertically downward, the torque compensation direction of the exoskeleton joint 262 is opposite. Compensation means 210 are provided that can be rotated to apply torque in the opposite direction when the orientation of Base 4 of Robot CMM Arm 1 changes direction. In another embodiment of the present invention, the compensation device 210 further includes a buffer 211 .

In an alternate embodiment, two compensators 210 are selected for the arms, where the first compensator is applied when the Robot CMM Arm 1 has a vertically up Base 4 orientation and the first is applied when the Robot CMM Arm 1 has a vertically down Base 4 orientation. A second compensating device is applied for orientation; a suitable compensating device 210 is adapted to the orientation of the base 4 of the Robot CMM Arm 1 . In another embodiment, a compensating device 210 is provided with a manual adjustment function for two different orientations, which can be installed manually during installation of the Robot CMM Arm 1 . In an alternative embodiment of the present invention, two compensating devices 210 are provided on either side of the exoskeleton joint 262 and set to approximately the same torque so that the bending moment across the exoskeleton joint 262 can be neglect.

In other base orientations such as the base of the Robot CMM Arm mounted horizontally, for example when mounted on a wall, there is preferably no compensating means 210 at the joint 2, unless the application is restricted so as to be available. In an alternative embodiment, the present Robot CMM Arm invention can operate without any compensating means 210 in the Exoskeleton 6 .

Connector Limits

This first embodiment of the Robot CMM Arm 1 has infinite rotation on the axial joints, and strict restrictions on the rotation of each orthogonal joint. Hard joint limiters are physical stops beyond which the joint cannot rotate in the direction of the hard joint limiter. It is an object of the present invention to transmit power and signals through a slip ring in the Internal CMM Arm 5 that can serve both the electronics of the Internal CMM Arm 5 and the drive train in the Exoskeleton 6 . In the 6-axis Robot CMM Arm 1, three axial axes are infinitely rotatable, while in the 7-axis Robot CMM Arm 1, four axial axes are infinitely rotatable. This means that the arm is stronger because the cable does not need to be coiled and unwound continuously 360 degrees around each axial joint.

Internal CMM connector hard limiter

In this first embodiment, there is no built-in hard joint limiter in the Internal CMM Arm 5 . Axial joints can be rotated infinitely. The inherently orthogonal joint limiters all extend slightly beyond the hard joint limiters of the Exoskeleton 6 so that the Exoskeleton does not press the Internal CMM Arm 5 against the hard joint limiters during normal operation. Simple rubber stops are provided to prevent damage when the Internal CMM Arm 5 is not supported by the Exoskeleton 6 during assembly. These rubber stops are not used in operation once the Robot CMM Arm 1 has been assembled.

Exoskeleton joint limiter

In this first embodiment, each exoskeleton joint 2, 4, 6 62, 64, 66 has first and second hard joint limiters. Each hard joint limiter is preferably a mechanical limiter with an impact absorbing element made of rubber attached to at least one impact side to attenuate any impact. For larger size Robot CMM Arm 1 inventions, shocks involving orthogonal joints can be considerable, the effect of this shock energy is dissipated by axially compressing a partially pre-crimped tube positioned to absorb this kind of shock. The pre-wrinkle method removes the initial high impact stress acting on the rigid body. After impacting, only the tube is replaced. The tube is preferably 100mm long, made of pure aluminum, 7mm in diameter, 1.5mm wall thickness and pre-compressed by 5% in a 9.5mm diameter clamp to fit in an orthogonal joint located on Robot CMM Arm 1 in the 10mm hole. Specifications are adjusted for different sizes of Robot CMM Arms that absorb different impact energies. It should be understood that any other suitable means or other modes of absorbing impact energy by plastic deformation could equally be used, such as by shearing the material rather than crumpling it. In this first embodiment, each exoskeleton joint 2, 4, 662, 64, 66 has first and second soft joint limiters. Each soft joint limiter is preferably a limit switch 182 .

Optimal Base Azimuth Direction

The base 4 of the Robot CMM Arm 1 preferably has the best orientation direction marked on it. The optimal orientation of the base is the direction in which the base 4 should face towards the center of the workspace used by the Robot CMM Arm invention. In an optimal orientation for an embodiment without infinite rotation, the exoskeleton joint 161 can rotate an equal amount to both sides before hitting the hard limiter.

Exoskeleton Joint 1 Limiter

In this first embodiment, the exoskeleton joint 161 is an axial joint. For embodiments without infinite rotation, a hard limiter is required. Referring to Figure 20, the total angular displacement of the exoskeleton joint 161 between the first and second physical joint limiters is 630 degrees. The first pair of hard joint limiters 222A, 222B and the second pair of hard joint limiters 223A, 223B of the exoskeleton joint 1 are arranged at equal angles of 315 degrees relative to the base best orientation direction 221 . Hard joint limiters 222A and 223A rotate with exoskeleton segment 242. Hard joint restraints 222B and 223B remain stationary with exoskeleton segment 41 . Hard joint restraints 222B and 223B each have a rubber damper element 224 attached to the impact surface. The two soft joint limit switches 182 are positioned so that they make contact with the limit switches just before the joint extends to its hard limiter limit switches. In another embodiment, provision is made for rotating hard joint limiters 222A and 223A that are moved by the operator relative to exoskeleton segment 242 to give an alternative total angular displacement of exoskeleton joint 161 that is 390 degrees. In alternative embodiments, the angular displacement of the exoskeleton joint 161 may be greater than 630 degrees or may be less than 390 degrees. There may also be multiple joint limiters set for maximum total angular displacement. Similar hard joint restraints are provided for exoskeleton joints 3, 5, 7 63, 65, 67. Similar soft joint limit switches 182 are provided for exoskeleton joints 2-7 62-67.

Exoskeleton Joint 2 Limiter

In this first embodiment, the exoskeleton joint 262 is an orthogonal joint. Referring to Figures 21A, 21B, the angular displacement of the exoskeleton joint 262 is preferably 185 degrees. Referring to Figure 21B, when the exoskeleton joint 262 begins to rotate, the exoskeleton segment 343 exceeds the vertical upward direction by 5 degrees, and the rubber pad 224 contacts the first pair 225A, 225B. Referring to Figure 21A, when the exoskeleton joint 262 completes the rotation, the exoskeleton segment 343 is vertically downward and the second hard joint limiter pair 226A-226B contacts the rubber pad 224. When the Robot CMM Arm Base 4 is in the vertical upward orientation, the compensating device 210 located on the Exoskeleton Joint 262 is used to rotate the Exoskeleton Segment 343 upwards towards the first pair of hard joint limiters 225A, 225B. When the Robot CMM Arm base is in a vertically downward orientation (not shown in Figures 21A-21B ), the compensating device 210 located on the exoskeleton joint 262 acts and directs the exoskeleton segment 343 toward the second hard joint limiter 226A, 226B rotate. Similar hard joint restraints are provided for exoskeleton joints 4, 6 64, 66. Referring to FIG. 21C , an arrangement of the Robot CMM Arm 1 and the Series Orthogonal Joint is shown, wherein the Robot CMM Arm 1 has an interaxial spacing SR greater than the interaxial spacing SM of an equivalent but conventional Manual CMM Arm without the Exoskeleton 790 . In the Robot CMM Arm 1, the CMM Segments 2, 3 32, 33 inside the Exoskeleton Segments 2, 3 42, 43 are shown. When the CMM segments 2, 3 32, 33 are in an orientation parallel to each other, the axial spacing SR between the CMM segments 2, 3 32, 33 is greater than that of an equivalent but conventional manual CMM arm without an exoskeleton 790. The axial spacing SM of the CMM segments 2, 332, 33, because the exoskeleton segments 2, 3 42, 43 of the exoskeleton 6 need space.

joint brake

The present Robot CMM Arm 1 invention is not supported by the operator against gravity. If the power to the transmission system is cut off, then without the brake 177 the Robot CMM Arm 1 will fall under the force of gravity and may be damaged or injure one or more persons or objects. In this first embodiment, all exoskeleton joints 1-7 61-67 have fail-safe brakes 177 that are automatically applied in the event of a power cut. Thus, in the event of a power cut, all exoskeleton joints 1-7 61-67 are locked, and this locking will work in any base mounting orientation and any robot arm spatial layout. In alternative embodiments where the Robot CMM Arm 1 should only be mounted with its base either vertically up or vertically down, the Exoskeleton Joint 161 does not have a stop 177. In this case, the exoskeleton joint 161 has a constant orientation and the action of gravity does not cause the exoskeleton joint 161 to generate acceleration. In an alternative embodiment, the exoskeleton joints 5-7 65-67 do not have brakes because the allowable moments and movements at the wrist under gravity are small. This has the benefit of a more compact wrist design and a lighter Robot CMM Arm 1 .

joint bearing

The bearings in the CMM Joint 1-7 51-57 are an important item to provide a highly accurate Robot CMM Arm 1. The CMM encoder 178 can provide the angle of each joint, but the CMM encoder 178 cannot measure errors introduced by the bearings in the CMM joints 1-7 51-57. The bearings in the CMM Joint 1-751-57 and their arrangement must maximize stiffness and minimize bearing noise while minimizing weight and joint size. Low friction bearings are used in the CMM Joints 1-7 51-57 of the Internal CMM Arm 5 in order to minimize the amount of temperature rise of the Internal CMM Arm 5, especially under heavy duty cycle conditions. The stresses on the bearings in the Internal CMM Arm 5 are generally lower than the corresponding stresses on the Manual CMM Arm because the Exoskeleton compensates for most of the arm weight. Referring now to FIG. 22, a pair of prestressed ceramic tapered roller bearings 230, such as from Barden Corp, USA, provide an axial joint in CMM joint 3 53 and an orthogonal joint in CMM joint 4 54. Tapered roller bearings 230 provide high rigidity and compactness. The tapered roller bearing 230 is prestressed by applying a predetermined torque to the nut 231 . The bearings 230 fit in the housings 100 and 103 using an interference fit, which is done using a heat shrink fit process in which the bearings are first cooled to -45C before insertion to form a strong interference fit at room temperature. In a similar arrangement, prestressed tapered roller bearings 230 are provided in each CMM joint 1-7 51-57. There are various ways of providing a bearing arrangement in the present invention. The scope of the present invention is not limited to the use of prestressed tapered roller bearings with thermal interference shrink fits. Any type of bearing and method of bearing fit and adjustment may be used as long as they meet at least the requirements of low weight, low friction and high rigidity. The bearings in the Exoskeleton Joint 1-7 51-57 are not critical items in the Robot CMM Arm 1 in terms of accuracy, but preferably have a life longer than the Robot CMM Arm 1 design life in order to avoid costly renewals.

impact protection

The Robot CMM Arm 1 is portable. It can be expected to experience shocks during operation, installation, disassembly and transportation. The prominent appearance of the profile of the Robot CMM Arm 1 has raised pads made of plastic attached to it to absorb bumps. During operation, the axis of tracking error is monitored to minimize impact damage by stopping the impact action. Before being de-energized during actuator 177 actuation, the Robot CMM Arm 1 is first moved by controlling the PCB 172 to a specially marked spatial layout for transport. The space layout specifically indicated for transport is one that keeps the dimensions of the arms as compact as possible to allow the rigid housing to be minimized in size. Referring again to Figure 21C, a spatial arrangement in which orthogonal joints allow adjacent segments to be arranged in parallel can be used to minimize the size of the rigid shell. During handling, the brake 177 on the motor 176 is movable; this makes the Robot CMM Arm 1 a rigid device; this makes it easy to manipulate the Robot CMM Arm 1 because parts of the Robot CMM Arm 1 do not rotate during manipulation .

Assembly process

It is an object of the present invention to provide a process for assembling a Robot CMM Arm 1 . Since the Internal CMM Arm 5 is first assembled, calibrated and tested before the Exoskeleton 6 is assembled, there are advantages in terms of production based on the highest quality with the fewest steps. Since the Exoskeleton 6 can be easily and quickly detached from the Internal CMM Arm 5, there are maintenance advantages.

In a first step of the preferred 'walk through' process for Robot CMM Arm 1 assembly, the Internal CMM Arm 5 and Exoskeleton 6 are each assembled separately from each other to an effective degree. In a second step, the Exoskeleton 6 is passed over the Internal CMM Arm 5 like a sock from the probe end to the base end. This assembly process actually requires that the inner CMM arm 5 is designed in the shape of a cone, while the exoskeleton 6 is designed with a hollow cone inside it. The actuator 10 can be placed before or after the Exoskeleton 6 passes through the Internal CMM Arm 5 .

In the first step of the 'insert' process for Robot CMM Arm 1 assembly, the Internal CMM Arm 5 and Exoskeleton 6 are assembled separately to an effective extent. In a second step, the exoskeleton 6 is opened. In a third step, the Internal CMM Arm 5 is inserted into the deployed Exoskeleton 6 . In a fourth step, the Exoskeleton 6 is fitted onto the Internal CMM Arm 5 .

In the first step of the 'wrapping' process for Robot CMM Arm 1 assembly, the Inner CMM Arm 5 and Exoskeleton 6 are assembled separately to an effective extent. In a second step, the Exoskeleton 6 is wrapped around the Internal CMM Arm 5 . Both the insertion and cladding processes require items such as exoskeleton bearings to separate. This design has several disadvantages in terms of increased part count and structural complexity.

In the first step of the 'build around' process for Robot CMM Arm 1 assembly, the Inner CMM Arm 5 is assembled to an effective extent. In a second step, the components or subassemblies of the Exoskeleton 6 are assembled around the Internal CMM Arm 5 one by one. In the first step of the 'build through' process for Robot CMM Arm 1 assembly, the Internal CMM Arm 5 is assembled to a useful extent. In a second step, the components or subassemblies of the Exoskeleton 6 are passed over the Internal CMM Arm 5 one by one. These construction techniques provide poor maintainability for the Robot CMM Arm since the Exoskeleton 6 has to be disassembled to allow access to the Internal CMM Arm 5 .

The scope of the present invention is not limited to the disclosed assembly process, but includes any manual or automatic process for assembling or disassembling the Robot CMM Arm 1 . Those of ordinary skill in the art to which the present invention pertains will appreciate that there are many other steps in the overall manufacturing and assembly process flow of the Robot CMM Arm 1, and that these process steps may be located before, between or after the assembly process steps disclosed herein .

Probes and Tools

Install

The Robot CMM Arm 1 has a base end 2 and a probe end 3 . It may include one or more measurement probes 90 or tools 98, which are preferably mounted on the probe end 3 after the CMM connector 757. The measuring probe 90 can be removed manually or automatically. Automatic removal is preferably accomplished by a probe changing system such as with a rack for two or more probe 90 positions and an accurate mounting mechanism for repeatably loosening and locking probes 90 . A Robot CMM Arm 1 may have one or more precision mounting mechanisms.

Referring now to FIG. 23, in this first embodiment, a probe mount 240 is provided on the probe end 3 of the Robot CMM Arm 1 invention behind the CMM connector 757 so that two of the three probe mounts 240 are used to To connect at most two probes 90 , the three probe mounting devices 240 include: a first probe mounting device 244 , a second probe mounting device 247 and a third probe mounting device 251 . The first probe mount 244 includes an M8×1.5 internal thread 241 from the first mounting surface 242 and an electrical contact 243 . The second probe mount 247 includes M20 external threads 245 from the second mounting surface 246 . The third probe mounting device 251 includes an M30 internal thread 248 and a third fitting surface 250 with three precision grooves 249 spaced 120 degrees apart; a female probe connector 255 is located in the third fitting surface 250 . An additional female probe connector 258 is located on CMM section 838 to connect probe 90 when female probe connector 255 is not available; connectors 255 and 258 are mechanically and electrically identical.

Referring now to Figure 24, the Renishaw TP20 probe body 93 is mounted on the CMM section 838 using the first probe mount 244 by screwing it into the threads 241 until it encounters the first mounting surface 242; making the Renishaw TP20 Electrical contact takes place between the probe body 93 and the electrical contact means. Mount the Renishaw TP20 probe module 94 to the Renishaw TP20 probe body 93 using the magnetic dynamic mount.

Referring now to FIG. 25, the solid contact probe 95 is mounted on the CMM segment 838 using the second probe mount 247 by screwing it onto the thread 245 until it encounters the second mounting surface 246. To install the solid contact probe 95 it is not necessary to remove the Renishaw TP20 probe body 93 but it is necessary to first lift the Renishaw TP20 probe body 93 at the magnetic dynamic mount. This means that the Robot CMM Arm 1 with the Renishaw TP20 probe body 93 does not need to be recalibrated each time the solid contact probe 95 is removed. After passing the bracket 253 through the solid contact probe 95, the optical probe 91 mounted on the bracket 253 with three cylinders at intervals of 120 degrees is mounted on the third probe mounting device 251, since the inner diameter is larger than the solid contact The outer diameter of the probe 95, so there is a gap between the bracket 253 and the solid contact probe 95. This means that the optical probe 91 can be removed without first removing the solid contact probe 95, which has the advantage that the Robot CMM Arm 1 with the solid contact probe 95 does not need to be recalibrated each time the optical probe 91 is removed. Likewise, the solid contact probe 95 or Renishaw TP20 probe body 93 can be removed without realigning the optical probe 91. The center of gravity 96 of the optical probe 91 is offset from the axis of the CMM section 838 by a distance 'd'. An example of an optical probe 91 is the ModelMaker X70 from 3D Scanners (UK). Referring now to FIG. 26 , the cradle 253 has a cradle connector 256 with a cable 257 connecting the cradle connector 256 to the optical probe 91 . The three cylinders of bracket 253 are positioned in precision grooves 249 and held in place by nuts 254 threaded onto threads 248 . As is the case with the barrel 252 of the bracket 253 positioned in the precision groove 249 , the bracket connector 256 is automatically positioned in the female probe connector 255 and held in place by the nut 254 . The position and orientation of the carriage 253 and thus the optical probe 91 relative to the CMM section 838 is repeatably positionable with an accuracy of approximately 0.025 to 0.05 mm (+/- 2 Sigma). The bracket can be placed in three different orientations spaced 120 degrees from each other, but only one preferred position makes automatic connection with the female probe connector 255 . In another embodiment, two or more sets of three precision grooves 249 are provided in face 250 . This means that with two sets of three precision grooves 249, the bracket 253 can be oriented in six different orientations spaced 60 degrees apart.

In this first embodiment, the center of gravity of each probe 90 is preferably approximately on the axis of the CMM section 838 in order to minimize the force used to rotate the CMM joint 757 and to minimize the force acting on the CMM joint 757. Any bending moments are minimized as the probe center of gravity 96 can also be offset from the axis of the CMM joint 757 in order to make this first embodiment fully operable up to that caused by an offset probe in the worst position with respect to gravity the maximum allowable torque.

In alternative embodiments, the Probe 90 may be mounted on any segment of the Robot CMM Arm 1, including the base end segment, the probe end segment, and any intermediate segments; one or more other joints are provided for mounting of the Robot CMM Arm segment between the part and the probe.

In another embodiment, an actuated dynamic mount such as an automatic joint from Renishaw is provided to automatically change probes. In another embodiment, side mount means are provided for offset attachment of another probe to the side of the shaft of the probe tip. Those of ordinary skill in the art to which this invention pertains will appreciate that any design of probe mounting means and any combination of probe mounting means in any feasible orientation may be provided in alternative embodiments.

Use of multiple probes

In surveying applications, it is often useful to mount two Probes 90 on the Robot CMM Arm 1 for joint use either simultaneously or one at a time. The present invention is not limited to one or two probes mounted on the Robot CMM Arm, but may include multiple probes.

An example of dual probe usage is where both the contact probe 95 and the optical probe 91 are mounted on the Robot CMM Arm 1 for 3D scanning of tools for automotive parts in the body coordinate system. The contact probe 95 is used to locate the object to be measured using a reference artifact such as a tool sphere or cone in a known position/orientation relative to the vehicle body coordinate system. The optical probe 91 collects data on the surface of the object 9 .

In this first embodiment of the Robot CMM Arm invention, a Robot CMM Arm using multiple probes is provided, wherein multiple probes are attached to the probe end of the Robot CMM Arm and can be used alternately so that the probes do not need to be attached or detached to perform its function. This means that time can be saved in automated measurement cycles and neither the expensive cost and possible inconvenience of probe change systems nor manual intervention is required. In another embodiment, multiple mounted probes 90 may be used simultaneously to perform their functions. In another embodiment, a combination of at least two of the plurality of mounted probes may be used simultaneously to perform their functions.

Probe type

There are many types of contact measurement probes that can be mounted on the Robot CMM Arm for dimensional measurements, including but not limited to:

- solid tactile contact probe 95;

- tactile trigger contact probes with at least one switch that emit an electrical signal upon contact with an object, such as Renishaw TP6 and Renishaw TP20;

- a pressure sensing probe such as Renishaw TP200 with at least one strain gauge;

- Electrical contact probes, where an electrical circuit is formed when the probe is in contact with a conductive object, and the object and the Robot CMM Arm are connected by a cable;

The tips of this solid state, tactile, electrical contact and pressure contact measurement probes are available in various shapes such as spherical, point, flat or custom shapes. An example of a custom shape is a contact measurement probe with a V-groove for measuring elbows. Another example of a custom shape is a contact measurement probe with two orthogonally curved surfaces for measuring the edge of a sheet metal.

- wall thickness measuring probes such as ultrasonic;

- Contact measuring probes for measuring other dimensional quantities such as coating thickness.

There are many types of non-contact measurement probes that can be mounted on the Robot CMM Arm for dimensional measurements, including but not limited to:

-point trigger probe

-Point distance measuring probe

- All types of streak probes

- All types of area probes

- Wall thickness probes such as ultrasound, which send signals through the air, gas or liquid layer between the probe end of the Robot CMM Arm and the pipe surface.

Non-contact optical probes can use monochromatic or white light. Where monochromatic light from a laser is used, the power of the laser is preferably low so that it is eye safe and the operator does not have to wear laser safety goggles and the robot's work area does not require a safety shield.

There are many types of contact and non-contact measurement probes that can be mounted on the Robot CMM Arm for dimensionless measurement, including but not limited to:

-temperature;

-Surface roughness;

-color;

-vibration;

-hardness;

-pressure;

-density;

- Detection of cracks and impurities in welding and bonding.

tool

There are many tools 98 that can be mounted on the Robot CMM Arm 1, these tools include but are not limited to:

- Marking with a marking device such as a pen or a foam jet printer needle; the positioning of the mark to be placed on the object being marked is determined during preparation using a three-dimensional software such as a CAD system; the positioning is determined using a model of the object that was formed into the object A CAD design model of the object upon which it is based, or an inverse engineered model of the actual object, or an inverse engineered model of another similar object; the operator of the 3D software uses 3D software tools to digitally define the positioning of the desired markers; alternatively , the positioning of a desired mark can be measured against another similar object during interactive data acquisition; during the assembly of mating parts such as in the aerospace industry, the positioning of a desired mark such as the center of a drill hole can be measured from a protruding part Then mark on the female part, or can measure from the female part and then mark on the convex part; the three-dimensional software generates a path program for the robot CMM arm 1 with the marking device installed; when the path program is on the robot CMM arm 1 When performed automatically, the marking device marks the object in a predetermined position; the Robot CMM Arm 1 has high utility for marking because it can be more accurate than industrial robot marking and more flexible than conventional CMMs; in addition, using the Robot CMM Arm 1 to mark Marking fixtures may not be required

-Coloring with spraying devices such as spray guns, foam jet printer needle assemblies including color foam jet printer needle assemblies

- cutting, grinding, drilling, forging, gluing, welding, milling

- Place the adhesive

Tool 98 may be static or may be a powered tool with translational or rotational elements and powered along the arm.

Probe quality

Contact probes typically weigh 50-200g. Optical probes typically weigh 100-2000g. The weight of the probe combination can exceed 3kg.

Probe Architecture and Identification

Probes 90 vary in complexity and power. The architecture for the optical probe 91 mounted on the present Robot CMM Arm 1 invention is disclosed. Referring now to FIG. 27A , the optical probe 91 has a probe connector 260 for the probe cable 259 or the bracket cable 257 . The probe PCB 270 has a probe static memory 261 , a probe processor 266 , a probe bus controller 267 , a probe wireless unit 268 and a probe detection device 269 . Probe program 272 and probe identification 271 exist in probe static memory 261 , and probe identification 271 includes: probe identification number 262 , probe calibration data 263 , probe alignment data 264 and probe information 265 . The probe calibration data 263 is data related to the calibration of the probe 91 used for measurement regardless of where the probe 91 is attached. Probe Alignment Data 264 is data related to the alignment of the Probe 91 with the Robot CMM Arm. Probe information 265 may include, but is not limited to: probe type, probe weight, probe center of gravity location and moment of inertia relative to installation reference point, date of last calibration, date of manufacture, manufacturer, accuracy, and serial number. This first embodiment ensures that any probe 90 has a probe ID 271 stored inside it. The probe identification 271 can be read after the probe 90 has been installed on the Robot CMM Arm 1 . It can be read along a wired connection or via a wireless connection. This means that each time the probe 90 is calibrated, the probe calibration data 263 is stored with the probe 90 and reduces the chances of it being lost or incorrectly replaced by old probe calibration data in the institution's IT system. The probe program 272 can be automatically updated by the laptop 151, or can even be automatically updated by the laptop 151 or the probe wireless unit 268 using the Internet or an intranet. This first embodiment also provides that a simple probe 90 without a digital identification stored therein can also be used. The probe digital identification is not limited to being stored in probe static memory 261; it may be stored without power in any form of digital memory that outlasts the probe 90 design life. Raw data from the probe sensor 269 may be processed by the probe processor 266 and may also be processed by the laptop 151 . In some probe architectures, probe processor 266 does most or all of the processing. In other probe architectures, the laptop 151 does most or all of the processing.

Probe Connectors and Probe Cables

Most of the probes sold in the market, especially the optical probe 91 have a dedicated connection device, while the custom optical probe 91 is usually developed to be connected to the positioner. The first probe mount 244 provides a Renishaw M8 x 1.5 mm threaded hole with automatic electrical contacts for a variety of Renishaw probes. The second probe mount 247 provides standard threads but no electrical contacts. The third probe mount 251 provides a dedicated mechanical mount and automatic electrical connection arrangement via the female probe connector 255, which can only be used with the permission of the intellectual property owner of the third probe mount 251 design. Manual connection of the probe can be made by plugging the short probe cable 259 into the additional female probe connector 258 located on the CMM segment 838. In a less preferred embodiment, the Probe Cable 259 may be located on the outside of the Robot CMM Arm 1 and connect into the Connection Port 194 at the Base 4 of the Robot CMM Arm 1 . Those of ordinary skill in the art will know that cables are always a problem with articulated arm robots, and would not want cables protruding from the probe end of a Robot CMM Arm that has not taken steps to properly route around the joints. The connection of the connector and interface port 194 is preferably the same as the female probe connector 255 and the additional female probe connector 258 . Probe electrical connections 243, 255, 258 and 194 provide one or more of the following: power, ground, trigger and data. Referring now to FIG. 27B, in another embodiment, three probe connectors 260 are provided on the probe 90; three probe cables 259 connect the probe 90: to the Robot CMM Arm 1 via the probe electrical connection 258; to the lap Model computer 151 and probe control box 295. The probe control box 295 is required when the size and weight of the probe 90 must be minimized and it is practical to move items from the probe 90 into the separate probe control box 295 . Referring now to FIG. 27C , in another embodiment, the probe cable 259 connects to the probe connector 260 on the probe 90 and runs along the outside of the Robot CMM Arm 1 to the probe control box 295 . The probe box to laptop cable 297 connects the probe control box 295 to the laptop 151 . A probe box to arm cable 296 connects the probe control box 295 to the interface connector 194 on the Robot CMM Arm 1 . Referring now to FIG. 27D , the Probe Control Box 295 is connected to a preferred embodiment of the Robot CMM Arm 1 . Probe cable 259 connects to probe connector 260 on probe 90 and to female probe connector 258 on Robot CMM Arm 1 . A probe box to arm cable 296 connects the probe control box 295 to the interface connector 194 on the Robot CMM Arm 1 . The scope of the present invention is not limited to the disclosed probe electrical connections and cables, but includes various types of probe wired and wireless connections. For example, probe 90 may send data directly to laptop 151 using wireless communication such as IEEE 802.11b (WiFi).

Probe Specifications and Performance

The specifications and performance of the probe 90 largely determine the manner in which the Robot CMM Arm 1 transports the probe 90 during a measurement task. As previously disclosed, there are many general types of Probes 90 that can be used in the present Robot CMM Arm invention, and for each general type there is a wide range of designs. A preferred optical probe 91 mounted on the Robot CMM Arm 1 is a stripe probe 97 . Referring now to FIG. 28 , the streak probe 97 includes a laser light source 298 and a plane-generating mirror 299 that projects laser light 280 fanning out to both sides of the direction +z, approximately represented by planar triangular segments. The measurement takes place within a polygonal segment 281 configured in such a way that the smallest fringe length 284 is closer to the fringe probe 97 and the largest fringe length 285 is further away from the fringe probe 97 . The distance between minimum fringe length 284 and maximum fringe length 285 is the depth of field 282 . Throw distance 283 is the distance from fringe probe 97 to the middle of polygon segment 281 . Detection device 269 located in fringe probe 97 collects laser light 280 through lens 300 in field of view 302 at projected triangulation angle 286 and scan rate 294 of captured fringes per second. Referring now to Figure 29, the stripe probe 97 mounted on the Robot CMM Arm 1 scans the object 9 by moving relative to the object in the X direction at a surface velocity of 293 inmm/second. The stripes 287 are formed on the surface of the object 9 by the projected laser light 280 . Measurements are taken along stripe 287 as long as stripe 287 is within segment 281 of the polygon. Referring now to FIG. 30, the fringe 287 located on the object 9 is divided into a sequence of N small areas 288 along the Y direction, which correspond to the respective 3D measurement results output by the probe. The average dot spacing 289 between adjacent small regions 288 along the stripe 287 is the distance DY. Referring now to Fig. 31, a set of fringes 287 along the X direction on the object 9 is recorded. The average fringe spacing 290 is the distance DX. The series of stripes 287 forms a scanned patch 291 . Referring now to FIG. 32 , the object 9 is scanned as a set of overlapping scanned patches 291 at a nominal overlap distance 292 . Referring now to FIG. 33A , a two-field fringe probe 301 includes two detection devices 269 and a lens 300 with two opposing fields of view 302 and 303 . Referring now to FIG. 33B , the two-field fringe probe 301 utilizes a step 304 to observe the object 9 . First field of view 302 has a clear path to stripe 287 , where laser stripe 280 illuminates object 9 . The second field of view 303 has a path to the fringe 287 which is blocked by the step 304 in the object 9 and the image fringe 287 is not visible at this location. Referring now to FIG. 34A, the two-stripe probe 308 includes a central detection device 269 and a lens 300 with a field of view 302, two laser sources 298, and a plane generating optic 299 that projects a first laser plane 305 and a second laser plane 305 intersecting a line 307. Two laser planes 306 . Referring now to FIG. 34B , the two-stripe probe 308 utilizes the steps 304 to observe the object 9 . The first laser plane 305 illuminates the face of the step 304 of the object 9 so that fringes 287 are formed and the field of view 302 has a path leading to the fringes 287 .

The following parameters of the probe affect at least the programmed motion of the Robot CMM Arm 1 and are disclosed in more detail below:

- fringe length: the fringe probe 97 is usually specified by a maximum fringe length 285; in practice, the actual fringe length will vary depending on the distance from the fringe probe 97 to the object 9; With a maximum fringe length of 75mm and an overlap of up to 25mm, objects can be scanned in ten patches using 50mm increments between each patch; longer fringe lengths require fewer patches; fringe lengths typically vary from 10mm to 200mm, but can be more or less; fringe length overlap typically varies from 5% to 50% of the fringe length, depending mainly on the shape of the object 9 but can be more or less

- Average point spacing: the stripes are actually output as a discrete sequence of 3D points; the typical number N of points in a stripe is currently about 750, but can be expected to increase in the future; if the stripe length is 75mm, the average point spacing along the stripe 0.1mm; objects 9 with fine features may need to be scanned with a smaller average point spacing of 0.01-0.05mm or less; larger objects 9 with fewer features may need to be scanned with 0.25-1mm or larger scan rate to scan

- Scan rate (stripes/sec): Typical current scan rates 294 are from 25 to 60 fringes per second; scan rates are expected to increase in the future; there are several possible scan rates:

o Constant scan rate: the time between any two stripes is always the same; this is common for detection devices 269 as video sensors

o Two alternating constant scan rates: this is common for the detection device 269 as an interlaced video sensor; CCIR rates of 25 or 50 fringes per second are common; 30 or 60 fringes per second are common CCIR rate; higher scan rates produce lower resolution data; operator can select which scan rate to use each time

οArbitrary constant scan rate up to maximum scan rate: operator sets his desired rate

ο Rate variable with trigger: the time between streaks can vary; another event can trigger the streak probe 97

o Rate that can vary with processing: time between stripes can vary; processing time per stripe can vary; next stripe will not be recorded until previous stripe has been processed

- Surface speed: There are several possible surface speeds:

o Constant Surface Velocity: The streak probe 97 moves over the object 9 at a constant surface velocity 293; the streak probe 97 can be at a constant orientation or varying orientation; the streak probe 97 moves relative to the object while taking measurements

o Variable Surface Velocity: The surface velocity 293 varies during the scan; varying the surface velocity can be done in a number of ways; for example if the surface is characterized in some areas and smooth in others, it is often desirable to scan the feature area more slowly

ο Stepping: the stripe probe 97 is moved from one location to another by the Robot CMM Arm 1; the stripe probe 97 is stationary at each location while taking measurements; step-by-step scanning is used to achieve the highest precision measurement; when the object 9 moves In the case of , the streak probe 97 is in a constant position relative to the object 9 while measuring

- Average stripe spacing: If the Robot CMM Arm is moving at a surface speed 293 of 30mm/second in a direction normal to the stripes, then the average stripe spacing 290 will be 0.5mm at a scan rate of 60stripes/sec; Objects9 with fine features may need to be scanned with a smaller average fringe spacing of 0.05mm or less; in this case, the Robot CMM Arm speed must be reduced to 3mm/second; larger objects with fewer features 9 may need to be scanned with a higher average fringe spacing of 1 mm or more

- Uniformity of fringe spacing: Robotic CMM Arm can scan at a constant surface velocity; the operator of a Manual CMM Arm cannot scan at a precise and constant surface velocity; this means that the Robotic CMM Arm can provide better Provides a more uniform fringe spacing;

- Uniform 3D point density: This is desirable in some applications; the Robot CMM Arm can achieve uniform 3D point density by setting the surface velocity so that the average Sampling points with stripes to increase the average point spacing

- Depth of field: 3D points can be measured across the depth of field 282, which typically has a depth between 50 and 200mm; in general, the greater the depth of field, the root mean square (RMS) of the 3D points from the fringe probe 97 ) Z noise is worse; the RMS of the existing stripe probe is about 1/10000 of the depth of field; for example: the stripe probe 97 with a maximum stripe length of 70mm and a depth of field of 100mm has an RMS of 10 microns in the Z direction

- Access: An object 9 such as a gear case provides a restricted access path for the probe 90 on the Robot CMM Arm 1 to scan features inside the object; access is usually possible by passing the probe 90 through a narrow hole located in the housing ; In this case, the probe 90 must be as small as possible and can be installed on the extension of the robot CMM arm 1 probe end 3, such as a pipe; in addition, the probe 90 can be at an angle such as 45 degrees or 90 degrees with the direction of extension degree orientation; the ability to configure the probe 90 at an angular orientation provides the possibility to scan a greater extent of the surface of the object 9

- Throw distance: Throw distance 283 is usually between 75 and 300mm; ideally, the throw distance should be larger in order to (a) reduce the risk of collision between Robot CMM Arm 1 and object 9 and (b) maximize penetration into deep areas such as slots; as the throw distance increases, so does the actual reach 81 of the Robot CMM Arm; when the actual reach 81 of the Robot CMM Arm increases, both the accuracy of the Robot CMM Arm and the accuracy of the Probe 91 are reduced; in some inaccessible applications, where the sensor has a mandatory and small maximum distance from the surface dictated by the design of the object 9, a smaller throw distance is ideal; in other inaccessible applications, Where the sensor has a mandatory and relatively large minimum distance from the surface specified by the design of the object 9, ideally a relatively large projection distance is selected; therefore, the selection of the projection distance is a compromise between accuracy and application

- Blockage: The advantage of the two-field-of-view fringe probe 301 mounted on the Robot CMM Arm 1 over the fringe probe 97 with one field-of-view is that it can acquire more data from the fringe 287 on the object 9, which has steps or Similar characteristics leading to occlusion; more cases are used with the fringe probe 97 than with the two-field fringe probe 301, in which case the region has to be rescanned in a different orientation in order to reach the object occluded in the first patch acquired 9; this means that the total measurement time used by the two-field fringe probe is reduced; however, the two-field fringe probe 301 is bulkier and heavier than the fringe probe 97. A preferred two-stripe laser probe 308 mounted on the Robot CMM Arm 1 has the advantage over the stripe probe 97 or the two-field-of-view probe 301 that it can acquire data on the vertically stepped wall 304 . Those skilled in the art to which the present invention pertains will appreciate that a fringe probe with three or more fringes that are angled to the scan direction but not perpendicular to the direction of the scan can be captured all the way around the inner wall of the cylindrical bearing in one linear scan path. data. Such streak probes will have two or more cameras to increase observation points. The advantage of a stripe probe with multiple stripes and cameras is that more comprehensive data about vertical walls can be collected in one scan pass, whereas a stripe probe with only one stripe and one camera may require the Robotic CMM to scan twice or more. pass the same feature twice to complete the scan

-Automation: The Robotic CMM Arm is automatic and can scan continuously for more than 24 hours; in comparison, the operator of the manual CMM Arm is more fatigued; this means that the Robotic CMM Arm can scan objects 9 more than the manual CMM Arm used by the operator Scan more data with better data quality.

The laser source 298 is a laser diode with a wavelength of approximately 660 nm and a power of 30 mW, which is commercially available from a number of suppliers including Toshiba Japan. Optical device 300 is a light pen from Rodenstock, Germany. The sensor 269 is a CCD NTSC video sensor chip, which is commercially available as a chip or more generally a camera from many suppliers including Sony. In conclusion, the scope of the invention is by no means limited to the design of the optical probe but can be incorporated into any suitable design of the optical probe. The projected light source can include any type of light such as: white light; invisible, infrared, ultraviolet, partially visible or fully visible laser radiation. Multiple projected light sources with different specific wavelengths or different bands can be used, which can then be differentiated by bandpass filters and multispectral sensors 269 . Projection optics 299 and imaging optics 300 may be stationary or dynamic. The dynamic optical device includes a galvanometer reflector and a rotating polygonal multi-mirror. The projection light source can be at constant power or its power can be variable. Lightcasting can be always on or gated on. Wherein the detection device 269 includes other devices made with CCD and CMOS technology. The detection device 269 may be an analog device such as a 1D and 2DPSD device. The detection device 269 may be a digital device with pixels such as an ID pixel line or a 2D pixel array. The detection means 269 may have different duty cycles and may use microlenses. The detection device 269 may have a fixed or variable shutter speed. Gating of the light projection may cause light to be projected for all or part of the shutter open time.

power supply

The power consumption of the Robot CMM Arm disclosed in this first embodiment is typically below 1 kW and in most cases below 2 kW. This means that 80-240V home/office mains power can be used and no three-phase power supply running at the higher voltage is required. A standard IEC socket 195 is provided for mains power connection via cable 155 . For field applications such as scanning corroded gas pipes, operation of the Robotic CMM Arm is provided by 24V DC powered by one or more 24V DC batteries of the type used in vehicles. A 24V DC socket 195 and a 20m long 24V cable 155 are provided. A rechargeable battery 170 is provided as a backup power source, which enables backup operations such as storing encoder positions in the event of a sudden power outage, so that the operation of the Robot CMM Arm can be restarted directly when mains power is fully restored, while No initialization procedure is necessary. The battery 170 is detachable. A built-in charger for battery 170 is provided.

Robot CMM Arm Cable and PCB Location

Internal cables 165 , 166 , 167 , 169 , 174 and 196 run along the Robot CMM Arm 1 from the control box 159 to the probe head 3 , connecting the connector PCB 173 and the motor 176 . Internal cables 165 , 166 , 167 , 169 , 174 and 196 extend between the Internal CMM Arm 5 and the Exoskeleton 6 . This means that all cables within the outer surface of the Robot CMM Arm 1 are protected. Most of the devices 177 - 184 local to the connector PCB 173 are mounted on the Internal CMM Arm 5 or on the Exoskeleton 6 . Each connector PCB 173 is connected to at least one local device 177-184 by wires, ribbon cables or round section cables extending between the Internal CMM Arm 5 and the Exoskeleton 6. The internal cables 165, 166, 167, 169, 174 and 196 and the wired connections 177-184 to the header PCB are of a standard and robust format commonly used in the art. Cable gauges are kept to a minimum to reduce weight. Serial cable 169 is an IEEE-1394 Firewire cable. Probe Box to Arm Cable 296 is a custom cable for the specific needs of a Probe Box or other interface device related to the services provided by Robot CMM Arm 1 through Interface Connector 194 . Laptop cable 152 is a Firewire IEEE-1394 cable from Firewire connector 197. Network connector 199 is a 100Mbps Ethernet connector that connects to Ethernet 200 made of standard CAT5 cables. Pendant cable 154 is a Firewire IEEE-1394 cable from Firewire connector 198.

The scope of the present invention is neither limited to the disclosed internal cable nor to the disclosed PCB arrangement. Optical probes are increasing in bandwidth of output data passed to the processing unit. High-bandwidth serial cables are available such as those specified in IEEE-1394b FirewireB, with bandwidths up to 3.2 GB/sec using optical signaling cables and less bandwidth using electrical signaling cables. Optical signal cables are largely immune to electrical noise and can carry signals over long distances without attenuation. This makes them suitable for robotic use, where extended distances and cables routed close to noisy motors are features. Alternatively, all networks could be 100BaseT Ethernet and provide hubs or switches for device interconnection. Those skilled in the art will well understand that the number and function of PCBs in the Robot CMM Arm can be changed without affecting the technical effects of the present invention. For example: Instead of seven connectors PCB173, three connectors PCB173 may be provided, these connectors PCB173 are located at the shoulder elbow and wrist of the Robot CMM arm with the associated two or more connectors connected to a single connector PCB173 Connected devices such as encoders, thermocouples and drives.

user interface

laptop personal computer

Referring now to FIG. 35, a laptop personal computer 151 is preferably provided for the primary user interface. An adjustable platform 310 is provided to mount the laptop personal computer 151 at a location remote from the base 4 of the Robot CMM Arm 1 . A battery 164 in the laptop is provided for operation without a mains power connection. Space is provided for a mouse 311 on the platform. The invention is not limited to laptop user interfaces. A fully detached PC box is available; a detached LCD screen can be attached to it. Laptop PCs can be provided. The computer can be integrated in a single Robot CMM Arm 1 unit and an external display connected to it. The display may have tactile detection capabilities. Where two or more Robot CMM Arms are working in a cell, a single laptop PC is preferably used to control all the Robot CMM Arms in the cell. Preferably, a compact printer 312 connected to the laptop 151 is provided. It is at least used to print out measurement records. A location for the printer is provided on the platform 310 below the laptop 151 .

suspension

Referring now to FIG. 36 , a Hand Holder 153 is provided for local control of the Robot CMM Arm 1 ; with wired 164 and wireless 324 connections to the Robot CMM Arm 1 . A battery pack 163 in the suspension 153 is provided for operation without mains power connection. A recharge point 158 is provided on the Robot CMM arm where the suspension 153 can typically be left overnight for recharging; the recharge point 158 is characterized in that the connection is made automatically, the suspension is simply put in the correct position and orientation in the bracket so that the suspension electrical contact 327 is in contact with the recharge point electrical contact 328 . The pendant 153 preferably has an 8" LCD display 322, but it could be smaller or larger; alternatively, no display can be provided on the pendant. The pendant has a microprocessor 323, Microsoft Windows CE in memory 325 Operating system 326, pendant software 330 and 3D graphics chip 329 located in memory 325. Pendant display 322 shows all results produced by using the Robot CMM Arm 1, including real-time 3D color graphics of scan data. This This real-time display provides the aid of the teaching procedure. The suspension has a number of buttons 320 for controlling the two directions of motion of each axis. The buttons are made using thin-film technology. A 3-axis joystick 321 is provided, but it may have more or fewer axes and may have two or more joysticks or trackballs. The suspension 153 has two alternate modes: a terminal mode or an active mode, in which the suspension 153 is used as a laptop personal computer terminal, while in active mode, the pendant 153 uses its own microprocessor 323 to run the application software. In an alternate embodiment, the pendant 153 is not provided or is optional; a laptop computer Software is provided to perform the user interface functions of the suspension. A green LED 157 is provided on the Robot CMM Arm 1 and the suspension 153 to indicate that power is on. All other operating information is displayed on the laptop 151 or the display of the suspension 153 screen.

Head Mounted Controls

Referring now to FIG. 37 , the operator 11 is provided with a headset 340 with a wired or wireless connection to the laptop 151 . The headset 340 includes a monocular display 341 with a resolution of at least 800 x 600 pixels, positioned so that the operator 11 can view it with one eye. The operator 11 can still see the surroundings with both eyes, but the eye that is able to see the monocular display 341 is slightly blocked. Monocular displays 341 with higher resolutions are becoming available and can be placed in the headset 340 . The earphone 340 also includes a headset 343 and a loudspeaker 342 . The operator 11 uses a small dictionary of commands controlling the Robot CMM Arm 1 by speaking into the loudspeaker 342 . Each operator 11 preferably tells the Robot CMM Arm 1 commands so that the voice recognition software on the laptop 151 will provide a higher recognition rate. The speech synthesis software on the laptop 151 will speak into the operator 11 through the headset 343 to provide a closed loop speech driven user interface.

button

Referring now to Figure 38A, several sets of buttons 183 operated in parallel are secured to the Robot CMM Arm. Preferably the group is a pair of buttons 183 for the controls. A pair of buttons 183 are located at Probe Tip 3 of the Robot CMM Arm on Segment 8 . The buttons are called A and B, with A being closest to the probe tip 3 . A is colored red and B is colored green. The buttons 183 are approximately 25 mm apart from center to center and are 11 mm in diameter. Button 183 is concave to reduce accidental actuation. Button 183 is of large diameter to fit a thumb or fingerprint size. Button 183 is used to control Robot CMM Arm 1 measurements and software selections. Other button pairs 183 that operate in parallel with the probe end pair are located: at probe end 3 on exoskeleton segment 8 48 on the other side of exoskeleton segment 8 48 away from the first pair; on control box 159 and exoskeleton segment 5 45 Between the upper elbow and the wrist. Referring now to FIG. 38B, a wireless foot switch 350 is provided. Referring now to FIG. 38C, a wireless remote control 351 with buttons is provided; it is secured to the Robot CMM Arm at the position of choice of the operator 11, preferably with a holster 352; alternatively, the operator 11 can hold the remote control 351 . The invention is not limited to the disclosed number of buttons 183 and their locations. The Robot CMM Arm can be operated using other devices such as pendant 153 or laptop 151 without any buttons attached to it. Control can be achieved with a single button 183 or with 3 or more buttons in each group. Single or multiple sets can be provided. Factors affecting the number of groups and their location include the reach of the Robot CMM Arm 1 and the application in which it is used.

environmental operation

The Portable Robot CMM Arm of this first embodiment is capable of operating in a temperature range of -10 to +50 degrees Celsius. One can imagine surveying applications like gas pipelines in Alaska and Egyptian tombs where the Robot CMM Arm 1 is operating outside in conditions ranging from freezing to direct sunlight. The Robot CMM Arm has an environmental sealing level IP62 and is not affected by the weather. Alternative embodiments of the Robot CMM Arm could be protected to IP64 level or even have dedicated protection for special applications where the environment is very harsh eg in radioactive areas. The Portable Robot CMM Arm 1 can also typically operate in up to 90% humidity.

Robot CMM Arm Coordinate System

Referring now to FIG. 39 , there are a number of coordinate systems 360 used by the Robot CMM Arm System 150 . These include but are not limited to:

- Object coordinate system 361

- Object Feature Coordinate System 362

-Robot CMM Arm Coordinate System 363

- probe (or tool) coordinate system 364

- exoskeleton coordinate system 366

The object coordinate system 361 is not known unless there is a datum feature on the object 9 such as a tool ball 368 or a datum plate on which the object 9 is mounted, which can be used to provide the object 9 with an object coordinate system 361 . It is most common in the automotive industry to provide an automotive linear object coordinate system 361 . Object feature coordinate system 362 is provided for feature 365 . Typically, objects are manufactured with reference marks for object characteristic coordinate system 365 , which can be measured to determine object characteristic coordinate system 365 . In this first embodiment, the Robot CMM Arm coordinate system 363, also known as the Internal CMM Arm coordinate system, and the Exoskeleton coordinate system 366 are the same because the Internal CMM Arm Base 31 and the Exoskeleton Base 41 are rigidly connected. In a repeatable magnetic mount 369 at the base 4 a reference ball 367 with a diameter of 25 mm is provided. The center of datum sphere 367 is designated as the zero point of Robot CMM Arm coordinate system 363 and Exoskeleton coordinate system 366 . When the Exoskeleton has an Exoskeleton Base 41 different from the Internal CMM Arm Base 31, especially if there is relative motion between the Exoskeleton Base 41 and the Internal CMM Arm Base 31, the Exoskeleton Coordinate System 366 is different from Robot CMM Arm Coordinate Frame 363; in this case a second reference sphere 367 is provided. As is generally understood in the field of robotics, different coordinate systems are provided for the probe 90 or the tool 98 fixed on the probe tip 3 of the Robot CMM Arm 1 . It is called the Robot CMM Arm Probe Frame 364 .

Control PCB

Referring now to FIG. 40 , the Control PCB 172 controls the Robot CMM Arm 1 . External connectors 156 , 157 , 194 , 195 , 197 - 199 are mounted on control PCB 172 and connect directly to the side of control box 159 . Interfacing with the arm is accomplished through amplifier analog output circuit 383 , trigger circuit 384 , firewire bus controller 385 , Ethernet bus controller 386 and WiFi radio 387 . DSP processor 380 runs control software 382 in memory 381 . Control software has access to kinematics software 391 and position averaging software 392 in memory 381 . The program 389 in text format is translated by an interpreter 390 . A Robot CMM Arm Internet Protocol (IP) address 388 is stored in memory 381 . Probe alignment file 264 is stored in memory 391 . Memory 381 consists of sufficient static and dynamic memory.

Connector PCB

Referring now to FIG. 41A and again to FIG. 11 , connector PCB 173 has the following functions:

- interconnect many local devices 177-184, 90, buses 169, 174, 161, 162 and power lines 165, 166, 160 all with each other via connector 400

- Responses to trigger signal on trigger bus 174 via latch encoder 178

- Receive data from multiple sensors 178-184, preprocess data, maintain data status such as encoder counts and send preprocessed data via serial bus 169 to control PCB 172

- Respond to status requests from the control PCB172

Splice PCB 173 includes DSP processor 401 , memory 402 , splice software 405 stored in memory 402 , trigger circuit 384 , firewire bus controller 385 and encoder interface circuit 403 connected to the output of Renishaw interposer 187 . The interpolated signal from Renishaw interpolator 187 is stored in memory 402 . In the single mode of operation for determining the position of the Robot CMM Arm 1, when the encoder 178 is latched, an angular position count 402 is sent from each joint PCB 173 to the control PCB 172, and using method, these counts 402 are used by the kinematics software 391 to calculate the position of the Robot CMM Arm 1 .

position average

Referring now to FIG. 41B , in the preferred mode of operation for determining the position of the Robot CMM Arm 1 , an encoder clock 406 is provided on the connector PCB 173 . An encoder clock 406 is used to time-stamp each encoder count 404 as it arrives at connector PCB 173 . Preferably, twenty encoder counts 404 are stored in memory 402 in a first-in-first-out (FIFO) fashion, but more or fewer than 20 FIFO counts may be stored. The encoder clock 406 is used to time stamp the trigger pulse TR when it arrives on the connector PCB 173 on the trigger bus. Referring now to FIG. 41C, counts 404 are plotted against time t on a graph. Each count Cn-9 to Cn+10 is recorded, resulting in 20 time-stamped counts in memory. Just after Cn, connector PCB 173 receives a trigger pulse TR requesting the encoder position. Trigger pulses are time stamped by the encoder clock 406 as they arrive. Header PCB 173 sends the 20 time-stamped counts Cnx and the time of receipt of trigger TR along serial bus 169 to control PCB 172 . Referring now to the position averaging process of Figure 41D:

- In a first step 440, the position averaging software 392 in the control PCB 172 receives from each connector PCB 173 a set of twenty time-stamped counts from the encoder 178 input by the trigger pulse TR and receives at the encoder The time of the trigger pulse TR;

- In a second step 441, the position averaging software 392 fits a spline in the time domain through the twenty counts of each encoder, resulting in seven splines for the seven CMM encoders 178;

- In a third step 442, the position averaging software 392 interpolates a count at time TR for each CMM encoder 178;

- In a fourth step 443, the seven interpolated counts are sent to the kinematics software 391, from which the position of the Robot CMM Arm 1 is determined.

The position averaging method is one method for improving the Robot CMM Arm accuracy by averaging and interpolating the precise position at the time of the trigger pulse TR. The present invention is not limited to this position averaging method, but includes all methods that can more accurately determine the position of the Robot CMM Arm by acquiring and processing more raw position data around the time of the trigger pulse. The location of the processing is not critical and can be performed at one or more processing locations including, for example, the encoder 178, the connector PCB 173, the control PCB 172, and the laptop 151. Using position averaging means that the position of the Robot CMM Arm 1 is more accurately determined than a simple encoder operation.

thermal compensation

It is an object of the present invention to provide a Robot CMM Arm that is thermally compensated and does not require recalibration when the temperature of the Robot CMM Arm changes. Thermocouples 180 are bonded to the aluminum of each of the housings 100 , 101 , 103 by the inner CMM arm 5 . CMM segments 1-8 31-38 are designed using finite element software to expand/contract linearly with temperature without twisting. Similarly, CMM segments 1-8 31-38 are fabricated using well-known methods and materials that do not create stresses that could cause distortion with temperature changes. Aluminum expands at a well known rate with temperature. The thermocouple 180 is read every 10 seconds via the connector PCB and the temperature is sent along the serial bus 169 to the control PCB 172 . Some parameters in the 45 parameter motion model of the Internal CMM Arm are then adjusted in proportion to the temperature changes measured by the thermocouples 180 in each enclosure, in the manner predicted by the finite element thermal model. When extreme temperatures are encountered, such as in Alaska or the desert, it is recommended to perform contact or non-contact probe calibration before using the Robot CMM Arm.

Monitoring force and torque

During measurements, the Internal CMM Arm 5 is subject to forces and torques. Referring now to FIG. 41E, strain gauges 181 mounted on CMM Segments 1-8 31-38 continuously sense strain on the Internal CMM Arm 5. Three strain gauges 181 are mounted orthogonally on each CMM segment 1-8 31-38. The strain gauge 181 is connected to the connector PCB173. The connector PCB 173 sends the value read from each strain gauge 181 to the control PCB 172 five times per second. The strain value can be sent more or less than 5 times per second. During assembly, after each Robot CMM Arm is fabricated, a series of strain gauge test programs are run and the values output from each strain gauge are monitored during program execution. Some test procedures are designed to overstrain the internal CMM arm 5; one method used is to move the arm rapidly while the heavy duty probe 90 is mounted on the CMM section 838. In this way, strain gauge 181 is calibrated with maximum acceptable compressive and tensile strains. In normal use, the strain from all strain gauges 181 is monitored 5 times per second and action is taken if the maximum acceptable strain is exceeded. Actions include: generating error messages to the operator, automatically repeating certain measurements at a slower rate to reduce strain levels, recording unacceptable strain and the conditions under which it occurred. In an alternative embodiment, strain gauges 181 may be placed in the bearings of the CMM Joint 1-7 51-57 to measure specific bending strains. These bearing strain gauges 181 can be used in addition to or instead of the strain gauges 181 on the CMM sections 1-8 31-38. To improve the reliability of strain measurements, multiple strain gauges are provided for each direction and the results are processed using comparison and or averaging methods. The scope of the invention is not limited to a particular number of strain gauges placed at a particular location. The present invention includes providing any strain, pressure torque or any other measurement device anywhere in the Robot CMM Arm 1 where force and torque feedback can be provided to the Control PCB 172 .

time selection

Measurements can be taken while busy or when the Robot CMM Arm is stationary. Precise timing between the Control PCB 172 in the Measurement Robot CMM Arm 1 and the Optical Probe 91 is important to maintain high accuracy when taking measurements on the go. Two methods of ensuring accurate timing between the control PCB 172 and the optical probe 91 are preferably calibration and time stamping methods. The scope of the present invention is not limited to these two methods, but includes any method that can guarantee precise timing between the Control PCB 172 and the Optical Probe 91 in the Control Robot CMM Arm 1 .

calibration

The calibration method is characterized by a pair of calibration measurements, the first being the probe measurement and the second being the position of the Internal CMM Arm 5 . Referring now to the process of Figure 42, when the data from the control PCB 172 and the optical probe 91 are calibrated, the optical probe 91 is preferably the primary and the control PCB 172 the secondary. In a first step, step 410 , the optical probe 91 sends calibration signals to the seven connector PCBs 173 via the trigger bus 174 . The calibration signal travels quickly through the trigger bus with a latency of less than 1 microsecond. In step 411 , the probe measurements and location data are sent to the laptop 151 . Connector PCB173 sends encoder data to control PCB172. The control PCB 172 combines the seven encoder positions, calculates the position of the Internal CMM Arm 5 at the probe tip and sends the position to the laptop 151 . The probe 91 sends the probe measurements to the laptop 151 . In step 412, the laptop 151 combines the probe measurements with the position of the Internal CMM Arm 5 to provide the measurements. This approach comes into play when the calibration signal has a delay longer than 1 microsecond to travel from the optical probe 91 to the connector PCB 173, such that the calibration method and apparatus have the technical effect of taking the probe measurements and encoder positions so that they can be combined to produce precise measurements. Referring now to Figures 43A-C, the optical probe 91 is primary and the control PCB 172 is secondary. Referring now to FIG. 43A, in order to make a measurement, two conditions must be met for an effective optical probe 91: light must be projected and the sensor shutter must be open to collect the light. In the mode of Fig. 43A, measurements are taken when the laser is on. The calibration signal should be sent from the optical probe 91 to the control PCB 172 at time T, which is the midpoint of the measurement period P. In this first embodiment, upon receipt of the calibration signal at time T, the Robot CMM Arm 1 can latch the encoder within a repeatable time, ie less than 1 microsecond. Referring now to Figure 43B, the measurement period P is from shutter open to laser off. Referring now to FIG. 43C, the measurement period P is the time the shutter is open.

When the control PCB 172 is the master and the optical probe 91 is the slave, the calibration can be performed in the second synchronous manner. An example of such a calibration is when the scan pattern is to take measurements at regular arm increments and is dominated by the control PCB 172 . Referring now to FIG. 44 , a calibration signal arrives at time T from the control PCB 172 to the optical probe 91 . It is preferred that both the laser turn-on and the shutter opening occur within a short period of time after T. In other cases, a laser determines the measurement period P or a combination of a shutter and a laser determines the measurement period P. It is important that, according to this second calibration mode, the delay t is known and repeatable for all measurements in order to maximize the accuracy of the Robot CMM Arm 1 when scanning on the go. In some optical probes 91 the delay t is varied by the optical probe 91 between different measurements. In this case, the optical probe 91 communicates the change in the value of delay t over the serial bus 169 before receiving the next calibration signal. Referring now to the process of FIG. 45 , in a first step 413 the optical probe 91 sends to the control PCB 172 a change in the value of delay t. Step 413 is only executed when the delay t is changed. In step 414 , the control PCB 172 sends a probe calibration signal to the optical probe 91 at time T. In step 415, the control PCB 172 sends an encoder calibration signal to the seven connector PCBs 173 at time T+t. The control PCB uses something like an internal clock to determine the correct timing to send the encoder calibration signal after the probe calibration signal. Where the probe 90 is a multi-stripe probe such as the two-stripe probe 308 with two fringes 305, 306, then measurements from the fringes can be made simultaneously with all fringes illuminated simultaneously or separately illuminated one fringe at a time , or to illuminate groups of stripes at a time. In any event, if the Probe 90 is moving on the Robot CMM Arm when the stripes are illuminated at different times, the Robot CMM Arm will be in a different position when each stripe is illuminated, and each stripe will be a separate Calibration method. It is an object of the present invention to use the first calibration mode in which the control PCB 172 is the primary and the probe 90 the secondary, and in the second calibration mode in which the probe 90 is the primary and the control PCB 172 the secondary.

Timestamping and Interpolation

Sometimes it is not possible to accurately calibrate the optical probe 91 and the control PCB 172 to produce a pair of measurements. For example, calibration is not possible if no means are provided for sending or receiving calibration signals. In the time stamping scheme, there are two cases: (i) the optical probe 91 and the control PCB 172 have the same measurement rate (ii) the optical probe 91 and the control PCB 172 have different and or variable measurement rates.

In case (i) the measurements are performed in pairs. It is important that the velocity measurements of the optical probe 91 and the control PCB 172 measure the velocity accurately and not drift over time. The two clocks in the optical probe 91 and the control PCB 172 run exactly so that they show the same time at the start and end of the scan. The optical probe 91 and the control PCB 172 take measurements at the same rate so that there is always the same time interval I between two adjacent optical measurements and two adjacent position measurements. Typical rates range from 25 measurements per second to 1000 measurements per second, but it can be greater than 1000 or lower than 25. In case (ii), measurements are streamed from the optical probe 91 at regular or irregular intervals, and from the control PCB 172 at the same or different regular or irregular intervals.

Referring now to the process of Figure 46, the same process is used for both cases (i) and (ii).

- In a first step 416, the two clocks in the scanning optical probe 91 and the control PCB 172 are aligned as close as possible, just before starting the scan;

- In step 417, the measurement is started by controlling the PCB 172 to request the optical probe 91 to start scanning;

- In step 418, the position data is acquired by the control PCB 172; using the clock in the control PCB 172, each position is time stamped. Obtain the measurement results in the optical probe 91; use the clock in the optical probe 91 to time stamp each position;

- In step 419, the Robot CMM Arm scanning procedure stops and asks the optical probe 91 to stop scanning;

- in step 420, the two clocks in the optical probe 91 and the control PCB 172 are checked against each other;

- In step 421, the control PCB 172 outputs a file of time-stamped locations. The optical probe 91 outputs a file of time-stamped measurements;

- In step 422, a combined measurement file is calculated by interpolating the control PCB 172 position to provide the best estimate of the position of the Internal CMM Arm 5 corresponding to each optical probe measurement. Each Internal CMM Arm 5 position contains the X, Y, Z position of the Probe Tip 3 and the I, J, K orientation vectors. Interpolation of the Internal CMM Arm 5 position is performed by fitting a three-dimensional polyline through the Internal CMM Arm 5 position and interpolating along the three-dimensional polyline proportional to the time stamp timing difference.

The scope of the present invention is not limited to the process of performing time stamping and interpolation in FIG. 46, but includes any process involving time stamping and interpolation that can achieve the same technical effect. For example, where it is not possible to accurately calibrate the optical probe 91 and control the two clocks in the PCB 172, then a method involving first scanning for known artefacts is used. Referring now to FIG. 47 , a ridged artifact 370 with two planes meeting at 90 degrees is positioned such that the ridge is approximately parallel to the laser stripe 287 . Two access paths are formed above the ridge artefact 370 by the optical probe 91 mounted on the Robot CMM Arm. The first passage 371 is along the +X axis direction and the second passage 372 is along the −X axis direction. The probe measurements and arm positions in the two time-stamped files are combined using an estimate of the calibration between the two clocks. Referring now to Fig. 48, when two paths 371, 372 are compared, an error E is calculated as a distance in the X-axis direction. The error E is used to accurately determine the difference that exists in the calibration of the two clocks. This difference is then used as a correction factor to estimate the alignment between the two clocks in order to provide an accurate alignment between the two clocks when the object 9 is subsequently measured.

sync pulse flag

There are ambiguities in the calibration of the Robot CMM Arm System 150 that can be resolved by a novel method of real-time sync pulse flagging. In some cases, one or more measurements from one or more devices are lost due to disturbances in the operation of the system, which creates ambiguity in accurately putting together synchronized measurements from multiple sources, This can lead to undesirable system conditions which either lose more data or provide incorrect calibration data. In other cases, there may be ambiguity as to the source of the calibration signal. It is an object of the present invention to add a calibration flag to each sync pulse from a calibration signaling device comprising (i) incrementing an integer with each successive calibration signal from a calibration signaling device; optionally (ii) The calibration signal emits a unique identification code for the device; optionally (iii) a time stamp. All systems require an incremental integer. A typical minimum value for an incremental integer is 0 and a typical maximum value is 255. When the largest integer is reached, then the next incremental integer is the smallest integer. After starting the Robot CMM Arm System 150, the first integer output is zero. The format of the sync pulses and calibration flags can be determined by anyone of ordinary skill in the art to which this invention pertains. For example, the sync pulse is a rising pulse with a pulse width of 10 microseconds, while the total flag calibration flag is 15 bits long, with each bit represented by the presence or absence of a 10 microsecond pulse. The calibration flag is encoded with checksum bits. A unique device identification code for each calibration signaling device is only required if there may be ambiguity between calibration signals from multiple calibration signaling devices. Time stamping is an option available to system developers to calibrate clock times between devices by toggling the bus (174), and it can be used for other purposes. There are a number of calibration signaling devices connected to the trigger bus (174) that can emit a calibration signal with a calibration flag, including but not limited to one or more of each of the following:

Optical probe (91) Manually operated button (183)

Quantity measuring probe(90) Remote control(351)

Contact Trigger Probe(92) Control PCB(172)

Pressure probe in scan mode (99) External control device

There is also one or more calibration signal receiving devices connected to the trigger bus (174), which can receive calibration signals with calibration marks, including but not limited to one or more of each of the following:

Optical Probe(91) Control PCB(172)

Quantity measuring probe (90) External control device

Connector PCB(173)

There is at least one collation device, which may also be a combining device in order to collate and combine measurement data from two or more devices. The calibration device can be an independent device or can be a part of the calibration signal sending device or the calibration signal receiving device.

A novel sync pulse marking method for marking sync pulses is disclosed. In a first step, the calibration signaling device emits a synchronization pulse on the trigger bus followed by a calibration flag comprising (i) a calibration signaling device increment integer, optionally (ii) a calibration signaling device identification code , optionally (iii) calibrating the signaling device time stamp. In a second step, the calibration signal receiver receives a trigger pulse on the trigger bus followed by a calibration symbol. In the third step, the calibration signal sending device directly or indirectly sends a calibration signal sending device data packet to the proofreading device on the communication bus, the data at least includes: (i) a code showing that the synchronization pulse has been sent, (ii) Data generated within the sending device, a copy of the calibration flag sent by the calibration signaling device, which contains (iii) the incremental integer of the calibration signaling device, (iv) the calibration signaling device identification code and optionally (iv) the calibration The signal emits a device time stamp. In the fourth step, the calibration signal receiving device directly or indirectly sends a calibration signal receiving device data packet to the calibration device on the communication bus, which at least includes: (i) a code showing that the synchronization pulse has been received, (ii) the received A backup of the calibration flag, (iii) data generated within the calibration signal receiving device in response to the trigger pulse, (iv) the calibration signal receiving device's incremental integer, (v) the calibration signal receiving device identification code, and optionally (vi ) to calibrate the signal receiving device time stamp. In the fifth step, the calibration device receives the calibration signal sending device data packet and the calibration signal receiving device data packet in any order. In the sixth step, when the calibration signal sending device increment integer in the calibration signal sending device data packet and the calibration signal receiving device data packet are the same, the calibration device merges the calibration signal sending device data packet and the calibration signal receiving device data data in the package.

This novel calibration marker and method is not limited to the disclosed embodiments, but includes any method that uses systematically varied markers to avoid ambiguity in calibration. For example, the integer range may be lower than 256 or greater than 256 in alternative embodiments. In another embodiment, flags may be changed in any systematic manner. In this sync pulse marking method, step 3 may occur at the same time or before step 2 or at the same time or before step 4.

Measurement programming

Fast and easy programming of the Robot CMM Arm 1 is very important because in general robots require skilled operators to program them and this is one of the challenges that will make the Robot CMM Arm 1 successful in the market. Robot CMM Arm program 389 is interpreted in real time by interpreter 390 and control software 382 executes the instructions in program 389 . Program 389 can be generated in many different ways. A text editor is provided for the operator 11 to create and edit the Robot CMM Arm program 389 on the laptop 151 . Program 389 can be generated in an off-line programming system such as EMWorkplace from Tecnomatix. The procedure 389 can be guided by the operator 11 using the pendant 153 or the laptop 151 to remotely activate the Robot CMM Arm 1; this means that remote guidance can be done without providing a stand for the operator to access if difficult to access Thereby manually move the Robot CMM Arm.

start check

The Robot CMM Arm 1 is powered by connecting to the mains cable 155 and switching it on using the switch 156 . The control software 382 in the control PCB 172 starts automatically on power up. The first task of the control software 382 is to perform a series of startup checks. It confirms that various aspects of hardware and software that can be checked within the Robot CMM Arm are operating correctly. The connector software 405 in the connector PCB 173 starts automatically at power-up. The first task of the connector software 405 is to perform a series of startup checks. It confirms that all aspects of hardware and software that can be checked connected to connector PCB 173 are operating correctly. The pendant software 330 in the pendant 153 starts automatically at power-up under the control of the pendant operating system 326 . The first task of the suspension software 330 is to perform a series of startup checks. It confirms that all aspects of the hardware and software that can be checked in the suspension 153 are operating correctly. After checking the hardware directly connected to the control PCB 172 , the control software 382 checks the seven remote connector PCBs 173 by requesting a status report on the serial bus 169 from each remote connector PCB. The Control Software 382 then requests a status report from any Probe 90 that may be mounted on the Robot CMM Arm 1 via the Serial Bus 169 . When the internal startup checks are complete, the control software 382 attempts to communicate with devices including the foot switch 350, the remote 351, the pendant 153 and the laptop 151 via the external bus. When all start-up checks are complete, the control software 382 in the control PCB 172 waits for instructions. Those of ordinary skill in the art to which the present invention pertains will understand that the start-up checks can be performed in many different orders and can take a short or long time, however, having the operator 11 wait for more than a few hours while the start-up check procedure is in progress seconds is undesirable.

refer to

Ideally the Robot CMM Arm always knows its joint angle. This can be achieved by using absolute encoders and interrogating them through connector PCB173 at start-up. When using an incremental encoder, it is desirable to maintain power through the battery 170 . However, if the control PCB 172 does not know the joint angle, then reference processing is required. After first checking that it is safe to do so, the operator 11 initiates the automatic reference process. During fiducial processing, each joint is rotated until a fiducial position is reached.

calibration

Automated Calibration Methods and Artifacts

There are various methods of calibrating a robot and various methods of calibrating a Manual CMM Arm, known to those skilled in the art to which this invention pertains and referenced in the Background of the Invention. Referring now to Figures 49 and 50, in this first embodiment, a calibration method that automatically measures known calibration artifacts 373 is used. A 45-parameter motion calibration model was adopted for the 7-axis Robot CMM Arm 1 . The Robot CMM Arm 1 is rigidly attached to the surface 7 and measures a calibration artifact 373 which is also rigidly attached to the surface 7 . The calibration artifact 373 comprises a block with four 90 degree cones 375 with a maximum diameter of 6 mm. One of the four cones 375 is positioned higher than the other three approximately coplanar cones 375 . Calibration artifacts 373 are certified and the distances, orientations between the four cones 375 are known accurately. The calibration artefact 373 is rigid and made of Invar, a material with a low coefficient of thermal expansion. Artifact 373 is rigidly attached to surface 7 by means of bolts 376 threaded into surface 7 through holes 374 . In another embodiment, the artefact 373 is rigidly attached to the surface 7 by clamps. The touch probe 92 is a Renishaw touch probe mounted on the Robot CMM Arm 1 . The calibration procedure is started by the operator 11 and executed by the control PCB 172 . It involves taking ninety contact probe measurements on each of the four balls 375 . During the three hundred and sixty contact probe measurements, the joint was exercised as much as possible; this meant measurements were made with various combinations of joint angles. None of the 360 contact probe measurements had the same joint orientation. For each measurement, seven encoder positions are recorded. The 360 sets of encoder positions were used to optimize the 45 parameters of the motion model using the method of least squares, well known to those of ordinary skill in the art to which the invention pertains. This calibration method can be used to align the probe coordinate system 364 of any contact probe 95 with the Robot CMM Arm coordinate system 363, which preferably reduces the number of measurements in order to speed it up; during this contact probe alignment process, the Robot CMM Arm Preferably there is no recalibration, but recalibration is possible. Referring now to FIG. 51A , in another embodiment, an artifact 373 is placed in eight locations proximate to the eight corners of a cube within the measurement volume of the Robot CMM Arm 1 . In each position, the artifact 373 is rigidly mounted relative to the surface 7 and thus the Robot CMM Arm 1 . In each position, 360 measurements are automatically taken. The 45 parameters of this motion model were optimized using the same least squares method with 8 x 360 sets of encoder positions. The calibration process simultaneously calibrates the arm and the contact probe.

calibration axis

One or more separate axes of motion may be provided that move the Robot CMM Arm and the coordinate systems of the calibration artefact relative to each other; these axes may be manually controlled or automatically actuated. They can be linear or rotary. For example, referring now to FIG. 51B , the Robot CMM Arm 1 can be mounted on a servo-controlled rotational axis 377, preferably such that the servo-controlled rotational axis 377 is aligned with the axis of the joint center 121, thereby enabling the Robot CMM Arm to rotate to any angle, Further measurements of the artifact 373 are made at each angular position. The servo-controlled rotational axis 377 must be rigid so as not to introduce errors due to the Robot CMM Arm 1 vibrating on the servo-controlled rotational axis 377 . The provision of a servo-controlled rotary shaft 377 allows the entire auto-calibration process to be automated. This has the advantage that the device is compact and does not require the construction of rigid structures in order to mount the artefacts 373 at different positions in the measurement volume. A manual rotation axis can be provided instead of the servo-controlled rotation axis 377, which has the advantage of simpler system structure and better portability, and is semi-automatic due to the periodic manual reset of the base orientation of the Robot CMM Arm 1.

Calibration throughout the measured volume

The Internal CMM Arm 5 of the Robot CMM Arm 1 is not completely rigid. Under the action of gravity, a long CMM segment in a horizontal spatial orientation will deflect by a certain amount. This deflection cannot be measured by the angle encoder in the Internal CMM Arm 5 and is a source of error. These errors can be measured through a calibration process and the calibration data used to correct for repeatable errors such as deflection under gravity. Another source of error is deflection in the joint bearings. During a good calibration, the Robot CMM Arm 1 takes measurements at a large number of points in the measurement volume, which are then used. The Robot CMM Arm 1 has redundancy in most of the measurement volume, in other words the Robot CMM Arm 1 can be in an infinite number of spatial orientations in order to measure a single position. During a good calibration, for each point in the measurement volume, the Robot CMM Arm 1 is put into a number of spatial orientations. The reason is that the more points measured, the more spatial orientations of the Robot CMM Arm 1 measured at each point, the better the calibration process. By providing an auto-calibration axis that moves the coordinate systems of the Robot CMM Arm and the calibration artefact relative to each other, it allows a large number of points to be measured with an automated process. This means that the Robot CMM Arm 1 will be more accurate due to having a better calibration process.

The scope of the present invention is not limited to the disclosed auto-calibration method. For example, the scope of the present invention includes any automatic, partially automatic or manual calibration method. Any contact or non-contact probe 90 may be used. This method can be non-portable and performed at the Robot CMM Arm manufacturing site or at a service center; alternatively, the method can be portable, advantageously enabling the Robot CMM Arm to be recalibrated in the field. Any number, type, position, or degree of automation of axis motion may provide relative motion between Robot CMM Arm 1 and Calibration Artifact 373 . There may be any number of calibration artifacts 373 . The calibration artefact 373 may be mounted on a post having a fixed height or adjustable in any of height, orientation and position such that the calibration artefact 373 is rigid when contacted by the probe 90 . Each one or more calibration artifacts 373 may be measured by contact probe 90 or without contact with non-contact probe 90 . Methods that do not require artifacts can be used. The scope of the invention includes any method that achieves the technical effect of an accurate and automatic calibration of the Robot CMM Arm 1 .

Alignment of Optical Probes

There are various methods of aligning the coordinate system of the Manual CMM Arm with the probe coordinate system 364 of the optical probe 91, known to those of ordinary skill in the art to which this invention pertains and referenced in the Background of the Invention. A preferred way of aligning the coordinate system 363 of the Robot CMM Arm 1 with the coordinate system 364 of the Optical Probe 91 utilizes the Optical Probe 91 mounted on the Robot CMM Arm 1 to scan the ball from a number of different probe directions and orientations. The ball is preferably 25mm in diameter, certified and has a matte surface finish; such balls are supplied by Renishaw. In the case of using the fringe probe 97, then five fringe probe directions are used: +X, -X, +Y, -Y, -Z directions in the Robot CMM Arm coordinate system 363 . For each direction, the ball is scanned by the fringe probe 97 in 45 degree increments in the orientation of the fringe plane 280, resulting in 8 localizations from each direction. At each of the 40 orientation/positioning combinations, with +X and -X in the probe coordinate system 364, a forward +X scan pass and a backward -X scan pass are performed. The resulting 80 sets of optical probe measurements and arm positions are processed using least squares methods well known to those of ordinary skill in the art to generate an alignment transformation between the Robot CMM Arm coordinate system 363 and the probe coordinate system 364 matrix. The scope of the present invention is not limited to the disclosed automatic alignment method, but includes any automatic, partially automatic or manual alignment method that can achieve the technical effect of accurately aligning the Robot CMM Arm 1 with the optical probe 91 .

Benchmark the object

It is often the case that the object 9 is referenced prior to the measurement. During the benchmarking process, the transformation matrix between the Robot CMM Arm coordinate system 363 and the object coordinate system 361 is measured. In most cases, datum features such as cones, tool balls and datum surfaces are provided in exact locations on the object 9 . In the case of referencing an object 9 relative to the Robot CMM Arm 1, the operator first specifies which referencing method to use on the laptop 151 or the Robot CMM Arm user interface software on the suspension 154, and the Robot CMM Arm then adopts that method . Common datum methods include: three orthogonal planes; two cones and one plane; three tool spheres. The operator then manually guides the Robot CMM Arm through the sequence of positions required to perform the referencing method, and once the position is reached, the Control PCB 172 applies automated techniques for each measurement.

Feature and Surface Inspection

The Robot CMM Arm is the measuring mechanism. Most but not all measurements performed are for inspection. The Robot CMM Arm is particularly well suited for feature and surface inspection of non-prismatic objects. Typical objects inspected include those made of sheet metal, plastic, or fiberglass and the tools used to make these items. These objects are manufactured, for example, in the automotive, aerospace, electrical appliance and toy industries. Objects are usually made through molding, cutting, bending, stamping processes. Examples of features on objects that can be inspected include: outside corners, square holes, rectangular holes, oval holes, round holes, edge contours, and inside corners. In most cases, a CAD file of the object is available. CAD files specify the exact three-dimensional positioning, orientation, and shape of object surfaces and features. Objects and any tools used to make them can be measured and compared to CAD files. The measurement results can be stored for quality assurance purposes. The object can be measured by contact or non-contact probe 90; the advantage of the non-contact probe is that it does not touch the object. In cases where the CAD file does not exist or has been lost, the master object or tool can be reverse engineered to provide a master CAD file for use in subsequent inspections.

controlling software

Control software 382 includes various manual, semi-automatic and automatic methods of use such as functions and modes. Some of these methods are disclosed below. Those of ordinary skill in the art to which the present invention pertains will understand that there are a number of methods that can be used to use the Robot CMM Arm provided by the Control Software 382, and that the methods disclosed thus are only all of the methods that can be used in using the Robot CMM Arm Instances in . Exemplary methods for controlling the software 382 are listed below:

Continuous Scanning: The kinematics module 391 in the control software 382 controls the motion of the exoskeleton along the path required by the program 389 using control algorithms well known to those of ordinary skill in the art of robotic control; this is the most commonly used method

Step-by-step scanning: the kinematics module 391 in the control software 382 controls the step-by-step movement of the exoskeleton along the path required by the program 389, and stops at the point specified by the program 389

Transitions: Transitions are movements performed during periods when no measurements are taken; the kinematics module 391 in the control software 382 controls the continuous movement of the exoskeleton along the transition path required by the program 389 without monitoring the strain gauges

Training: the kinematics module 391 in the control software 382 acts according to the motion commands received through the pendant 153, headset 340 or laptop 151 directly specified by the operator 11

Thermal monitoring: The control software 382 monitors the thermocouple 180 and adapts the dynamic parameters to its temperature; this has the advantage of keeping the temperature of the Robot CMM Arm within limits under varying environmental conditions while minimizing its impact on duty cycle time the smallest

Strain Detection: Control software 382 monitors strain gauges 181 to check for excess strain values in continuous scan mode

Collision Monitoring: The control software 382 monitors the following errors and if they are excessive, the emergency stoppers are applied and an error message is issued, which can be included via a speaker in the laptop 151 or via the headset 340 audible alarm

Zeroing the Coordinate System: Control Software 382 zeros the Robot CMM Arm Coordinate System 363, which finds its center by measuring the reference sphere 367, preferably with the tactile trigger probe 92, and uses the center of the reference sphere 367 as the Robot CMM Arm coordinates Realized by the zero point of the 363

Datum Reference to Object: Control Software 382 references Robot CMM Arm Coordinate Frame 363 to Object Coordinate Frame 361 by a datum. This function is performed automatically if the control software 382 knows approximately where to take the reference on the object 9 . If the operator 11 first has to teach the Robot CMM Arm where the fiducials are on the object 9, this function is done in a semi-automatic manner.

Feature localization: the control software 382 measures the position of one or more features on the object 9 relative to the object coordinate system 361

Dimension measurement: the control software 382 measures the dimensions of one or more features on the object 9; those of ordinary skill in the art to which this invention pertains will appreciate that a range of functions are provided to measure various types of dimensions

Surface measurement: the control software 382 measures all or part of the surface of the object 9

Software reference: the control software 382 checks the measured surface data of the object with the CAD model of the object 9 through the least squares fitting method

Error generation: the control software 382 compares the measured data of the object surface with the CAD model of the object 9 and generates individual errors and error maps

Report Generation: The control software 382 automatically generates a report and/or pass/fail data regarding deviations of the measured data on the surface of the object 9 from the CAD model of the object

Statistical Trending: The control software 382 compiles statistical trending information regarding the position of one or more features on the object 9 relative to the object coordinate system 361, the size of the one or more features on the object, and the size of the object's surface The deviation of the measured data from the CAD model of the object.

Method for Robot CMM Arm Measurements

Referring now to FIG. 52 , in a first step 431 , the control PCB 172 outputs a signal to at least one amplifier 175 which causes at least one motor 176 to output torque. In step 432, the motor driver applies torque to at least one exoskeleton segment 42-48. In step 433, at least one actuator 72-78 is compressed from at least one exoskeleton segment 42-48. In step 434, at least one actuator 72-78 applies a force to at least one CMM segment 32-38 at a location proximate to the center of gravity of the CMM segment 32-38. In step 435, the probe 90 measures data. In step 436 , the control PCB 172 receives the encoder data from the connector PCB 173 . In step 437 , the control PCB 172 receives measurement data from the probe 90 . In a method for calibrating a Robot CMM Arm measurement, in a further step the probe 90 sends a calibration signal. In the method used for time-stamped Robot CMM Arm measurements, probe measurements and positions are time-stamped.

Robot CMM Arm Advantages

It is an object of the present invention that the Robot CMM Arm disclosed herein can reach longer and operate more accurately than an equivalent Manual CMM Arm. First, the reach of the Robot CMM Arm can be longer than 2 meters because it is supported by an exoskeleton rather than an operator who cannot handle it. Second, the Exoskeleton supports the Internal CMM Arm at an optimal location to minimize the forces acting on it. Third, the Internal CMM Arm uses larger diameter encoders with increased resolution and accuracy, which may be inconvenient for the operator to handle. The combination of these three factors results in a Robotic CMM Arm with a longer reach and more accurate operation than a Manual CMM Arm. This means that a Robotic CMM Arm can offer its owner more utility than a Manual CMM Arm in the long-term trend of users demanding increased precision.

A feature of the invention is that it weighs less than existing robots. Typical weights range from 5kg to 35kg, depending on the reach of the arm. This means that the smaller and intermediate size versions of the Robot CMM Arm invention are light enough to be portable. The Portable Robot CMM Arm of this first embodiment comprises a single compact unit; it can be transported by one person in a simple housing with wheels. The possibility to use a gantry means that the Robot CMM Arm does not need to be bolted to the ground like the robot does; this means that the Robot CMM Arm can be moved from one location to another very quickly.

applicability

The Robot CMM Arm combines the precision benefits of a CMM Arm with the flexibility and automation of a robot. This means that it is the preferred device for solving a large number of intermediate precision measurement tasks for which existing solutions are disadvantaged in terms of one or more of accuracy, flexibility and automation. The robot CMM arm invention has both automation and accuracy. It is suitable for the various requirements of the automotive industry for measurement. It is light in weight and relatively inexpensive to manufacture. Robotic CMM Arm automated measurements work more reliably than manual operation of a Manual CMM Arm due to inaccurate measurements caused by an operator not applying forces and torques. On a production line, a Robotic CMM Arm reduces operating costs compared to a human operating a manual CMM Arm, especially when working in 2 or 3 shifts. It is anticipated that the present invention will be used as a general purpose measurement tool for a number of applications similar to the general purpose of conventional CNC CMMs.

There are two broad measurement applications: reverse engineering and inspection. This Robot CMM Arm invention is applicable to both, but will see more adoption in inspection applications as reverse engineering is less common than regular inspection. The following applications of the use of the present invention are listed by way of example. Applications of the present invention are not limited to those listed below.

Check application

-Gap and flush measurement for car hood doors

- Inspection of dimensional tolerances

- River bed analysis

- VR simulation

- Processing inspection

-Prototype design

- Development of foam

- Body inspection on the production line

- Seat inspection on the seat production line

- Scene car interior

- Remove engine parts with site

-Turbine blades

- Housing and ventilation hood

- Gas tank inspection

- Glass quality analysis

- Internal trimming

- Prototype assembly of the car; verifying that the panels have been manually placed in the correct position

-press mold

- Scanning of bridge brackets

- Sheet Metal Parts: Features

- Sheet metal parts: surface shape

-External pipe corrosion measurement and pipe thickness measurement

reverse engineering design

- Used for spare military parts whose drawings have been lost

- Clay car shape design model for car design

- Industrial Design Model

- surface reconstruction

- Models of characters or props used in film/broadcast, video game cartoon production

- Precious works of art such as large sculptures, statues and artefacts for archiving, research, reproduction and conservation

- Rapid prototyping

- Manual measurement of time-consuming and labor-intensive complex objects

medical

-Breast reconstruction

-neurosurgery

- radiation therapy

- robotic surgery

other

- Tactile toys for play

-Research

-train

The unit of several Robot CMM Arms is an advanced device compared to the existing rigid structure of a stationary optical probe on an automotive line. The Robot CMM Arm is more flexible for dynamic reprogramming for different end-of-line car models. For optical scanning of single-use objects, the Robot CMM Arm removes strenuous human effort from the operator and maximizes dimensional accuracy by minimizing forces on the internal CMM Arm. For applications involving inaccessible objects, the gantry is often built so that the operator measures the object with a manual CMM arm; often the operator is in an awkward position, which is both unsafe and can cause back tension. Applying the Robot CMM Arm invention will mean that measurements can be manually controlled using a hand-held control panel. This means that no benches need to be built and operators do not need to go into inconvenient, dangerous and unhealthy locations to take measurements.

second embodiment

Industrial Robot CMM Arm

In this second embodiment, the disclosed Industrial Robot CMM Arm is used to provide accurate robot motion. In this second embodiment, a seven-axis industrial robot CMM arm with a common base section and a common probe section 8 is provided. The common probe section can carry heavy probes or tools and is subject to significant forces while providing precise position information. The industrial robot CMM arm is not only more reproducible than existing industrial robots, but also about 10 times more accurate. Referring now to FIG. 53, the Industrial Robot CMM Arm 450 has a common base 4 comprising a CMM segment 31, a transmission 171 and a robot exoskeleton segment 141. The Industrial Robot CMM Arm 450 also has a Common Probe Section 8 451 that includes a CMM Section 838, Gearing 878, and Exoskeleton Section 848. In fact, it provides a rigid transmission 878. The CMM section 2-7 32-37 of the CMM arm of the industrial robot 450 is connected to the exoskeleton section 2-7 42-47 through the transmission device 2-7 72-77. The transmission 2-7 72-77 is preferably not as rigid as disclosed in the first embodiment. The main difference between the portable robot CMM arm 1 of the first embodiment and the industrial robot CMM arm 450 of the second embodiment is that the transmission device 878 of the portable robot CMM arm 1 is not rigid and the transmission device 878 of the industrial robot CMM arm 450 for rigidity. Referring now to FIG. 54 , in another embodiment of this second embodiment, an Industrial Robot CMM Arm 450 has two probes 90 and 91 . It is provided in a hybrid six/seven axis format where probe 90 is positioned using 6 axes of rotation and probe 91 is positioned using 7 axes of rotation. CMM segments 7/8 37/38 are rigid bodies without joints inside. The probe 90 is an axially symmetrical probe such as a solid probe or a trigger probe, and its measurement action has nothing to do with the radial direction of the action. This means that for the probe 90 to be operable, there is no need for the last joint preceding it to be an axial swivel joint. Probe 90 has six CMM Connectors 1-6 51-56 between it and Base End 2 of Industrial Robot CMM Arm 450. The optical probe 91 is rigidly attached to the exoskeleton segment 848 behind the exoskeleton joint 767. The optical probe 91 is preferably a stripe probe 97 . The measuring action of the probe 91 depends on both its orientation relative to the arm and the radial direction of the movement. This means that for the probe 91 to be easily manipulated, it is necessary that the last joint before it be an axial swivel joint. The optical probe 91 has seven exoskeleton joints 1-7 61-67 between it and the base end 2. Exoskeleton bearings 452 located between CMM Segment 7/8 and Exoskeleton Segment 8 48 allow for axial rotation. The probe 91 mounted on the exoskeleton segment 848 rotates on a seventh axis about the centerline 453 of the single CMM segment 7/837/38, which is driven by the motor 176. Exoskeleton bearings 452 serve as rigid transmissions 78 to transmit forces axially along centerline 453, radial forces perpendicular to centerline 453, and moments across the bearing in any non-rotational direction.

Those of ordinary skill in the art of the present invention will understand that, in addition to the situation described in this second embodiment, the second embodiment of the industrial robot CMM arm 450 can be provided in various other embodiments, and they all have the present invention. With the same technical effect of the invention, the scope of the second embodiment of the industrial robot CMM arm 450 is not limited to the above-disclosed embodiments. For example the present second embodiment could be provided in a six-axis format similar to FIG. 1A , but with a common probe section 8 . In the case of the embodiment of FIG. 54 , this second embodiment may be provided in a hybrid five-axis/six-axis format similar to FIG. 1A , but with exoskeleton bearings 452 .

Robustness and Materials

The Exoskeleton 6 of the Industrial Robot CMM Arm 450 is rigid, strong and strong. It is designed for high accelerations and positioned with high reproducibility. In a complex environment such as a car assembly line, industrial robots will accidentally collide with car bodies from time to time. Industrial robots are constructed to survive such collisions with damage to the body. The Exoskeleton 6 of the Industrial Robot CMM Arm 450 is capable of withstanding a collision with a body on an automotive production line without being replaced or undergone significant repair. The materials used for the exoskeleton 6 of the Industrial Robot CMM Arm 450 are similar to those used by industrial robots on a car production line. Aluminum castings are used for most segments. Compared to the Portable Robot CMM Arm 1, the drive train power of the Industrial Robot CMM Arm 450 is higher in order to drive the higher mass Exoskeleton 6 and perform the higher accelerations required by the application. The Internal CMM Arm 5 of the Industrial Robot CMM Arm 450 is constructed in a similar manner as the Internal CMM Arm 5 of the Portable Robot CMM Arm 1 .

thermal environment

It is an objective of this second embodiment that the Industrial Robot CMM Arm 450 operate accurately from the moment it is switched on and over a wide range of static and dynamic thermal conditions. The Industrial Robot CMM Arm 450 will be put into a production environment. If the temperature is fully controlled, the temperature of this production environment is not exactly controlled. The temperature can vary by large changes over 15C and in steeper temperature gradients over 5C per hour. Additionally, the drive train of the Industrial Robot CMM Arm 450 generates considerable heat. The Industrial Robot CMM Arm 450 takes about 1 hour to warm up and reach thermal stability. Looking back at Figure 13, the air 192 flow rate will be much higher than the air flow rate used by the portable robot CMM arm 1; the filter 191 will be larger in order to accommodate the higher air 192 flow rate and be able to better clean the dirty air 192 from the production environment . In a separate embodiment, the air 192 can be recirculated internally and a combined heat exchanger and cooling means is provided in the base to cool it down; this prevents dust from entering the gap between the exoskeleton 6 and the internal CMM arm 5 . Air 192 circulation will remove hot spots on the Internal CMM Arm 5 during the warm-up cycle and continuous operation. Therefore, the Internal CMM Arm 5 of the Industrial Robot CMM Arm 450 can maintain its accuracy in this thermal environment. This means that from the moment it is switched on, the Industrial Robot CMM Arm 450 maintains high accuracy consistently throughout the warm-up cycle, under light and heavy cycles, and at all static and dynamic temperatures encountered in a typical production environment .

application

As discussed in the background of the invention, industrial robots are repeatable but not accurate; this means that there are many possible applications of industrial robots that require a level of precision that is currently not achieved because industrial robots are not accurate enough. The Industrial Robot CMM Arm 450 is accurate enough, repeatable enough, and robust enough to meet the requirements of many of these applications. Another purpose of this second embodiment is that the industrial robot CMM arm 450 can have both the probe 90 and the tool 98 installed on the common probe section 8451. This means that a dual use cycle is provided wherein the Industrial Robot CMM Arm 450 works with the tool 98 and takes measurements with the probe 90 during the cycle. Another purpose of the first embodiment is that the Portable Robot CMM Arm 1 has a Tool 98 mounted on the Exoskeleton 6 and a Probe 90 mounted on the Internal CMM Arm 5 . This means that a dual use cycle is provided wherein the Portable Robot CMM Arm 1 is working with the tool 98 and taking measurements with the probe 90 during the cycle. This means that at a workstation, the Robot CMM Arm can perform a task and measure the results of said task, or perform a task in one location and take a measurement in another. It also means that the robotic accuracy of performing tasks with the tool 98 has increased by an order of magnitude compared to before. The Exoskeleton 6 of the Industrial Robot CMM Arm 450 is powerful enough to manipulate the tools required for the application. It is rigid and has high reproducibility. It has a powerful drive system that allows for greater acceleration. The Industrial Robot CMM Arm 450 of the present invention has design specifications similar to existing ranges of industrial robots, except that it is about 10 to 100 times more accurate than industrial robots. The Internal CMM Arm 5 of the Industrial Robot CMM Arm 450 is similar to the Internal CMM of the first embodiment, except that it can withstand greater accelerations acting on it through the transmission 10 located between the Exoskeleton 6 and the Internal CMM Arm 7 arm 5.

global coordinate system

When two or more Industrial Robot CMM Arms 450 are working together on a common object 9, it is useful to provide a global coordinate system 461 to which the Robot CMM Arm coordinate system 363 can refer. One way of providing such a global coordinate system is by providing a global coordinate system artifact. Referring now to FIG. 55 , four Industrial Robot CMM Arms 450 are located in a cell 454 on a production line 455 . A global coordinate system artifact 456 is provided comprising two sets of three survey spheres 459 on a rigid artifact structure 460 with a global coordinate system reference point 458 for a global coordinate system 461 . The reach 457 and position of each Industrial Robot CMM Arm 450 is such that each Industrial Robot CMM Arm 450 can measure at least one set of three measurement spheres 459 to position its Robot CMM Arm coordinate system 363 relative to the global coordinate system 461 . The scope of the invention is not limited to providing global coordinate system 461 by providing global coordinate system artifact 456 . Those of ordinary skill in the art of the present invention will understand that the global coordinate system 461 can be provided by various means and methods. For example, laser trackers can be used. The invention includes any device that provides a global coordinate system.

method

While the Portable Robot CMM Arm 1 of the first embodiment is well suited for surveying, the Industrial Robot CMM Arm 450 of the present second embodiment is suitable for both precise robotic manipulation involving tools carried by a robot in an industrial environment, and for Measurement. Methods include one or more steps. Control software 382 executes the method. A general method that can be used by this second embodiment is disclosed. The exemplary method described for Robot CMM Arm 1 can be used for Industrial Robot CMM Arm 450 . The following other exemplary methods are provided in the control software 382 to use the Industrial Robot CMM Arm 450:

Datum referencing features: Control software 382 references industrial robot CMM arm coordinate system 363 to object feature coordinate system 362 features

Overall reference: industrial robot CMM arm coordinate system 363 relative to the global coordinate system 461

Probe Reference: The control software 382 references the industrial robot CMM arm coordinate system 363 with respect to the measurement probe coordinate system 364 of the probe 90

Automatic tool change: The control software 382 organizes automatic tool change for the tool 98 located on the Industrial Robot CMM Arm 450; this is used when the automatic tool change system is provided with the Industrial Robot CMM Arm 450:

Tool Reference: The Control Software 382 references the Industrial Robot CMM Arm Coordinate Frame 363 with respect to the Tool Coordinate Frame 364 of the Tool 98; this is used for example after the tool has been changed

Processing: Control software 382 performs processing on object 9 using tools 98

Adjust tool offset: Control software 382 adjusts tool coordinate system 364 of tool 98

Handling: Objects are transported to and from the location of the Industrial Robot CMM Arm; there are many methods of handling objects, including but not limited to: transport on the production line; transport by conveyor belt while on a pallet; manual loading by the operator.

Mounting: Objects can be mounted prior to being manipulated by other industrial robot CMM arms; mountings can be repeatable or non-repeatable; mountings can be rigid to withstand operating forces without the object moving or mountings can simply be static for Optical inspection; in general, the Industrial Robot CMM Arm has high motion flexibility and the object only needs to be mounted in one location in order to provide access access for the remaining operations; there are various methods of mounting the object in this location, including but not limited to : Place an object on a surface non-repeatably; lock an object on a pallet and lock the pallet in position; mount an object on a production line; mount an object in a fixture.

feature checking method

Referring now to FIG. 56 , in a first step 470 an object 9 is brought into position and mounted within the reach of the Industrial Robot CMM Arm 450 . In step 471 , the Industrial Robot CMM Arm coordinate system 363 is positioned relative to the object coordinate system 361 . This step is not required if the object 9 is mounted in a precision fixture in a known position and orientation relative to the Industrial Robot CMM Arm. In step 472 , probe 90 located on Industrial Robot CMM Arm 450 measures one or more features 365 located on object 9 according to measurement program 389 . In step 473 , the position and or size of each feature 365 is calculated from the measurement data collected during step 472 . In step 474, the location and size of each feature 365 is compared to the design location and size of each feature 365 and their tolerances, typically in the form of a CAD model and inspection program. If the positioning process of step 471 includes measuring features on the object 9, then step 471 may be performed concurrently as part of this step. In step 475, the measurement results are output. In step 476, the object 9 leaves the position.

Surface inspection method

Referring now to FIG. 57 , in a first step 480 the object 9 is brought into position and mounted within the reach of the Industrial Robot CMM Arm 450 . In step 481 , the Industrial Robot CMM Arm coordinate system 363 is positioned relative to the object coordinate system 361 . In step 482 , the probe 90 on the Industrial Robot CMM Arm 450 measures the surface of the object 9 according to the measurement program 389 . In step 483 the surface measurement data collected during step 482 is pre-processed. In step 484, the preprocessed surface measurement data of the object 9 are compared with the design surface. In step 485, the measurement results are output. In step 486, the object 9 leaves the position. An example of the applicability of the method is a crankshaft inspection unit. The unmachined crankshaft is checked against the CAD design to verify that the crankshaft produced by the forming process is within tolerance.

Tool operation method

Referring now to FIG. 58 , in a first step 490 the object 9 is brought into position and mounted within the reach of the Industrial Robot CMM Arm 450 . In step 491 , the Industrial Robot CMM Arm coordinate system 363 is positioned relative to the object coordinate system 361 . In step 492 , tool 98 located on Industrial Robot CMM Arm 450 performs an operation on object 9 according to robot program 389 . Industrial Robot CMM Arm 450 uses known transformations between Tool Coordinate Frame 364 and Industrial Robot CMM Arm Coordinate Frame 363 to perform operations. In step 493, the object 9 leaves the position.

Operation check and tool adjustment method

This method requires at least one tool 98 and probe 90 mounted on the Industrial Robot CMM Arm 450 . Referring now to FIG. 59A , in a first step 500 an object 9 is brought into position and mounted within the reach of the Industrial Robot CMM Arm 450 . In step 501 , the Industrial Robot CMM Arm coordinate system 363 is positioned relative to the object coordinate system 361 . In step 502 the tool 98 located on the Industrial Robot CMM Arm 450 performs an operation on the object 9 according to the robot program 389 . In step 503 , probe 90 on Industrial Robot CMM Arm 450 measures one or more processed features 365 on object 9 and or the surface of object 9 according to measurement program 389 . In step 504 , the position and or size of each treatment feature 365 is calculated, and surface pre-processing is performed or based on the measurement data collected during step 503 . In step 505, the location and size and or surface of each treatment feature 365 is compared to the design location and size of each treatment feature 365 and tolerances thereof. In step 506, a tool adjustment is calculated from the results of step 505, and the tool coordinate system 364 is adjusted using the adjustment operation. Adjustments to the tool coordinate system 364 can be made on the basis of statistical trends from a large number of identical operating conditions in order to identify and quantify any deviations in error. In step 507, the measurement results are output. In step 508 the object 9 leaves the position. This method can be used in three exemplary modes, but is not limited to these three modes

- check only (skip step 506)

- Only do tool adjustments (skip step 507)

- perform inspection and tool adjustment (including each step 500-508)

Those of ordinary skill in the art to which the present invention pertains will appreciate that there are a variety of other methods that can be used to take measurements and perform operations using the Industrial Robot CMM Arm 450 with much greater precision than is presently achievable, and the disclosures disclosed herein The method is exemplary of all methods that can be used to take measurements and perform operations using the Industrial Robot CMM Arm 450 with a much higher precision than previously possible.

production line

The Industrial Robot CMM Arm 450 can be mounted as a single unit at any applicable location on the production line, or multiple Industrial Robot CMM Arms 450 can be mounted together in one unit or several units to complete a measurement task. An example is on an automobile production line. Generally speaking, cars on a production line move at a known and steady rate; however, accuracy decreases when measuring moving objects. It is therefore preferred to construct a unit in which the vehicle is stationary during the entire measurement cycle. Alternatively, such a unit could be placed adjacent to the production line and sample a portion of the objects produced. Typical production line measurement applications include: body in white, engine compartment, rear compartment, underbody and dashboard fixtures. Typical features inspected include: edge and surface location, hole location, slot location, gap and flush measurements. Also check the surface shape. Typically, a production line will have a line control system that initiates operating cycles in the units on the line. One or more Industrial Robot CMM Arms 450 in the cell can be connected to the production line control system by any means known to those of ordinary skill in the art to which the invention pertains. The Control PCB 172 in the Industrial Robot CMM Arm 450 can receive signals and information and return signals and information. Signals and information from the production line control system to the industrial robot CMM arm 450 usually include, for example: start cycle; emergency stop cycle; use program number XXX; program XXX itself; return measurement result YYY; control parameters; status requirements. Signals and information from the Industrial Robot CMM Arm 450 to the production line control system typically include, for example: status reports; measurement results; measurement result reports; feedback control parameters. The Industrial Robot CMM Arm 450 will typically be hardwired into the production line's emergency stop circuit. Measurements and feedback control parameters from the Industrial Robot CMM Arm 450 can be used to feed forward data for control or adaptive control of downstream processes on the production line. Measurement requirements on flexible production lines often require the Industrial Robot CMM Arm 450 to extend beyond 2m and sometimes beyond 3m. It is preferred that the Industrial Robot CMM Arm 450 has a minimum of 6 axes in order to have the flexibility to allow it to approach the location being measured. It is preferred that the Industrial Robot CMM Arm 450 be able to accelerate rapidly to move between positions in the shortest possible time. The Industrial Robot CMM Arm 450 has flexibility, agility and a relatively small footprint. The Industrial Robot CMM Arm 450 may thus be installed within the operating unit along the production line and/or in the middle of the production elements on the production line. Care must be taken so that collisions do not occur between the Robot CMM Arm and other items. This means that the Industrial Robot CMM Arm 450 can be inserted into most locations along the production line and will not take up valuable space like a dedicated measuring cell in the production line. The Industrial Robot CMM Arm 450 takes measurements with high precision and can be located next to or just upstream of an operating element such as a welding robot. One or more operating elements may receive feedback data from one or more Industrial Robot CMM Arms 450 and thereby perform more precise operations appropriate to the actual measured position of an object, such as a sheet metal item. This means more efficient processes that are faster, better or less expensive but require greater precision can be used on the production line.

Parts Adjustment Method

The Industrial Robot CMM Arm 450 is especially suitable for the prototype production process where 200-250 prototypes of a new car model are usually manufactured. Since integrated high-precision measurements can be achieved by the Industrial Robot CMM Arm 450 located at the production cell, it is possible to change the method of prototyping and/or improve the accuracy of existing methods. For example, by feeding back errors in the positioning of the sheet metal parts before they are welded or bonded, the sheet metal parts can be manually or automatically adjusted until they are in the correct position. Therefore, this means that the Robot CMM Arm invention can save a large investment in precision prototyping tools by allowing the use of simpler tools. A novel component adjustment method is disclosed. Referring now to FIG. 59B, in a first step 510, the movable first part is manually positioned by an operator relative to the second part. In step 511, the Industrial Robot CMM Arm 450 acquires measurement data regarding the position and orientation of the first part and the second part. In step 512, measurement data from the second part is recorded into the CAD model of the second part. In step 513, the measurement data from the first part is compared with the CAD model of the first part; the CAD model of the first part is in the same coordinate system as the CAD model of the second part, and the CAD model of the first part is relative to the CAD model of the first part. The CAD model of the second part is located in the ideal design position. In step 514, the error in the actual location and orientation of the first part from the ideal CAD location and orientation of the first part is calculated and displayed to provide useful information that can be processed by an operator. In step 515, the manual operator uses the displayed error to decide whether to further manually adjust the positioning and or orientation of the first part and go to the first step, or if the first part is well positioned and stops. In step 516, the manual operator manually adjusts the position and or orientation of the first component using the displayed error; this seventh step is followed by the second step of the method. Those of ordinary skill in the art to which the present invention pertains will appreciate that there are various other manual and automated methods that can be used to use the Industrial Robot CMM Arm 450 to assist in the positioning of a first part relative to a second part with a much higher accuracy than is currently achievable. Positioning, and the methods disclosed herein are exemplary of all the methods that can be used to use the Industrial Robot CMM Arm 450 to help position a first part relative to a second part with a much higher accuracy than previously possible. In an alternative embodiment, steps 510, 515, and 516 may be automated so as to automate the entire component adjustment process.

Body Repair Methods

The Industrial Robot CMM Arm 450 is suitable for a body repair process after a car body twisting accident. The industrial robot CMM arm 450 is first used in a diagnostic operation in order to quantify the degree of body distortion and decide which parts need to be replaced, and corresponds to steps 511-514. The Industrial Robot CMM Arm 450 is used after each correction process like stretching, bending to measure the remaining error from the ideal shape; this corresponds to steps 511-516. The Industrial Robot CMM Arm 450 is used during each replacement process where a new part, such as a body panel, replaces a damaged corresponding part in order to help the new panel align properly; this is consistent with all steps 510- 516 corresponds. Diagnostic operations, calibration processes, and replacement procedures are specific examples of application of the component adjustment method. The scope of the invention is not limited to the repair of automobile bodies, but is applicable to the repair of objects of any complex shape. The invention is applicable to the repair of objects formed entirely of one part or of more than one part.

processing machine

Referring again to FIG. 7J , an Industrial Robot CMM Arm 450 may be mounted on or adjacent to one or more processing machines 137 . Where a production line is formed by two or more processing machines 137, measuring and pass/fail checking objects 9 between high value operations can reduce the waste value % of the production line. In addition, the Industrial Robot CMM Arm 450 can provide dual functions of measurement and material handling. In some applications, Industrial Robot CMM Arm 450 may provide three operations: measurement operations, material processing operations with tools, and material handling operations. An example application of the Industrial Robot CMM Arm 450 is in a turbine blade production line. The speed and accuracy of optical measurements by the Industrial Robot CMM Arm 450 can make this application more cost effective compared to manual inspection.

Advantages of Using the Robotic CMM Arm Invention on the Production Line

The following advantages are provided by way of example and are not limited to the advantages of using the Robotic CMM Arm invention on the production line:

1. As long as it allows, the Robot CMM Arm can be installed anywhere along the production line in an existing cell, not just in a dedicated cell that takes up space on the line.

2. The robot CMM arm can inspect the surface and feed forward data to the subsequent process

3. The robot CMM arm can inspect the surface and feed back data after or during machining

4. The robot CMM arm can increase the precision of processing such as joining

5. The robot CMM arm can facilitate the reduction of the changeover time between products

6. The robot CMM arm can become a common tool everywhere on the production line, with all the advantages of production agility brought about by standardization of processing and tools

7. The robot CMM arm can provide more accurate project assembly before the connection process, so that the connection process to be used can be more accurate

8. The robot CMM arm can provide a more precise method for assembling various tools and components in various industries including, for example, automotive and aviation and aerospace

9. The robotic CMM arm can provide a real-time feedback loop to the manual operator to adjust the position of the part before another process

10. The Robotic CMM Arm can provide a real-time feedback loop to the movable member to automatically adjust the position of the part prior to joining or another assembly process

11. The robot CMM arm can be automatically benchmarked relative to the production line benchmark

12. The robot CMM arm can be automatically benchmarked relative to the object reference datum such as the car body line coordinate system located at the cell

13. The Robot CMM Arms can be referenced relative to each other in a common coordinate system

14. The robot CMM arm can be integrated with the production line control system

15. The Robot CMM Arm enables different machining methods. Therefore, it has advantages such as reducing processing input, increasing processing speed, improving product quality, and improving processing accuracy.

16. The robot CMM arm can improve the main production line process and prototype production process

17. The robot CMM arm can eliminate the need for fixtures used to inspect car dashboards

18. Robotic CMM Arm Can Eliminate Human Error

19. Compared with industrial robots, the robot CMM arm is only slightly more expensive to manufacture, but it provides added value beyond its added cost

20. The robot CMM arm increases the accuracy of processing, allowing the use of less accurate tools for more efficient processing and saving space on the production line compared to two-station products

21. A single Robot CMM Arm can handle one or more of the following operations: measurement, material handling, material handling; this provides more utility than a robot that cannot perform accurate measurements.

grinder

The purpose of this embodiment is to provide an industrial robot CMM arm 450 capable of grinding complex shapes. A standard CNC control system is used to ensure low error following paths. Machining paths are generated by standard 7-axis CAD software packages. The precise position feedback from the CMM encoder 178 is used to calculate the exact six degrees of freedom position and orientation and close the loop with the required six degrees of freedom position and orientation, as is well known to those of ordinary skill in the art to which this invention pertains. This means that the Industrial Robot CMM Arm 450 is able to grind complex shapes more accurately than standard industrial robots. The main advantage is that the magnitude of the machining error of the Industrial Robot CMM Arm 450 will typically be an order of magnitude lower than the magnitude of the machining error of the industrial robot. Another advantage of using the Industrial Robot CMM Arm 450 for grinding is that no additional manual finishing operations are required where rough parts such as steps are manually leveled due to imprecise access. Another advantage is that the Industrial Robot CMM Arm 450 is capable of grinding complex shapes such as large spheres that a machining center or a Horizontal Arm CMM cannot. It is anticipated that the Industrial Robot CMM Arm 450 will find application in a wide variety of industries for accurate machining of complex shapes.

third embodiment

In this third embodiment, a movably supported Robot CMM Arm is disclosed which significantly reduces the forces and moment.

Forces and moments acting on the Robot CMM Arm of the first embodiment

At some spatial layouts of the Robot CMM Arm 1 there are considerable loads acting on the Internal CMM Arm 5 such that the provided seven motors acting through the seven Exoskeleton Joints 1-761-67 of the Exoskeleton 6 The 176 setup does not provide enough control output to reduce these loads. In some spatial arrangements, all the weight of the following segments of the Internal CMM Arm 5 acts on the joints. For example, the total weight of the CMM Segment 2-8 32-38 falls directly on the CMM Joint 151 when the Internal CMM Arm 5 is in a vertical spatial layout. Similarly, the total weight of CMM Sections 3-8 33-38 falls directly on CMM Joint 2 52, and similarly CMM Joint 3 53 through CMM Joint 7 57 to the arm. The seven drive trains in the exoskeleton cannot compensate for this load on the bearings in the CMM joint. For CMM joints 1, 3, 5, 751, 53, 55, and 57 with an axial configuration, when the internal CMM arm 5 is in a vertical spatial layout, the loads acting on these CMM joints pass through the axial direction. Axis of the CMM joint. For CMM Joints 2, 4, 6, 52, 54, and 56 with an orthogonal configuration, when the Internal CMM Arm 5 is in a vertical spatial layout, the loads acting on these CMM Joints are aligned with the axis of the Orthogonal CMM Joint. Orthogonal. In any spatial position of the Robot CMM Arm 1, a network of non-zero forces and moments acts from the Exoskeleton 6 on the Internal CMM Arm 5, regardless of whether the Robot CMM Arm 1 is at rest or in motion. These forces and moments reduce the measurement accuracy of the Robot CMM Arm 1 by straining the joints and segments of the Internal CMM Arm 5 .

Active Support Robot CMM Arm

The Active Support Robot CMM Arm of this third embodiment includes strain gauges for detecting the forces and moments acting on the Internal CMM Arm 5 and Active Support Controls with a balance for the forces and moments acting on the Internal CMM Arm 5. The active gear of the software. This means that the accuracy of the Actively Supported Robot CMM Arm is greater than the accuracy of the Robot CMM Arm 1 or the Industrial Robot CMM Arm 450 with the same extension range as the Actively Supported Robot. Furthermore, compared to both the Robot CMM Arm 1 of the first embodiment and the Industrial Robot CMM Arm 450 of the second embodiment, the reach to which the Mobile Supported Robot CMM Arm can operate with a specified accuracy is increased.

Referring now to FIG. 60, the Actively Supported Robot CMM Arm 550 includes Active Transmissions 2-8 562-568 between the Exoskeleton 6 and the Internal CMM Arm 5. Strain gauges 181 are attached to the Internal CMM Arm 5 as previously disclosed and are shown in Figure 41E.

active transmission

Each active transmission 2-8 562-568 provides a drive direction through the transmission 2-8 72-78 as previously disclosed in the first embodiment and one or more for movably supporting the internal CMM The active support direction of the weight of the arm 5. Each active transmission 562-568 is located at or near the center of gravity of its corresponding CMM segment 2-8 32-38; this reduces the support task of each CMM segment to two active force components: radial and axial Towards. No torque needs to be effectively applied because each movable transmission 562-568 is located at or near the center of gravity of its corresponding CMM Section 2-832-38.

Direction Drive Movable supporting device

Movable transmission 2 562 Torsion Axial, radial

Active Transmission 3 563 Radial Axial

Movable transmission 4 564 Torsion Axial, radial

Active Transmission 5 565 Radial Axial

Movable transmission 6 566 Torsion Axial, radial

Active Transmission 7 567 Radial Axial

Movable transmission 8 568 Torsion Axial, radial

Active gear 2 562 is the first gear and is in a constant orientation relative to gravity. The transmission 272 within the movable transmission 2562 is torsional and provides no radial or axial movable support. In the common case where the base orientation of the Actively Supported Robot CMM Arm 550 is vertical, the only active support required within the Active Transmission 2562 is axial; in the case where the base orientation of the Actively Supported Robot CMM Arm 550 is horizontal In the case of , the only active support required within the active transmission 2562 is radial. At any other base orientation, both axial and radial movable support are required within the movable gear 2562.

Movable transmission 3563 can be in any orientation. The drive through the transmission 373 in the movable transmission 3 563 is radial; this means that no radially movable bearings are required in the movable transmission 3 563. However, axially active bearings are required within the active transmission 3563. The situation of mobile gear 5, 7 565, 567 is similar to that of mobile gear 3 563.

Movable actuator 4564 can be in any orientation. The drive through the transmission 474 within the movable transmission 4 564 is torsional; this means that both radial and axial movable supports are required in the movable transmission 4 564. The situation of the movable gear 6,8 566, 568 is similar to that of the movable gear 4 564.

Axial movable bearing

Movable transmission device 3,5,7 563,565,567 provides radial drive and movable axial support. Referring now to FIG. 61 , an active transmission such as active transmission 3 563 comprises two components: a passive radial drive transmission 373 and an active axial support 3 583 as previously disclosed and shown in FIG. 17 . The movable axial support 3 583 consists of two support motors 571 which apply force through the support gearbox 572 means and the support ball screw 574 means to the CMM segment support flange 570 mounted on the CMM segment 333 of the inner CMM arm 5. The axial thrust of the ball race 575 device. Two support motors 571 are positioned 180 degrees from each other to provide uniform axial thrust on the CMM Segment support flange 570 . The support motor 571 is bolted to the support gearbox 572 , and the support gearbox 572 is bolted to the support bracket 573 . A support ball screw 574 protrudes from the support gearbox 572 and is supported at the distal end by a support bracket 573 . A support ball race 575 is positioned distally between the support gearbox 572 and the support bracket 573 . Support bracket 573 is connected to exoskeleton segment 343 by elastic material 203. A support encoder 579 is connected to each support motor 571 . The support motor 571 can apply an axial force between the exoskeleton segment 343 and the CMM segment 333 in any relative direction determined by the movable support control software. For example, if the CMM Segment 333 is in a vertically upward spatial orientation, then the axial force acting on the CMM Segment 333 will be upward so as to effectively balance the downward gravitational force acting on the CMM Segment 333.

In this arrangement, the passive radial drive transmission 373 is located on one side of the movable axial support 3583 along the axis of the CMM section 333. In another embodiment of the present invention, the passive radial drive transmission 373 is located on the other side of the movable axial support 3583. In another embodiment of the present invention, the passive radial drive transmission device 373 and the movable axial support 3583 can be integrated so that the active center of the radial drive passing through the passive radial drive transmission device 373 and the movable The center of action of the axial support 3 583 is at the same position.

Axial/radial movable bearing

Movable transmissions 4, 6, 8 564, 566, 568 provide torsional drive, movable axial support and movable radial support. Referring to Fig. 62 now, movable transmission device 4 564 comprises three parts: torsional transmission device 4 74, movable axial support 4 584 and movable radial support 4 594. In this arrangement, the three components of the Active Transmission 4564 are provided in a row between the CMM Segment 434 and the Exoskeleton Segment 444 of the Actively Supported Robot CMM Arm 550. The scope of the present invention is not limited to this arrangement. For example, in another embodiment of the present invention, the three components may be provided in any other order. In another embodiment of the present invention, these three components can be integrated so that the center of action of the torsion passing through the passive torsion transmission device 474 is at the same center as the center of action of the movable axial support 4 544 and the movable radial support 4 594 Location. In another embodiment of the present invention, any two of the three components are integrally formed.

Referring now to FIG. 63, the movable radial support 4594 includes three units 594A, 594B and 594C. Active radial support 4 unit 594A is shown in section AA and BB. Movable radial bearing 4 units 594B and 594C are shown in section BB. In each movable radial support 4594 unit, the support motor 571 exerts a radial thrust through the support gearbox 572, the support 90-degree transmission gearbox 577 and the support ball screw 574, and the radial thrust passes through the support ball race 575 Acts on the radial support bracket 578 and through the elastic material 203 and low friction material 202 to the CMM segment 434 of the inner CMM arm 5. The three movable radial support 4 units 594A, 594B and 594C are positioned 120 degrees from each other to provide directional control of the radial thrust acting on the CMM section 434. The support motor 571 is bolted to the support gearbox 572 , and the support gearbox 572 is bolted to the radial support motor bracket 576 . The support gearbox 572 drives the support 90 degree transmission gearbox 577 . A support ball screw 574 emerges from a support 90 degree drive gearbox 577 . Support ball race 575 receives thrust from support ball screw 574 , which is transmitted through radial support bracket 578 and through resilient material 203 and low friction material 202 to CMM segment 434 of inner CMM arm 5 . The support encoder 579 is connected to the support motor 571 . The three units 594A, 594B and 594C of the Active Radial Bearing 4594 can provide radial force in any relative direction between the Exoskeleton Section 444 and the CMM Section 434, as determined by the Active Bearing Control Software. For example, if CMM Segment 434 is in a horizontal spatial orientation, the radial force will upwardly overcome the force of gravity acting on CMM Segment 434 effectively balancing the downward force of gravity acting on CMM Segment 434.

Number of Active Gears

In a preferred embodiment of the 7-axis movable support robot CMM arm 550 with the base in any orientation, there are eleven movable support devices: movable axial supports 2-8 582-588 and movable radial supports 2, 4, 6, 8 592, 594, 596, 598. If the base is always vertical, then ten movable supports are sufficient and no movable radial supports 2 592 are required. In the embodiment of the 6-axis Active Support Robot CMM Arm 550 with the base in any orientation, there are nine active supports since there are no active drives 4564: eight active supports if the base is always vertical device is sufficient and does not require movable radial support 2592.

Some Active Support devices have a greater impact on the overall accuracy of the Active Support Robot CMM Arm 550 than others. For example, a live support near the probe end will have less impact on overall accuracy than a live support used for the heavier section. Providing only one active support increases the accuracy of the Actively Supported Robot CMM Arm 550 compared to the accuracy of a similar Robot CMM Arm 1 without any active support. It is an object of the present invention that the Actively Supported Robot CMM Arm 550 has one or more Active Support Devices.

In general, the Actively Supported Robot CMM Arm 550 can be made more precise by increasing the number of Active Gears 560 to reduce the forces and moments in the Actively Supported Robot CMM Arm 550 . For example, two or more movable gears 560 may be provided to support each CMM segment. In practice, each increase in the number of active transmissions will yield a finite return. In another embodiment of the Actively Supported Robot CMM Arm 550, two Active Gears are provided to the longer CMM Segments 3,5 33,35 to provide more support. The scope of the present invention includes any Actively Supported Robot CMM Arm 550 with one or more active actuators.

Structural materials

The Inner CMM Arm 5 and the Exoskeleton 6 of the Mobile Supported Robot CMM Arm 550 are preferably made of the same material in order to minimize differences in thermal expansion. The axes of CMM joints 51-57 and exoskeleton joints 61-67 are also aligned. This way the Internal CMM Arm 5 and the Exoskeleton 6 change length by the same amount as the temperature changes.

Active Support Control Software

Referring now to FIG. 64 , movable bearing control software 552 is provided in memory 381 of control PCB 172 . For each space layout, the mobile support control software 552 optimizes the mobile support of the Internal CMM Arm 5 by the Exoskeleton 6 . Support motor 571 is driven by amplifier 176 according to the output of amplifier analog output circuit 383 in control PCB 172 as determined by control software 382 . Each support encoder 579 is connected to a header PCB 173 which is connected to a control PCB 172 .

Referring now to FIG. 65 , active bearing control software 552 has inputs from strain gauges 181 , kinematics software 391 and control software 382 . Strain gauges 181 indicate the forces and moments acting on the Internal CMM Arm 5 . Kinematics software 391 provides the spatial layout position, velocity and acceleration of the Actively Supported Robot CMM Arm 550 . The control software 382 provides the position, velocity and acceleration of the movable actuator 2-8 562-568. The movable support control software 552 has as output the required control commands for the support motor 571 to the control software 382 . The control software 382 receives as input the positions of the exoskeleton encoder 179 , the CMM encoder 178 and the support encoder 579 . The control software 382 outputs drive signals for driving the motor 176 and the support motor 571 to the amplifier 175 . Control software 382 provides a single control loop for both motor 176 and support motor 571, which avoids the undesirable situation of having two competing control loops that are difficult to coordinate. It is an object of the present invention to provide precise Articulation of the Robot CMM Arm 550 through the Articulation Control Software 552 to minimize the forces and moments acting on the Internal CMM Arm 5, where Input, Strain Gauge 181 measures forces and moments in the Internal CMM Arm 5 and outputs from the Active Bearing Control Software 552 to control the Active Transmission 2-8 562-568 that can apply forces and moments from the Exoskeleton 6 to the Internal CMM Arm 5 . In this way, the Inner CMM Arm 5 is fully supported by the mounts of the Base CMM Segment 31 and the Movable Transmission 2-8 562-568. Those of ordinary skill in the art to which the present invention pertains will appreciate that there are a number of ways to provide Active Support Control software for the Active Supported Robot CMM Arm 550 and integrate it with the Master Control Software 382 to enable actions on the Active Supported Robot CMM Forces and moments on arm 550 are minimized. Those of ordinary skill in the art to which the present invention pertains will further understand that the active bearing control software can automatically compensate for heavy probes 91 mounted on or near the probe end 3 of the internal CMM arm 5, and can provide at least two active transmissions for The CMM section 838 is supported to compensate for the probe 91 not being mounted near the center of gravity of the CMM section 838.

Air Bearings in Transmissions

Air bearings can be used to eliminate contact between the Internal CMM Arm 5 and the Exoskeleton 6 . Referring to Fig. 17 again, in radial transmission device 373, air bearing will be used to replace low friction material 202. Referring again to Figure 18, in the torsion drive 474, in addition to the elastic material 203, an air bearing will also be used. Referring again to 61 and 63, in the movable axial bearing 563 and the movable radial bearing 594, air bearings will be used in place of the low friction material 202. Air for the air bearing may be provided by a compressor and introduced at the location of the air bearing by a hose extending between the Internal CMM Arm 5 and the Exoskeleton 6 . The air coming out of the air bearing may have the secondary function of cooling the Actively Supported Robot CMM Arm 550 . Primary exhaust for air is provided at the probe end, and secondary exhaust is provided at an appropriate distance from the air bearings in each section. The main advantage of air bearings is the elimination of friction between the Internal CMM Arm 5 and the Exoskeleton 6; this ensures that a force applied in one direction does not have a detrimental component due to friction in the other direction, making the active bearing Type Robot CMM Arm 550 is more precise.

Elastic material, pressure sensor and movable bearing control

Referring again to Figures 17, 18, 61 and 63, elastic material 203 is provided within each component of the Mobile Transmission 2-8562-568 where the Internal CMM Arm 5 and the Exoskeleton come into contact. The elastic material 203 protects the Internal CMM Arm 5 by absorbing force peaks from the Exoskeleton 6 . The force across the resilient material 203 is created by at least the following factors: gravity, change in spatial position of the Actively Supported Robot CMM Arm 550 due to its motion, inertial acceleration of the Actively Supported Robot CMM Arm 550, assembly interference fit , Thermal expansion/contraction and support motor 571. Using the calculated force extremes for the spatial and inertial capabilities of the Actively Supported Robot CMM Arm 550, the thickness, cross-sectional area, and material modulus of elasticity of the elastic material 203 at each location are carefully calculated to optimize the elastic material 203 relative expansion/contraction.

In an alternative embodiment, the pressure sensor is in the elastic material 203 instead of the strain gauge 181 mounted on the Internal CMM Arm 5 . The actual resultant force across the elastic material 203, whether compressive, tensile or shear, can be measured at each active actuator. Calculations based on the design of the Actively Supported Robot CMM Arm 550 are used to determine the ideal resultant force across each elastic material at the existing spatial position and inertial conditions of the Actively Supported Robot CMM Arm 550 . Bearing motors 571 are actuated by a new active bearing control software algorithm to reduce or increase the actual resultant force across each elastic material 203 .

Environmental Factors and Operating Performance

For best accuracy, the Actively Supported Robot CMM Arm 550 should be used in a thermally controlled environment with no external vibrations. Best results are achieved when measurements are made at relatively low speeds and when the forces generated by the acceleration are small. However, the user demand throughput from the user's measurement equipment and velocity, acceleration that can be had with the Mobile Supported Robot CMM Arm 5 is an important factor. Internal CMM Arm 5 Supported by and by Multiple Active Transmissions The design performance of the Internal CMM Arm 5 may differ from that of a Manual CMM Arm which may be subjected to considerable forces and moments applied by an operator. This means that the mass/inertia of the Inner CMM Arm 5 in the Actively Supported Robot CMM Arm 550 can be lower and the corresponding accelerations it may experience while maintaining high accuracy can be higher, making it a highly productive and precise robot CMM Arm 550. measuring equipment.

Effectiveness of the invention

The forces and moments acting on the Internal CMM Arm 5 due to gravitational and inertial forces are balanced by moving gears. Such a Actively Supported Robot CMM Arm 550 can effectively support the Inner CMM Arm 5 such that the forces and moments at the mounts of its Base CMM Segment 31 are one or more lower than the corresponding forces and moments if no active transmission was provided. order of magnitude. Furthermore, such Actively Supported Robot CMM Arm 550 can effectively support the Inner CMM Arm 5 such that its forces and moments at each joint are lower by one or more amounts than the corresponding forces and moments if no active transmission was provided. class.

More accurate than manual CMM arms

This third embodiment enables the forces and moments acting on the Internal CMM Arm 5 to be reduced by about an order of magnitude compared to those acting on a Manual CMM Arm of a corresponding size. This means that the Actively Supported Robot CMM Arm 550 can be more precise than a Manual CMM Arm of similar reach where forces and moments cannot be reduced to negligible amounts. With small forces and moments, the Internal CMM Arm 5 can be designed to be very light; with the double benefit that the Exoskeleton 6 can thus be lighter and the drivetrain can be lighter since they are less powerful.

Alternatives to Active Bearings

There are other ways of achieving active support, and the scope of this embodiment is not limited to the devices described above. For example, in another embodiment for axial support, one motor 571 could be used to drive two support ball screws 574 through a drive transmission such as a belt. In an alternative embodiment for axial or radial support, a controllable linear actuator such as a voice coil actuator can provide the required linear force without the need to know the position of the movable transmission; providing a ratio band A simpler control loop for motors with encoders.

Fourth embodiment

Measured parameters

In this fourth embodiment, methods and devices are disclosed for another object of the invention: measuring a parameter, constructing a model of the parameter and analyzing its model. Examples of parameters that may be measured by applicable contact or non-contact parameter measurement probes 90 include, but are not limited to: temperature; surface roughness; color; vibration; hardness; pressure; density; crack/impurity detection in welds, bonds. The object 9 or part of the object to be measured is located within the extension of the Robot CMM Arm 1 . Either the Object 9 can be brought to the Robot CMM Arm 1 or the Robot CMM Arm can be brought to the object. Parameters are measured relative to the Robot CMM Arm 363 coordinate system. Alternatively, the object coordinate system 361 may be set as previously disclosed and the parameters measured relative to the object coordinate system 361 . The parameter measurement probe 90 is connected to the probe end 3 of the Internal CMM Arm 5 , but may be connected to the probe end of the Exoskeleton 6 . When the probe end of the internal CMM arm 5 and the probe end of the exoskeleton 6 are common, the parameter measurement probe is connected to the common probe end.

Measurement process, timing and multiple probes

The measurement process is performed by the Robot CMM Arm 1 moving the parameter measuring probe 90 relative to the object 9 and taking measurements by the parameter measuring probe 90 . As previously disclosed, the positioning/orientation of the probe tip in the X, Y, Z, I, J, K coordinates of the Robot CMM Arm and the measurement of the parameter measurement probe 90 can be synchronized, either time-stamped or otherwise on a time basis Determine the coordinates directly or by interpolation. Measurements are taken along the path of motion of the Robot CMM Arm 1 . The measurement is preferably performed in a continuous scanning motion, wherein the parameter measuring probe 90 performs the measurement on the fly; such an on-the-fly measurement is performed for a relatively short time, usually below 100 milliseconds and often several milliseconds. The method is suitable for the quantity measuring probe 90 . Alternatively, the measurement can be performed stepwise, wherein the parameter measurement probe 90 takes the measurement while the Robot CMM Arm 1 is virtually stationary; such a stepwise measurement is possible where the measurement takes a relatively long time, usually greater than 100 milliseconds and often several seconds The method is suitable for the quantity measuring probe 90 . A Parametric Measurement Probe 90 can be mounted on a Robot CMM Arm 1 with one or more other Probes 90 so that any combination of parametric and/or dimensional measurements can be taken. One example scans the tube with a non-contact optical probe 91 for dimensional measurements and a non-contact temperature measurement probe for temperature measurements. It should also be understood that a single probe 90 may measure two or more different quantities. It should also be understood that the two Contact Probes are preferably not mounted on the Robot CMM Arm 1, since only one Contact Probe 95 will be in contact with the Object 9 under the preferred operating conditions of the Robot CMM Arm, unless in the design of the Contact Probe 95 Exclusively available. Measurements of the mounted probe 90 are preferably performed along a single measurement path during a single measurement pass so that the trajectories do not repeat; this is most effective in minimizing the measurement pass time. The measurements of all probes 90 may be performed synchronously during the measurement process so that all probes 90 take measurements virtually simultaneously and at the same rate. Alternatively, one or more installed probes 90 may take measurements at different rates. As previously disclosed, the measurements of each probe 90 may be directly related to the position/orientation of the arm, preferably directly, using calibration or by interpolation. Data from the Robot CMM Arm 1 and one or more probes including the parameter measuring probe 90 are stored.

Parameter measurement probe measurement position

The quantity measuring probe 90 has many different embodiments. They can be contact or non-contact. They can take one or more measurements per Robot CMM Arm positioning/orientation. They can measure one or more different parameters, such as temperature and pressure. The measurement position of the Quantity Measurement Probe may be a known position or may be known within limits related to Robot CMM Arm positioning/orientation. Examples of measurement locations include:

(a) The location of single parameter measurement can be located at the tip of the parameter measurement probe;

(b) The location of a single parameter measurement may be at an unknown distance but a known orientation from the tip of the parameter measuring probe;

(c) The location of a single quantity measurement may be at a known fixed distance and a known orientation from the tip of the quantity measurement probe;

(d) The location of a single parameter measurement may be at a fixed distance measured from the tip of the parameter measuring probe at a known orientation;

(e) multiple parametric measurements may be made simultaneously along the projection plane, where each parametric measurement is at a known location relative to the tip of the tip parametric measurement probe;

(f) multiple parametric measurements can be made simultaneously in the projected area, where each parametric measurement is at a known location relative to the tip of the tip parametric measurement probe tip;

(g) multiple parametric measurements can be made simultaneously in the projected area, where each parametric measurement is at a known orientation but unknown distance relative to the parametric measurement probe tip;

Multiple mounted probes 90 preferably have different measurement positions relative to the Robot CMM Arm coordinate system 363 so that the measurement process does not interfere with each other; the different measurement positions are preferably close to each other to minimize additional measurement motion. Multiple mounted Probes 90 preferably have the same orientation relative to the Robot CMM Arm Coordinate System 363 to make motion path planning easier. When there are three or more mounted probes 90, the probes are preferably located such that all measurements are coplanar. For multiple mounted probes of the single point type but measuring different parameters, the path and orientation of the Robot CMM Arm is preferably determined such that all measured locations follow the same path rather than paths alongside each other. For single-point multiple mounted probes measuring the same quantity, the path and orientation of the Robot CMM Arm is preferably determined such that all measured locations fall in mutually side-by-side paths such that by following several approximately parallel paths Simultaneous measurements enable the Robot CMM Arm to be more productive.

Calibration and Alignment of Parametric Measurement Probes

The Parametric Measurement Probe 90 is aligned with the Robot CMM Arm's coordinate system by a method primarily determined by the design of the Parametric Measurement Probe. Preferably, the supplier of the parametric measurement probes pre-calibrates these measurement devices in some way to have a clear and sufficiently accurate probe reference setup structure that simply requires a known offset/orientation relative to the Robot CMM Arm coordinate system Assembled on the Robot CMM Arm; provide this offset/orientation data as a Parametric Measurement Probe Calibration File; use this calibration file to provide alignment of the Parametric Measurement Probe with the Robot CMM Arm's coordinate system. It should be understood that if such pre-calibration is not available from the supplier of the parameter measurement probe, then a special calibration fixture can be constructed which is suitable for the parameter being measured in order to calibrate the probe relative to the probe reference during the calibration process. It should be understood that if such a pre-calibration is not available from the supplier of the parameter measurement probe, then an artifact may alternatively be provided which is adapted to the parameter being measured so as to be measured by means known to those of ordinary skill in the art to which this invention pertains. A calibration process to align the probe coordinate system with the coordinate system of the Robot CMM Arm, said alignment process comprising taking a sufficient number of measurements of the artifact with a parametric measurement probe mounted on the Robot CMM Arm.

Referring now to the parameter measurement process of Figure 66:

- in a first step 601, the object and the Robot CMM Arm are positioned relative to each other so that the object is within the reach of the Robot CMM Arm for measurement;

-In step 602, the parameter measurement probe is installed on the probe end of the robot CMM arm;

- in step 603, align the coordinate system of the parameter measurement probe with the coordinate system of the robot CMM arm;

- in step 604, moving the Robot CMM Arm along the path and taking measurements with the parameter measurement probe;

- In step 605, the measurements from the parametric measurement probe and the position/orientation from the Robot CMM Arm are stored.

The scope of the present invention is not limited to this parameter measurement procedure and this procedure is provided as an example only.

modeling

A method is disclosed to extract parametric measurement data and Robot CMM Arm positioning position data and combine them to build a parametric model for an object. In this approach, one or more parameters can be combined into a model or kept as a separate model. It should be understood that, as disclosed, there are various definite and indeterminate positioning of a quantity measurement relative to the Robot CMM Arm. Another method is disclosed for extracting a CAD model of an object and combining it with parametric measurement data and Robot CMM Arm position/position data to build a parametric model for the object. In this other approach, the CAD model of the object is referenced to the parametric measurement data and the Robot CMM Arm positioning/position data. This alternative method is suitable for determining previously uncertain positions by means of comparison with a CAD model of the object. For example, if the CAD model of the object provides the surface definition and the quantity measured with the uncertain position is a surface quantity, then the position can be determined by projecting the quantity at a known orientation until it encounters the CAD surface of the object. In general, the quantity can be a surface-related quantity such as color or an internal quantity such as impurities in the weld or cracks in the bond.

Now refer to the modeling process of Figure 67:

- In a first step 611, a set of positioning parameter measurement data is prepared from previously stored parameter measurement results and Robot CMM Arm position/orientation using an interpolation method according to time and space;

- in step 612, using a modeling method to place the set of positioning parameter measurement data into an applicable data structure model;

- At step 613, the CAD model of the object is combined with the positioning parametric data structure model using a combination method to provide an integrated CAD and parametric model.

The scope of the present invention is not limited to this modeling process, and this process is provided as an example only. For example, step 613 need not be provided on a simple object such as a metal plate. In another example, instead of providing a CAD model, three-dimensional scan data of the external shape of the model may be provided.

Analysis and Visualization

Analysis can be performed to determine analytical data from the integrated CAD and parametric measurement model. For example:

(a) the maximum and/or minimum of the parameter and its location can be derived

(b) Colors can be assigned to parameters according to value ranges and a color display can be given to parameters on surface protrusions of objects

(c) pass or fail criteria may be set for an object or region of an object and pass or fail determined by analyzing the measurement results of a parameter against the criteria

(d) Deriving statistical data of measured parameters and separating individual data of measured parameters and providing these data to the production control system for feedback to the production process for trend monitoring and production process adjustment

Analysis data and or integrated CAD and parametric measurement models are preferably visualized on a color computer monitor. In most cases, parametric measurements and or analysis data are displayed on the surface of the CAD model or within the voxel model. Visualization can be performed using immersive 3D visualization techniques. The visualization technique chosen will depend on whether the parameters to be visualized are surface or intrinsic; the visualization technique chosen will also depend on whether a CAD model or a 3D scanned surface model of the object is available. The models may be visualized using any technique or device known to those of ordinary skill in the art to which the invention pertains, including various types of perspective views and various types of three-dimensional displays.

Now refer to the process of analysis, visualization and feedback in Figure 68:

- in a first step 621 the integrated CAD and parametric measurement result model is analyzed using analysis means;

- in step 622, outputting the analysis data;

- in step 623, the output analysis data is displayed for visualization;

- In step 624, analysis data is provided as feedback during production.

The scope of the present invention is not limited to this analysis, visualization and feedback process and such process is provided as an example only. For example, in an unmanned automated line, step 623 may generally not be included unless a display terminal is available for occasional visual observation of the process.

fifth embodiment

Mobile Robot CMM Arm

In this fifth embodiment, a mobile robot CMM arm embodiment is disclosed. Currently, measurements of larger objects such as vehicles are performed in two conventional ways: using a CMM that is larger than the vehicle such as a trailer CMM or an opposed horizontal arm CMM, or one that moves around the vehicle with a smaller measurement reach of removable devices. Larger CMMs, especially if they are automated, require larger capital investments. Movable equipment requires skilled manual work and is susceptible to human error.

It is an object of this fifth embodiment to provide a Mobile Robot CMM Arm for measuring large objects such as vehicles that is automatic, precise, flexible, and smaller in size and less costly than a large CMM.

Referring now to FIG. 69, the Mobile Robot CMM Arm 700 is shown in side, end, and bottom views, respectively. The Mobile Robot CMM Arm 700 includes a Vehicle 701 on which the Robot CMM Arm 1 is mounted. The Robot CMM Arm 1 is rigidly connected to the tripod base 704, and the three pointed feet 706 are lowered from the tripod base 704 by the action of the foot lowering actuator; when the pointed feet 706 are in the lowered position, the mobile Robot CMM Arm 700 The total weight is supported by the pointed feet 706 and can be accurately measured. The vehicle also includes four wheels 702, a battery 705, automatic charging/communication contacts 710, a motor/gearbox unit 703 for driving the wheels, a control unit 709, and a belt tracking/object recognition sensor 708 for manual setting and The suspension 153 that controls the Mobile Robot CMM Arm 700 is connected to the control unit 709 . Referring now to FIG. 70 , a typical floor plan of a vehicle measurement area using a Mobile Robot CMM Arm 700 is shown. The Mobile Robot CMM Arm 700 follows a trajectory laid out by the belt 712 around the vehicle 9 . At intervals along the strip 712 are targets 714 that indicate the location of the Mobile Robot CMM Arm 700 to stop and measure the vehicle. Each target 714 is preferably unique and identifiable to the measurement procedure 389 used at that location. An array of reference cones 713 is provided on the ground 718 of the vehicle's measurement area, from which the Mobile Robot CMM Arm 700 can accurately reference its position. A charging/communication station 711 is provided to automatically charge the battery 705 from a power supply 719 and communicate with a computer network 720 via an automatic charging/communication link 710 on the mobile robot, CMM arm 700 . Referring now to FIG. 71 , the plug-in reference cone 715 may be permanently located in the ground 718 . Removable reference cone 716 may be temporarily glued to ground 718 . A raised reference cone 717 is provided where increased reference fiducial accuracy is desired. Referring now to FIG. 72 , the three-dimensional position of reference cone 713 is stored in reference cone location array 721 . The three-dimensional position of target 714 is stored in target position array 722 . The three-dimensional polylines for the tape are stored in the tape polyline array 723 .

preparation process

The precise position of each reference cone 713 in the reference cone array 721 is measured using an accurate three-dimensional measuring device such as an optical tracking device provided by Leica or Faro Technologies. The path of the strip 712 as strip multi-prong array 723 and the position of the target 714 as target position array 722 are also measured. Reference cone array 721 provides global coordinate system 461 . These measurements only need to be taken annually or in case of layout changes. The array of reference cone 721 , belt path 723 and target 722 positions are provided to an off-line programming system which can also provide a simulation of the process. The operator generates the measurement program 389 using the off-line programming system. The battery 705 of the Mobile Robot CMM Arm 700 is charged at the charging/communication station 711. The measurement program 389 and the arrays 721 , 722 , 723 are downloaded to the control unit 709 of the Mobile Robot CMM Arm 700 . The object 9 , which may be a vehicle, is approximately moved into the programming position for generating the measurement program 389 . The object 9 generally has a reference datum relative to the object coordinate system 361 . The position of the object 9 is adjusted to be within a small error range of the programmed positioning.

Now refer to the preparation process of Figure 73:

- In a first step 731, the reference cone 713, the target and the band 712 are measured; the arrays 721, 722, 723 are provided to the offline programming system

- In step 732, the measurement program 389 is generated using the off-line programming system;

- in step 733, the battery 705 is charged;

- in step 734, the measurement program 389 is downloaded into the Mobile Robot CMM Arm 700;

- In step 735, the object 9 is moved to an approximate position and adjusted.

This process is an example of a preparation process and is intended to illustrate a possible preparation process, but the present embodiment is not limited to this preparation process. For example, step 733, the battery can be charged at any point in the process.

measurement process

The operator 11 starts the measuring operation. The Mobile Robot CMM Arm 700 executes the measurement procedure 389 . The Mobile Robot CMM Arm 700 travels with a belt 712 and proceeds to a first programmed target 714 . It stops and uses the foot down actuator 707 to lower its pointed foot 706 . The Mobile Robot CMM Arm 700 positions itself relative to the Global Coordinate System 461 by measuring all reference cones 713 within the arm's extension. The reproducibility of the location and orientation of the Mobile Robot CMM Arm 700 relative to the target is assumed to be better than 5mm. The procedure for measuring the location of the reference cone 713 includes a search routine over a range greater than 5 mm to first locate the reference cone before measuring it. Using the location of the local reference cone 713 , the Mobile Robot CMM Arm 700 coordinate system 363 is referenced to the global coordinate system 461 . The Mobile Robot CMM Arm 700 executes the measurement procedure 389 for this position. It then lifts its pointed foot 706 and advances to the next position. This process is repeated until the measurement procedure 389 is complete and the Mobile Robot CMM Arm 700 has returned to the charging/communication station 711. The measurement results are uploaded from the Mobile Robot CMM Arm 700 to a designated computer via the communication network 720 . At the position of at least one target 714 a reference datum on the object 9 is measured with respect to the object coordinate system 361 . This provides a reference between the object coordinate system 361 and the global coordinate system 461 .

Referring now to the measurement procedure of Figure 74:

- in a first step 741, the Mobile Robot CMM Arm 700 is moved to a first target;

- in step 742, stop the Mobile Robot CMM Arm 700 over the target, lowering the pointed foot 706;

- in step 743, referencing the Mobile Robot CMM Arm 700 to the local reference cone 713 by measuring the local reference cone 713;

- in step 744, the Mobile Robot CMM Arm 700 measures the object 9 according to the measurement program 389;

- in step 745, lift the pointed foot 706;

- In step 746, is the verification procedure complete? If finished, go to step 747. If not completed, then turn to step 748;

- In step 747, move the Mobile Robot CMM Arm 700 to the next target; go to step 742;

- in step 748, return the Mobile Robot CMM Arm 700 to the charging/communication station 711;

- In step 749, the measurement results are uploaded.

This procedure is an example of a measurement procedure and is intended to illustrate a possible measurement procedure, but the present embodiment is not limited to this preparation procedure. For example, an additional step of recharging the battery unit in the middle of the entire measurement process may be required.

Those of ordinary skill in the automated guided vehicle art will understand that the Mobile Robot CMM Arm 700 provides all the equipment needed for this application. For example, automatic actuation of wheel steering angles to steer the vehicle 701 is provided. Algorithms for belt tracking and object recognition are provided. A location map of the reference cone is provided. Safety sensors are provided to detect possible collisions. A visual and audible warning system is provided.

The scope of this fifth embodiment is not limited to the disclosed method and apparatus, but includes all methods of providing a Mobile Robotic CMM Arm 700 for automatic, precise and flexible measurement of large objects. For example, the Mobile Robot CMM Arm 700 may have three, five, or more than five wheels. The tripod base 704 can have four or more pointed feet and the foot down actuator 707 can provide a constant force on each pointed foot. Each wheel 702 can be turned independently. A radiolocation system or dead reckoning navigation system may be used in place of belt 712 and target 714 . A tool ball, optical target, or any other contact or non-contact fiducial artifact may be used in place of reference cone 713 . Multiple batteries may be provided. The measurement process can be performed on the Mobile Robot CMM Arm 700 or a computer on the network. Vehicle 701 can be combined with Robot CMM Arm 1 and Tripod Base 706 to form a self-contained system, or the vehicle can tow Robot CMM Arm 1 on Tripod Base 406 from one location to another and then withdraw during the measurement process . Vehicle 701 may be powered and operated by one or more of a variety of energy sources including: batteries, electrical power along permanently fixed cables, electrical power from rails, fuel cells, and combustibles such as gasoline. In another embodiment of this fifth embodiment, the dynamic mount is rigidly secured to the ground 718 . The Robot CMM Arm 1 can be raised and lowered by the Mobile Robot CMM Arm 700 . The Mobile Robot CMM Arm 700 tracks the belt 712 and stops at the dynamic mount. The Robot CMM Arm 1 is lowered onto the dynamic mount. The automatic locking mechanism positions and locks the Robot CMM Arm 1 in a repeatable position and orientation. When in place, the repeatability of these dynamic mounts is better than 10 microns. This is accomplished using dynamic mounting methods known to those of ordinary skill in the art to which this invention pertains, such as three cylinders oriented at 120 degrees. Prior to using the Mobile Robot CMM Arm 700, the position and orientation of the Robot CMM Arm 1 in each dynamic mount fixed to the ground is mapped using an accurate 3D measurement device such as a Leica optical tracking device. In this way, the Robot CMM Arm 1 is in the known global coordinate system 461 without needing to refer to the reference cone 713 at every location when the Mobile Robot CMM Arm 700 is used each time.

Sixth embodiment

Robotic CMM Arm with Displaceable Exoskeleton

In this sixth embodiment, an embodiment of a Robot CMM Arm with a displaceable exoskeleton is disclosed. As disclosed above, the robot program for the Robot CMM Arm can be generated off-line or formed by interactively training a series of robot movements. For most objects, both methods of programming the Robot CMM Arm are significantly slower than manually measuring the object with the Manual CMM Arm.

It is an object of this sixth embodiment to provide a Robot CMM Arm with a displaceable exoskeleton to manually measure a first object with the exoskeleton removed and automatically measure all others with the displaceable exoskeleton similar objects.

Referring now to Figure 75, there is shown a Robot CMM Arm with a Displaceable Exoskeleton 750, wherein the Exoskeleton 6 is either removed or retracted and the Internal CMM Arm 5 is manually operable. Referring now to Figure 76, the exoskeleton segment 3 43 is provided as a tube with slots milled therefrom so that the CMM segment 333 can be lifted out of the exoskeleton segment 3 43 during displacement of the exoskeleton 6. CMM segment 535 can similarly be derived from exoskeleton segment 5 45, and CMM segment 8 38 can similarly be derived from exoskeleton segment 8 48. The slotted tube has sufficient wall thickness to provide the required strength. Referring now to Figure 77, a transmission 3 73 connected to the exoskeleton segment 343 is provided as a split bearing assembly comprising an upper bearing 751, a lower bearing 752, a hinge 753 and a fastener 754 so that when fastened When member 754 is released, CMM section 333 can be lifted. Transmission 5 75 and transmission 7 77 are similarly provided as split bearing assemblies.

Referring now to Figure 78 for the measurement process using the Robot CMM Arm with Displaceable Exoskeleton 750:

- In a first step 760, the Exoskeleton 6 is displaced from the Internal CMM Arm 5; the Robot CMM Arm with the displaceable Exoskeleton 750 is automatically moved into the proper spatial layout when (a) the Internal CMM Arm 5 can easily When released from the Exoskeleton 6 and (b) the Exoskeleton 6 does not interfere with future manual use of the Internal CMM Arm 5; the transmission is manually released; the Internal CMM Arm 5 is lifted from the Exoskeleton 6; optionally, for example, by Hinge the Exoskeleton 6 to retract away from the Internal CMM Arm 5; Optionally, the Exoskeleton 6 may be removed, for example by mechanically loosening its bolted connection and de-energizing it;

- in step 761 the object 9 is manually measured using the Internal CMM Arm 5;

- In step 762, replace the Exoskeleton 6 if it has been retracted or removed; lift the Internal CMM Arm 5 into the Exoskeleton 6 and tighten the transmission;

- In step 763 one or more similar objects 9 are automatically measured using the Robot CMM Arm with the displaceable Exoskeleton 750 .

The scope of this sixth embodiment is not limited to the disclosed method and apparatus, but includes all ways in which a Robot CMM Arm with a displaceable exoskeleton 750 can be provided. Displacement of the Exoskeleton is not limited to the disclosed methods of unobstructed positioning, removal and retraction, but includes any method of displacing the Exoskeleton so that the Internal CMM Arm can be used manually. Those of ordinary skill in the art to which the present invention pertains will appreciate that the Robot CMM Arm with Displaceable Exoskeleton 750 carries all the equipment required for its manual and automatic operation. Most users have a variety of objects to measure, some objects are best measured with a Manual CMM Arm, while others are best measured with a Robotic CMM Arm. With one purchase, the Robot CMM Arm with Displaceable Exoskeleton 750 provides the user with both a Manual CMM Arm and a Robot CMM Arm. The Robot CMM Arm with Displaceable Exoskeleton 750 also has the advantage of being easy to assemble, test and repair.

Seventh embodiment

Coupling Robot CMM Arm

In this seventh embodiment, a Robot CMM Arm comprising a Coupling CMM Arm and a Robot Exoskeleton is disclosed. A CMM arm with sufficient joints exhibits spatial redundancy, where for most given positions and orientations of the probe tip, the middle joints of the arm may have a successive set of different positions. In order to manipulate the probe end of the CMM Arm while limiting the acceleration of the intermediate joint under gravity or inertial forces, the CMM Arm must be supported by the robotic exoskeleton in at least two locations: near the end of the probe and near the middle. One particular embodiment of a coupled Robot CMM Arm is now disclosed. Referring now to FIG. 79 , the CMM Arm 5 and Robotic Exoskeleton 6 are mounted adjacent to each other on Surface 7 to form a coupled Robotic Arm 780 . The base distance between the CMM Arm 5 and the robot exoskeleton 6 is optimized, which is partly done according to the extension range of the CMM Arm and the robot exoskeleton and application requirements. The CMM Arm carries the probe 90 on its final segment 38 . The CMM Arm 5 and the robotic exoskeleton 6 are connected in two locations by driven beams 771 and driven linear shafts 779 . Driven beam 771 is rigidly attached to robotic gripper 770 so that driven beam 771 sweeps a circular path as robotic gripper 770 rotates about robotic exoskeleton joint 767 . The driven beam 771 is connected to the CMM segment 737 through a rotating collar 772 and a partially constrained universal joint 778 so that the robotic exoskeleton 6 can control the positioning and orientation of the CMM segment 737. Driven linear axis 779 is connected between robot exoskeleton segment 545 and CMM segment 535. The driven linear shaft 779 is connected to the robotic exoskeleton segment 545 via a rotating collar 774 and a universal joint 776. The driven linear shaft 779 is connected to the CMM segment 535 by a rotating collar 775 and a universal joint 777. The driven linear axis 779 constitutes an 8th driven axis in addition to the seven driven axes of the robot exoskeleton 6 . The length of driven linear shaft 779 can be increased/decreased under program control using methods known to those of ordinary skill in the art to which this invention pertains. By increasing or decreasing the length of the driven linear shaft 779, the positional redundancy of the elbow of the CMM Arm 5 at the CMM Joint 454 and associated segments can be limited. The 9th driven shaft, driven rotational shaft 773, drives the CMM joint 757 and allows the probe 90 to rotate about the axis of the CMM segment 838.

There are multiple Robotic Exoskeletons 6 that can be coupled to the CMM Arm 5 to provide an embodiment of a coupled Robotic CMM Arm 780 . The scope of the seventh embodiment is not limited to the coupled Robot CMM Arm 780 disclosed in the seventh embodiment above, but includes various types of couplings of the robot exoskeleton 6 and the CMM Arm 5 through transmissions and other devices. For example, in another embodiment, the CMM Arm 5 and the Robotic Exoskeleton 6 may be connected in more than two locations. In a separate embodiment where the CMM Arm exhibits spatial redundancy and the spatial orientation of the intermediate joints is not critical, the CMM Arm 5 and the Robotic Exoskeleton 6 may only be connected at the probe end. In a different embodiment where the CMM Arm 5 does not exhibit spatial redundancy, the CMM Arm 5 and the robotic exoskeleton 6 may only be connected at the probe end.

Eighth embodiment

Manual CMM Arm with Exoskeleton

A typical Manual CMM Arm in typical usage mode has forces/moments acting on it in the following way.

- by a base 2 rigidly mounted on the support structure

- by a contact probe 95 in contact with an object rigidly mounted on the support structure

- by the operator's left hand

- by the operator's right hand

- Gravity acting on the entire Manual CMM Arm

-Connection device via balance spring

There are various causes of measurement errors of the Manual CMM Arm that make it less robust for its measurement use, including forces/moments acting on the Manual CMM Arm that cause small geometric deformations that lead to measurement errors . Some of the most significant causes of measurement errors on Manual CMM Arms include:

- Cause 1: Damage due to the Manual CMM Arm being accidentally dropped or hit against a hard object. In the first damage mode, severe damage requires that the Manual CMM Arm be returned to the factory for repair and recalibration. In the second damage mode, the accumulation of bumps over the years tends to loosen the joints in the Manual CMM Arm and thereby lose its precision;

- Cause 2: Forces and moments applied to the Manual CMM Arm by the operator's left and right hands; these forces and moments can deform the bearings and segments of the Manual CMM Arm; if the Contact Probe 95 comes into contact with an object or support structure, these forces and torque may be increased; a bad situation of bearing and segment deformation is when CMM segment 3-5 33-35 is lined up and the operator crosses CMM segment 3-5 33-35 and CMM joint 3-4 by hand 53-54 When the bending moment is applied, it may cause an error of about 0.5mm;

- Reason 3: If compensating means 210 such as internally machined springs are built into CMM joint 2 22, the balancing moment across the CMM joint 2 22 between CMM segment 2 32 and CMMS segment 3 33 can be taken from the vertical orientation of segment 3 The horizontal azimuth of segment 3 varies within a typical range of around 0Nm to around 10Nm. This variable moment will cause measurement errors from two sources: deflection of the CMM segment 333 due to the moment acting on it, and incorrect Accuracy

- Cause 4: local asymmetrical heat transfer due to operator's hand;

- Reason 5: The non-infinite rotation axis of the Manual CMM Arm collides with the buffer block, causing an impact on the Manual CMM Arm;

-Reason 6: The non-infinite rotation axis of the Manual CMM Arm bends against the bumper so that the bending moment acting on the Manual CMM Arm can be quite high (a torque of more than 10Nm on axis 2 is unusual);

- Reason 7: When measuring with a moving Manual CMM Arm as in the case of scanning with the Stripe Probe 97, the mass and inertia of the Manual CMM Arm produces dynamic measurement errors; most of the typical 10kg mass of the Manual CMM Arm is due to the need Construct a robust Manual CMM Arm that can withstand mishandling without the need for recalibration;

- Cause 8: Force exerted on the arm by the contacts at the tip of the Touch Probe 95; thus, a considerable weight of the Manual CMM Arm acts through the Touch Probe 95; if the operator 11 is carried by the Manual CMM Arm, then part of the weight of the operator It can also act through the contact probe 95;

- Cause 9: Forces and moments exerted by the optical probe 91 when held by the operator;

- Cause 10: Shocks and vibrations applied during transport; in most cases, the design of the transport situation provides undesirable forces and moments acting on the arms.

There are thousands of Manual CMM Arms on the market and they become more accurate over time. A major user issue in newer, more accurate arms is the overall balance between accuracy and robustness. As Manual CMM Arms are more precise, they are less robust. An arm that is precise in a calibration facility at the manufacturing site may lose its precision after shipping to the customer or after a short period of use by the customer.

In this eighth embodiment, a Manual CMM Arm with Exoskeleton is disclosed that includes a lightweight Internal CMM Arm and an Exoskeleton that is held by the operator, which significantly reduces these causes of measurement error and More precise and stronger than an equivalent Manual CMM Arm where the CMM is held directly by the operator.

Referring now to FIG. 80A , a provided Manual CMM Arm with Exoskeleton System 802 includes a Manual CMM Arm with Exoskeleton 800 connected to a laptop computer 151 using a cable 152 . The Manual CMM Arm with Exoskeleton 800 has a base end 2 and a probe end 3 . A Manual CMM Arm with an Exoskeleton 800 is mounted on Surface 7 . The probe 90 is mounted on the probe end 3 of the Manual CMM Arm with the exoskeleton 800 . Optical probe 91 is also mounted on probe end 3 of the Manual CMM Arm with Exoskeleton 800 . An operator button 183 is mounted adjacent to the probe tip 3 . The Manual CMM Arm with Exoskeleton 800 includes Base 4 , Internal CMM Arm 5 , Exoskeleton 801 , Compensation Device 210 on Exoskeleton Joint 262 and Transmission 10 . The measured object 9 is located on the surface 7 .

The Exoskeleton 801 is lightweight and the Transmission 10 supports the Internal CMM Arm 5 in order to minimize the stress on the Internal CMM Arm 5 . The Exoskeleton 801 protects the Internal CMM Arm 5 . The exoskeleton 801 is flexible with typical segment deflection on any one long segment xxx, xxx being from 0.1 to 5mm, but segment deflection may be greater than 5mm or less than 0.1mm. Any bending of the exoskeleton 801 is absorbed by the compliance in the actuator 10 supporting the rigid inner CMM arm; in other embodiments, the exoskeleton 801 may be rigid. The exoskeleton 801 is made of high-strength and light-weight material such as carbon fiber or hard plastic, and may also be made of any functional material. The Exoskeleton 801 fully encapsulates the Internal CMM Arm 5 to fully protect it, but it may only partially encapsulate the Internal CMM Arm 5 in other embodiments. Exoskeleton 801 is ergonomically designed to be held by an operator. The Internal CMM Arm 5 is lightweight; due to the protection of the Exoskeleton 801, the Internal CMM Arm 5 does not need to be designed to be strong enough to withstand the loads imposed in use against operating procedures. The Internal CMM Arm 5 does not include the additional weight associated with protective functions for normal use and violations of operating procedures, environmental sealing, ergonomics, electronics, and decorations, all of which are provided by the Exoskeleton 801 to process. For this reason, the Internal CMM Arm 5 weighs less on average per unit length.

The eighth embodiment of the Manual CMM Arm with Exoskeleton 800 invention of the CMM Arm with Exoskeleton is used with an optical probe 91 attached to the Internal CMM Arm 5 . The exoskeleton 801 is held by the operator 11 . The optical probe 91 is designed such that it is protected by the exoskeleton 801 from being held by the operator 11 . In this way, the operator cannot directly stress the Internal CMM Arm 5 or the Optical Probe 91 , and the Manual CMM Arm with Exoskeleton System 802 is more precise than an equivalent Manual CMM Arm without Exoskeleton 790 .

In an alternative embodiment, a Manual CMM Arm with an Exoskeleton 800 is used with an Optical Probe 90 attached to the Internal CMM Arm 5 . The exoskeleton 801 is held by the operator 11 . As such, the operator cannot place direct stress on the Internal CMM Arm 5 or the Optical Probe 90 , and the Manual CMM Arm with the Exoskeleton System 802 is more precise than an equivalent Manual CMM Arm without the Exoskeleton 790 .

wireless button unit

So far, the buttons used to control the Manual CMM Arm with Exoskeleton 800 have been hardwired to and through the arm. This constrains the button to one or more fixed positions, or at most one rotational position on the seventh axis or on a rotary button collar with a slip ring. A new embodiment for controlling the Manual CMM Arm with Exoskeleton 800 provides an integrated wireless button unit 814 where the control buttons 183 are conveniently placed by the user. The wireless button unit 814 includes one or more buttons 183 , a transmitter 815 and is powered by a self-contained battery 816 . The wireless button unit 814 carries a carrier 843 that includes a seat for the wireless button unit and one or more Velcro straps 844 for securing the carrier at almost any location along the exoskeleton 6 . A wireless receiver 847 is provided, integrated on the Manual CMM Arm with Exoskeleton System 802 and built into Base 4 . Antenna 848 for wireless receiver 847 may or may not be present. Antenna 848 may or may not be external and/or removable. In another embodiment, a sliding and rotating carrier 845 is provided on each of the long cylindrical sections of the exoskeleton 6 . The wireless button unit 814 has a simple compliant press fit into the carrier 843 or slide and swivel carrier 845 so that it can be quickly positioned on or removed from any compatible carrier. Sliding and rotating carriers 845 are generally not removed from their respective exoskeleton segments. The slide and rotate carrier has a simple brake/release control 846; in the brake position it cannot slide or rotate; in the release position the operator can slide or rotate it to the desired position. Brake/release controls 846 can be operated individually. When the Manual CMM Arm with Exoskeleton 800 is used as an indicator and the buttons 183 are used as select buttons, the buttons 183 can control any function of the Manual CMM Arm with Exoskeleton System 802 using appropriate system hardware and software, including User interface point and select function.

buffer block

Referring now to FIG. 80B , the Manual CMM Arm with Exoskeleton 800 has bumpers 818 to allow the arm to rest in a parked position with base end 2 oriented vertically upward, with joint center 424 being the highest joint center and probe end 3 facing The base 4 hangs downwards so that the section of the arm behind the joint center 222 is not under the force of gravity. The bumper 818 located on the exoskeleton joint 2 62 provides a parking point beyond the parking angle R from the vertical, wherein the exoskeleton joint 2 62 passes just past the exoskeleton joint 1 61, thereby allowing the The center of gravity of that portion of the Manual CMM Arm of skeleton 800 is located on the bumper side of the vertical shaft above joint center 222 . A typical value for R is 5 degrees but could be more or less. When the exoskeleton is parked on the bumpers, the CMM Joint 252 rotates fairly freely before reaching any hard limiters. The advantage of the bumper 818 acting within the exoskeleton 802 is that if the exoskeleton 802 is pushed hard against the bumper 818, the Inner CMM Arm 5 is not affected by the impact when the bumper 818 contacts or is subjected to a bending moment, which is Meaning the design of the Internal CMM Arm 5 can be lighter and the Manual CMM Arm with Exoskeleton 800 stronger overall. In addition, a magnet 817 may be provided between the exoskeleton segment 242 and the exoskeleton segment 343 positioned close to the bumper 818 or in an alternative leverage position such that considerable actuation pressure is required to overcome the magnetic attraction and actuate the rotation of the joint center 222; This means that it is more difficult to accidentally bump the arm when passing vertically, causing it to fall under gravity and become damaged. In an alternate embodiment, magnet 817 may serve the dual purpose of a bumper and damping magnet.

Characterization and reduction of measurement errors

The Manual CMM Arm with Exoskeleton 800 is provided in various embodiments of devices that include the benefits previously disclosed in this invention, including but not limited to: with one, two, or more Read Heads 186 CMM encoder 178, CMM temperature sensor 180, CMM strain gauge 181, gantry 110 and other mounting devices, prestressed bearings, any type of optical probe, any type of contact probe including pressure probe 99, any number of Probes, calibration devices, moving gear, batteries and battery charging devices for the arm and any or all equipment such as probes attached thereto, and any design that enables the functioning of the Manual CMM Arm with Exoskeleton System 802 The overall structure of the system.

This eighth embodiment of the Manual CMM Arm with Exoskeleton 800 reduces the sources of measurement error in a number of ways:

Reason 1 reduction: Manual CMM Arm with Exoskeleton 810 is designed to withstand bumps and drops up to a reasonable level of protocol violation. The exoskeleton 801 absorbs most of the impact, the inner CMM Arm 5 is shielded by the exoskeleton 801 and all impact loads are transmitted through the transmission 10 only. If falling, one of the most likely points of impact is the probe 90 and other means for reducing this cause of measurement error are disclosed later in this disclosure.

Reason 2 reduction: Transmission 10 ensures that only the optimal support force against gravity is applied to the Internal CMM Arm 5 of the Manual CMM Arm with Exoskeleton System 812 . In this way, the torque applied by the operator is mainly absorbed by the Exoskeleton 801 and not applied to the Internal CMM Arm 5 . This includes the case where the CMM segments 3, 4 33 and 34 are lined up, and where the operator manually applies a bending moment across the exoskeleton segment 3-5 43-45 and the exoskeleton joint 3-4 63-64, at In this case, the exoskeleton segment 3-5 43-45 and the exoskeleton joint 3-4 63-64 are then deformed without being imposed by the transmission 3-5 73-75 across the CMM segment 3-5 33- 35 and CMMJ joints 3-4 53-54 significant bending moments because the gearing is low in stiffness and absorbs deformation without transmitting significant moments.

Reason 3 reduction: The balance torque applied by the compensating device 210 is applied through the exoskeleton 801 and not through the internal CMM arm 5 . This means that the moments of the compensating device 210 do not act on the CMM section 333 which is simply supported. The deflection of CMM Segment 3 33 is approximately 30 times lower than the deflection of a corresponding Manual CMM Arm with a balancing torque applied to CMM Segment 3 33. This balancing torque applied to the Manual CMM Arm on the CMM Segment 333 requires a stiffer and heavier CMM Segment 333. Thus, a Manual CMM Arm with Exoskeleton 810 is more precise and lighter than a Manual CMM Arm with a balancing torque applied to CMM Segment 333.

Reason 4 reduction: The operator's hand holds the exoskeleton instead of the internal CMM arm. The exoskeleton is thermally insulated from the internal CMM arm, significantly reducing localized heat transfer through the operator's hands.

Reduced for reason 5: Having a bumper on the exoskeleton so there is no need for a bumper on the inner CMM arm. When the operator moves the Manual CMM Arm with the Exoskeleton 810 and it hits a bumper to decelerate the Exoskeleton 801 quickly, the Transmission 10 absorbs more of the shock, reducing the level of deceleration on the Internal CMM Arm 5 .

Reduced for reason 6: Having a bumper on the exoskeleton so there is no need for a bumper on the inner CMM arm. When the operator bends the Manual CMM Arm with Exoskeleton 810 against the bumper, Exoskeleton 801 deflects to absorb all bending moments while the Internal CMM Arm 5 experiences no bending moments.

Reason 7 Reduction: The Internal CMM Arm 5 of the Manual CMM Arm with Exoskeleton 810 can be lighter than the Manual CMM Arm. This will reduce measurement errors in its dynamic scanning performance.

Probes and Optical Probe Covers

Referring now to FIG. 81 , the probe cover 803 is attached to the probe end of the exoskeleton 801 . The probe cover 803 has three modes of use: down, displaceable and retracted. The probe cover lever 805 is used to move the probe cover 803 between the three modes of use. In the lay-down mode, the probe cover 803 protects the probe 90 in case of accidental bumps; the lay-down mode is the normal mode for transport, assembly in a new location, and when using the optical probe 91 . In the displaceable mode, the probe cover 803 is displaceable to enable the probe 90 to perform contact measurements. The probe cover 803 is displaced axially upwards against the probe cover spring 806 so that it is normally in a position covering the probe 90 and protecting the probe 90 from side impacts. When the probe 90 is placed axially onto the object 9, the probe cover spring 806 bears some of the weight of the Manual CMM Arm with the Exoskeleton 800 and thus acts as a compensator. In the retracted mode, the probe cover 803 is retracted leaving the probe 90 fully exposed. The probe cover 803 can be used with any type of probe 90, especially one that is not pliable or fragile, including a trigger probe 92 with or without a detachable stylus, with or without a detachable stylus. Needle pressure probe 99 and fixed contact probe 95. The probe cover 803 can be made from most engineering materials, but is preferably a lightweight, rigid material. Preferably, a soft coating such as rubber is preferred to make it comfortable to hold and move between the three modes more comfortably. The probe cover 803 is transparent so that the probe 90 can be seen through it.

Cause 8 Reduction: The probe cover 803 reduces this source of measurement error in a number of ways, including: The probe cover 803 absorbs the exoskeleton 810 through the exoskeleton 810 in the various orientations of the lay-down mode and the displaceable mode. The weight of the Manual CMM Arm and protects the probe 90 from bumps. When measuring in displaceable mode, small additional pressure by the operator on the exoskeleton 810 brings the probe 90 into contact with the surface of the object 9 with low contact force; ideal contact weights are in the range of 10-30g. Renishaw TP 20 probes are preferred for probe 90 but most tactile trigger and fixed probes can also be used. In retractable mode, there is no reduction in measurement error, but the retracted probe cover 803 has the advantage that it enables sufficient access to the Manual CMM Arm with Exoskeleton 810 to measure inaccessible areas.

Referring now to FIG. 82A, an optical probe cover 804 is disclosed. The optical probe cover 804 is connected to the exoskeleton 801 and configured to protect the optical probe 91 . The optical probe cover 804 can be gripped by the operator and does not transmit force or moment to the optical probe 91 . The optical probe cover 804 protects the optical probe 91 in the event of an accidental bump. Referring now to FIG. 82B , the second purpose of the Optical Probe Cover 804 is to serve as a handle so that the Manual CMM Arm with Exoskeleton 800 can be more easily held by the Operator 11 . Either or both of optical probe cover 804 and probe cover 803 may be provided in the Manual CMM Arm with Exoskeleton 800 . The Optical Probe Cover 804 reduces sources of measurement error in many ways, including:

Reason 9 Reduced: Optical Probe Cover 804 absorbs the weight of the Manual CMM Arm with Exoskeleton 810 and can be held by the operator. When the operator holds the optical probe cover 804, the optical probe 91 receives no force or moment.

part exoskeleton

In another embodiment of this eighth embodiment, exoskeleton 802 may be a partial exoskeleton with fewer exoskeleton segments than CMM segments. Referring now to FIG. 83A, a partial exoskeleton 807 is provided comprising three exoskeleton segments 1-3 41-43 and two exoskeleton joints 1-2 61-62. This partial exoskeleton 807 has compensating means 210 at the exoskeleton joint 262 which are preferably machined springs and are contained within the shell of the partial exoskeleton 807 . This means that a Manual CMM Arm with Exoskeleton 800 where the exoskeleton is a partial exoskeleton 807 has the usability of a counter-arm, the portability advantages of a single housing around the lower section, and the compensating device does not pass through any of the CMM sections 1- 3 31-33 or CMM joint 1-2 51-52 apply torque, which provides the advantages of accuracy and aesthetics of a neat and compact fit around the CMM section 1-3 31-33. The partial exoskeleton is not limited to partial exoskeleton 807, but may include fewer segments and or joints than partial exoskeleton 807, or more segments and or joints. Referring now to FIG. 83B, an extension portion exoskeleton 808 is provided comprising four exoskeleton segments 1-4 41-44 and two exoskeleton joints 1-3 61-63. Extended Partial Exoskeleton 808 is closer to CMM Joint 454 than Partial Exoskeleton 807 is when supporting Internal CMM Arm 5 . This means that in the extension part exoskeleton 808, the bending moment acting on the CMM segment 434 is smaller compared to the part exoskeleton 807, and has the aesthetic advantage that the extension part exoskeleton 808 terminates neatly at the elbow . Exoskeleton joint 363 has substantially the same joint location as CMM joint 353 . Alternatively, the exoskeleton joint 363 could be provided closer to the elbow and combined with the transmission 474 as a bearing. However, the CMM connector 4 is vulnerable to collisions. Referring now to Figure 83C, a protective extension partial exoskeleton 809 is provided, which is a preferred partial exoskeleton embodiment comprising five exoskeleton segments 1-5 41-45 and four exoskeleton joints 1-4 61-64. The exoskeleton segment 545 is the short segment that covers the elbow and contains bumpers 819 as impact absorbing elements. The Protective Extension Exoskeleton 809 supports the Internal CMM Arm 5 near the CMM Joint 454 in the same area as the Extension Exoskeleton 808 via the Transmission 474. The short exoskeleton segment 545 rotates around the exoskeleton joint 464. Gearing 5 is provided to minimize any bending moments acting on CMM Segment 535. This means that the short exoskeleton segment 545 and in particular the bumper 819 protects the CMM joint 454 from bumps during use, from heat transfer from the operator's hand, and from protocol violations such as drooping elbows. This partial exoskeleton embodiment is not limited to the disclosed embodiments, but may include any arrangement in which the number of joints and segments in the Exoskeleton 6 is lower than the number of joints and segments in the Internal CMM Arm 5 . For example, a partial exoskeleton may include exoskeleton segments 1 - 5 , exoskeleton joints 1 - 5 and two actuators 10 located in front of the elbow CMM joint 4 and in front of the wrist CMM joint 6 . The advantage of this setup is the ease of supporting the two long CMM segments so that the load is repeatable over most of the length of the Inner CMM Arm 5 wherever the Exoskeleton 6 is held.

Connector grouping

In a conventional manual CMM arm, CMM Joint 3 53 is provided adjacent to CMM Joint 4 54 rather than adjacent to CMM Joint 252 so as not to inconvenience the operator from holding the rotating section. Similarly, CMM Connector 5 is provided adjacent CMM Connector 6 56 rather than CMM Connector 4 54. Conventional manual CMM arm CMM joint layouts grouped by CMM joints at shoulder-elbow-wrist are called 2-2-2 for 6-axis arms and 2-2-3 for 7-axis arms, the advantages of which are During motion the mass is closer to the base than to the probe end; this means the user feels the arm is lighter and the user is less tired. At each joint there is mass from at least the bearings and the encoder. In a Manual CMM Arm with Exoskeleton 800 or its alternate embodiment with Partial Exoskeleton 807, Extended Partial Exoskeleton 808, or Protection Extended Partial Exoskeleton 809, or any other type of Partial Exoskeleton, the CMM Joint 353 may Provided adjacent CMM connector 2 52 rather than adjacent CMMJ connector 4 54, as shown in Figure 83C. The shoulder-elbow-wrist CMM joints are grouped into 3-1-2 for the 6-axis arm and 3-1-3 for the 7-axis arm, respectively. In a Manual CMM Arm with Exoskeleton 800, CMM Joint 5 55 may be provided adjacent to CMM Joint 2 52 instead of adjacent to CMM Joint 454. This means that the shoulder-elbow-wrist CMM joints are grouped as 3-2-1 for 6-axis arms and 3-2-2 for 7-axis arms. On the same arm, the shoulder-elbow-wrist exoskeleton joints are grouped as 2-2-2 for the 6-axis arm and 2-2-3 for the 7-axis arm, respectively. This means that the CMM joint grouping is different from the Exoskeleton joint grouping and provides the advantage that the Manual CMM Arm with Exoskeleton 800 is easier to use. The Manual CMM Arm embodiment with exoskeleton 800 and embodiments with partial exoskeleton 807, extension partial exoskeleton 808, or protective extension partial exoskeleton 809 or any other type of partial exoskeleton can have one transmission per moving segment The device may alternatively have less or more than one transmission per moving section.

Measurement and Scanning Methods

Provides a measurement method for manual contact measurements using a Manual CMM Arm with Exoskeleton 800 without requiring the operator to hold the Internal CMM Arm 5 or the Contact Probe 95 mounted on the probe on terminal 3. Referring now to FIG. 83D , in a first step 881 the operator grasps the Exoskeleton 801 of the Manual CMM Arm with the Exoskeleton 800 and moves it to bring the Contact Probe 95 into contact with the Object 9 in the desired location. In step 882, the operator depresses the operator button 183 thereby triggering the measurement. In step 883 , the Manual CMM Arm with Exoskeleton System 802 responds to the button trigger signal and generates a position and/or orientation of the Contact Probe 95 .

Provides a measurement method for automated contact measurements using a Manual CMM Arm with Exoskeleton 800 without the need for an operator to hold the Internal CMM Arm 5 or the Force Probe 99 mounted on the probe end 3 on. Referring now to FIG. 83E , in a first step 891 , the operator grasps the Exoskeleton 801 of the Manual CMM Arm with the Exoskeleton 800 and moves it so as to bring the force probe 99 into contact with the object 9 in the desired position. In step 892 the force probe 99 detects the contact of step 881 and automatically triggers the Manual CMM Arm with Exoskeleton System 802 . In step 893 , the Manual CMM Arm with Exoskeleton System 802 responds to the signal and generates a position and or orientation of Force Probe 99 . This method is applicable when using a touch probe 92 instead of the force probe 99 . Another advantage of this method is that the operator does not need to press a button in order to extract points.

Provides a non-contact scanning method using a Manual CMM Arm with an Exoskeleton 800 having a Optical probe 91 on. Referring now to FIG. 83F , in a first step 901, the operator grasps the Exoskeleton 801 of the Manual CMM Arm with the Exoskeleton 800 and moves it so that the surface of the object 9 in the desired position is within the range of the optical probe 91. within the measurement range. In step 902 , the operator depresses operator button 183 located on the Manual CMM Arm with Exoskeleton 800 . In step 903, the Manual CMM Arm with Exoskeleton System 802 responds to the signal and starts scanning. In step 904 , the operator moves the Manual CMM Arm with Exoskeleton 800 relative to the object 9 so that the surface of the object 9 stays within the measurement range of the optical probe 91 . In step 905 , the operator depresses operator button 183 located on the Manual CMM Arm with Exoskeleton 800 . In step 906, the Manual CMM Arm with Exoskeleton System 802 responds to the signal and stops scanning.

A contact scanning method is provided that utilizes a Manual CMM Arm with an Exoskeleton 800 that has a A force probe 99 with automatic scanning capability such as the Renishaw MSP-3. Referring now to FIG. 83G , in a first step 911 the operator grabs the Exoskeleton 801 of the Manual CMM Arm with the Exoskeleton 800 and moves it so that the Force Probe 99 contacts the Object 9 in the desired area and leaves it there. There for a minimum period of time T. In step 912 the force probe 99 detects the contact of step 911 for a minimum period longer than time T and automatically starts scanning. In step 913, the operator moves the Manual CMM Arm with Exoskeleton 800 relative to the object 9 so that the force probe 99 remains in contact with the surface of the object 9 while the force probe 99 continues to scan. In step 914 , the operator moves the Manual CMM Arm with Exoskeleton 800 away from the object 9 in order to disengage the force probe 99 from the surface of the object 9 . In step 915, the force probe detects the contact loss of step 914 and automatically stops scanning. Another advantage of this approach is that the operator does not need to press buttons during the scanning process.

Automatic Calibration of the Manual CMM Arm

Novel robotic calibration equipment is provided for automatic calibration of Manual CMM Arms in order to remove human error in the calibration process and provide benefits such as repeatability and cost savings associated with automation.

In a modular embodiment of the novel robotic calibration apparatus, the drive unit is temporarily mounted on the Manual CMM Arm with Exoskeleton 800 . Referring now to FIG. 83H , the modular robot calibration apparatus 920 includes seven drive unit modules 921 connected to the control box 159 by seven cables 922 . Drive unit 921 is assembled on the Manual CMM Arm with Exoskeleton 800 in a rapid assembly process. The drive unit 921 drives the Exoskeleton 801 such that no forces and moments are exerted on the Internal CMM Arm 5 . The exoskeleton 801 provides at least two clamping flanges 923 at each joint, one flange 923 attached to each segment adjacent the joint capable of receiving and distributing input from the drive unit module 921 through adjacent exoskeleton segments. torque. The combined Manual CMM Arm with Exoskeleton 800 and Modular Robotic Calibration Set 920 is effective in a temporary embodiment of the Robotic CMM Arm. The preferred number of shafts is 6 or 7, but any other number of shafts may be provided. The combined Manual CMM Arm with Exoskeleton 800 and Modular Robotic Calibration Apparatus 920 can automate calibration procedures, such as those previously disclosed, in order to calibrate the Robot CMM Arm 1 .

In an alternative temporary Robotic CMM Arm embodiment of a novel robotic calibration apparatus, the Internal CMM Arm 5 is manipulated by an Exoskeleton 6 with automatic drives for automatic calibration of the Internal CMM Arm 5 . Thus, the device is temporarily the Robot CMM Arm 1 for calibration purposes.

A method is provided for calibrating a Manual CMM Arm with Exoskeleton 800 using any of the above embodiments of the novel robotic calibration apparatus. In an optional first step, the Manual Exoskeleton 6 is removed from the Internal CMM Arm 5; this step is not required if the Internal CMM Arm 5 has just been manufactured and has no Manual Exoskeleton 6 fitted to it. In a second step, the Robotic Exoskeleton 6 is attached to the Internal CMM Arm 5 . Attachment may be achieved by any of the disclosed procedures such as 'wrapping', 'sock' or 'inserting' or any other attachment method. In a third step, calibration is performed automatically by any of the previously discussed methods. In a fourth step, the Robotic Exoskeleton 6 is removed from the calibrated Internal CMM Arm 5 . In a fourth step, the Manual Exoskeleton 6 is connected to the calibrated Internal CMM Arm 5 to form a calibrated Manual CMM Arm with Exoskeleton 800 . Attachment may be achieved by any of the disclosed processes such as 'wrapping', 'sock' or 'inserting' or any other attachment process.

In a preferred external embodiment of the novel robotic calibration apparatus, the Manual CMM Arm is covered by a robotic exoskeleton. Referring now to FIG. 83I , the external robotic calibration device 930 includes a Manual CMM Arm with an Exoskeleton 800 and a Robotic Exoskeleton 6 that supports the Existing Manual CMM Arm with an Exoskeleton 800 through another transmission 10. exoskeleton6. The robot exoskeleton 6 is connected to the control box 159 by a cable 922 . A unique feature of this embodiment is that the Internal CMM Arm 5 has two Exoskeletons: a middle Manual Exoskeleton 6 and an outer Robotic Exoskeleton 6 . In this embodiment, less robotic actuators are required to support the Manual CMM Arm with Exoskeleton 800, since the Manual Exoskeleton 6 already optimally supports the Internal CMM Arm 5 and the robotic actuators only need to move the The 6-axis or 7-axis Manual CMM Arm of skeleton 800 is held in a minimum of two positions to allow it to be moved in any orientation. As previously stated, a minimum of 3 or 4 positions is preferred in order to reduce drive train volume.

The combination of the Manual CMM Arm with Exoskeleton 800 and the Robotic Exoskeleton 6 can automate calibration procedures such as those previously disclosed for calibrating the first embodiment of the Robot CMM Arm 1, which may include additional axes, Additional artifacts, a large number of measurement points, and a large number of spatial orientations. This integrated embodiment of the new robotic calibration device can also be used to calibrate a conventional Manual CMM Arm without an Exoskeleton 790 .

In an alternative hybrid embodiment of the novel robotic calibration apparatus, the novel robotic calibration apparatus comprises a partial robotic exoskeleton and a partial modular drive unit and is used for automatic calibration with partial exoskeleton 807, extended partial exoskeleton 808, or protective extended partial exoskeleton 809's Manual CMM Arm. The lower joint with exoskeleton is driven by drive unit 921 and the upper unit without exoskeleton is driven by part of exoskeleton 6 .

Another method is provided for calibrating the Manual CMM Arm using any of the above-described embodiments of the novel robotic calibration apparatus without disassembling the Manual CMM Arm. This alternative method is suitable for calibrating Manual CMM Arm with Exoskeleton 800, Regular Manual CMM Arm without Exoskeleton 790, Manual CMM Arm with Partial Exoskeleton 807, Manual CMM Arm with Extended Partial Exoskeleton 808 Any of a CMM Arm and a Manual CMM Arm with Protective Extension Exoskeleton 809. In the first step, the drive unit is attached to the Manual CMM Arm. Connection may be achieved by any one or any combination of the disclosed processes such as 'modular connection', 'wrapping', 'sock' or 'insertion' or any other connection process. In a second step, calibration is performed automatically by any of the previously discussed methods. In a third step, the drive device is removed from the Calibration Manual CMM Arm. An advantage of this alternative method is that it does not require the steps of disassembly and reassembly of the Manual CMM Arm.

The advantages of automatically calibrating the Manual CMM Arm with Exoskeleton 800 or the Internal CMM Arm 5 using any of the above embodiments of the novel robotic calibration apparatus are:

- No human work except for connecting and disconnecting the drive equipment; this saves costs

- No human error; this increases accuracy

- faster acquisition in terms of calibration points per second

-The calibration process can last for a longer period than an equivalent manual process, as the operator becomes tired while the robot-driven device can operate tirelessly

-More calibration points can be extracted than with an equivalent manual process; this increases accuracy

Whatever the case, the Manual CMM Arm with Exoskeleton 800 or without Exoskeleton 790 will need to be designed to take into account the need to interface with equipment for automatic calibration. In particular, the Internal CMM Arm 5 will need to be strong enough to be calibrated accurately whether it has a manual exoskeleton 5 or a robotic exoskeleton 6 . Preferably, the supported Internal CMM Arm 5 is located in the same position and the transmission 10 is of the same type for manual and robotic Exoskeletons 6 . The invention is not limited to the described embodiments, but includes all methods of automatically manipulating a Manual CMM Arm or an Internal CMM Arm for calibration.

shipping box

The Manual CMM Arm with Exoskeleton 800 is portable and will typically be transported in a transport case. The only direct connection of the Internal CMM Arm 5 to the transport case is through the Base 4. In all other positions, the Internal CMM Arm 5 is isolated from shock and vibration by the transmission 10, which is designed to absorb noise and vibration. Most of the mass of the Manual CMM Arm with Exoskeleton 800 is in the high density base 4 and has a small contact surface area with the foam in the transport case. The majority of the contact surface area of the Manual CMM Arm with Exoskeleton 800 is the surface of Exoskeleton 801 whose corresponding mass and volume is low density compared to the base. In impact conditions, when the accelerations between the transport case and the Manual CMM Arm with Exoskeleton 800 are not consistent, the force density generated by the impact is low around the surface of the Exoskeleton 801 and is generated by the impact around the surface of the Base 4 The force density is high. The force density generated by the impact is approximately 5-100 times higher around the surface of the base 4 than around the surface of the exoskeleton 801 . During a crash, the foam around the base 4 may compress 5-100 times more than the foam around the surface of the exoskeleton 801 . This compression ratio is related to the different mass to surface area ratios of the base 4 and the exoskeleton 801 along each impact force direction. Base 4 and exoskeleton 801 have two different decelerations. These two different decelerations create shock forces and moments inside the Manual CMM Arm with Exoskeleton 800 that can cause damage to it. In the event that the shock is longitudinally downward and the base 4 of the transport case and the Manual CMM Arm with Exoskeleton 800 is higher than the exoskeleton joint 464, such as when the transport case is dropped on its end, the movement of the base 4 The mass will accelerate and generate significant compressive forces on the exoskeleton segments 2-4 32-34 between the base 4 and the exoskeleton joint 464. In the event that the impact spans the transport case laterally and the Manual CMM Arm with Exoskeleton 800 is approximately horizontal, as when the transport case is dropped on its base, the base 4 will be displaced further down than the Exoskeleton 801 And after the base 4 encounters the exoskeleton segment 2 32, a significant bending moment is produced on the exoskeleton segment 2-3 32-33.

Referring now to FIG. 84 , a transport case 830 for a Manual CMM Arm with Exoskeleton 800 is disclosed that reduces the shock and vibration experienced by the Internal CMM Arm 5 during transport. The transport case 830 has upper and lower halves connected by hinges 836 along the long sides of the transport case 830 . The shipping box 830 is filled with a filler material 831 such as foam. There are two arm cutouts 837 in the filler material 831 . Arm cutout 837 is precise and packing material 831 is in contact with the Manual CMM Arm with Exoskeleton 800 , there will be no air gaps other than cutouts 832 in filler material 831 . In this embodiment of the invention, a light and rigid spreader form 833 is provided which significantly increases the surface area in contact with the fill material 831 in the desired direction. Before, during or after placing the transport box 830 in the Manual CMM Arm with Exoskeleton 800, the Base 4 of the Manual CMM Arm with Exoskeleton 800 is attached to the Spreader Form 833 by fixing means such as bolts 838 . The spreader form 833 has a substantial effective surface area in contact with the fill material 831 in all directions. In a preferred embodiment, the surface area of the spreader form 833 lies primarily in three orthogonal planes. The overall surface area of Spreader Form 833 in any direction is optimized to minimize the damaging forces and moments on the Manual CMM Arm with Exoskeleton 800 due to different local deflections of packaging material 831 . In either direction, the center of area of the Spreader Form 833 approximately passes through the centroid Cg of the Base 4 of the Manual CMM Arm with Exoskeleton 800 . This means that, in the event of an impact, little moment of inertia is generated in the base due to the apparent misalignment of the center of mass Cg of the base 4 with the center of area of the spreader form 833 . In alternative embodiments of the spreader form 833, other shapes of the spreader form 833 may be used which: (a) minimize different local deflections of the fill material 831, (b) spread the spreader form in any direction The center of area of 833 approximately passes through the center of mass Cg of the base 4 . In this way, the directional force density of the impact on the transport box 830 is the same as that on the rigidly connected spreader plate 833 /base 4 and exoskeleton 801 . In the support area around the probe tip 3, the filler material 831 can be cut away so that neither the CMM section 838, the probe tip 3, nor the probe 90 is in contact with the packing material 831, since, if present, the CMM section 838, probe tip 3 and The probes 90 are all supported by the transmission 10 . The filler material 831 may also be optimized to avoid contact with the exoskeleton 801 by cutting 832 at one or more locations. Optionally, a localized mass of less elastic wrapping material 834 may be provided at the location of contact with the Manual CMM Arm with Exoskeleton 800 , which is less elastic than the bulk of the wrapping material 831 . Optionally, a localized mass of higher elastic packaging material 835 may be provided at the location of contact with the Manual CMM Arm with Exoskeleton 800 , which is more elastic than the bulk of the packaging material 831 . One of ordinary skill in the art can use 3D CAD analysis software for simulating the inertia under impact conditions to optimize the splitter plate 833, cut-out material 832, local mass of less elastic filler material 834 and local mass of higher elastic fill A combination of one or more of materials 835. In order to minimize the size of the transport case 830, when the Manual CMM Arm with Exoskeleton 800 is in the transport case 830, the two long sections of the Manual CMM Arm with Exoskeleton 800 will be parallel or nearly parallel. The shape and position of the spreader form 833, cutout material 832, localized mass of lower elastic wrapping material 834, and localized bulk of higher elastic wrapping material 835 are optimized for longitudinal and transverse impact conditions. The outer shell 839 of the transport case 830 is made of a suitable material such as ultra high molecular weight polyethylene and has shape features such as ribbing to absorb shock and vibration. The overall shape is not limited to six orthogonal sides, but can have any number of sides with complex curvilinear shapes. The size and shape of the housing 839 and the location and placement of the Manual CMM Arm with Exoskeleton 800 in the transport case 830 define the distance between the housing 839 and the Manual CMM Arm with Exoskeleton 800 at any point. The size and shape of the housing 839 is optimized to coordinate the deflection of the filler material 831 due to impact from various directions. Fittings such as tongue and groove edges and neoprene gaskets are provided to prevent moisture ingress. Heavy duty latches are provided.

Reason 10 Reduction: The Transport Case 830 greatly reduces the forces and moments on the Manual CMM Arm with Exoskeleton 800 due to impacts to the Transport Case 830 during transport by enabling an even force density during impact.

Ninth embodiment

Manual CMM Arm with Holding Exoskeleton

In another embodiment of the Manual CMM Arm with Exoskeleton, a holding device 811 is provided. Referring now to FIG. 85, the Manual CMM Arm with Retention Exoskeleton System 812 has retention devices such as brakes 811 provided at Exoskeleton Joints 1-4 61-64 of the Manual CMM Arm with Retention Exoskeleton 810. The holding means is preferably a brake 811 which is an electromagnetic brake operating on a disc 813, but the holding means may hold the arm by any means including:

- manually operable mechanical connection;

- force-actuated mechanical connection;

- brakes using any force including electromagnetic, pneumatic and hydraulic;

- Clutches using any force including electromagnetic, pneumatic and hydraulic forces.

The brake 811 may be actuated when the exoskeleton joint is at rest. Alternatively, the brake 811 may be actuated while the exoskeleton joint is moving and then not braked until the exoskeleton joint comes to rest at the held point. The brake 811 can be applied to more or fewer exoskeleton joints than the exoskeleton joints 1-4 61-64. The brakes 811 act on the Exoskeleton 801 rather than the Internal CMM Arm 5 . This means that there is no moment applied across the joints of the Internal CMM Arm 5 due to the application of the brake 811, and the Manual CMM Arm with the Retaining Exoskeleton 810 is faster than the equivalent Manual CMM Arm with the Retaining Device but without the Exoskeleton 801. more accurate. The actuator 811 can be actuated by an operator using a switch using a wired or remote wireless transmission. Different switches can actuate different combinations of brakes 811 . In the event of an electrical power failure, the use of electrically actuated brakes 811 can perform work to brake in the event of loss of electrical power and prevent the Manual CMM Arm with Retaining Exoskeleton 810 from falling under the force of gravity. In an alternative embodiment, gearing could be provided between the brake 811 and the exoskeleton joint in order to reduce the required braking torque and thereby reduce the weight of the brake; this has the disadvantage of increasing the Manual work required for the 810's Manual CMM Arm.

Tenth embodiment

Manual CMM Arm with Endoskeleton

In this tenth embodiment, a Manual CMM Arm with an Endoskeleton is provided. Referring now to FIG. 86A , there is shown an unsupported Manual CMM Arm with a vertical base axis and CMM Segment 3 33 in a horizontal spatial orientation, which is one embodiment of a prior art Manual CMM Arm. In this horizontal spatial orientation, CMM Segment 3 33 is supported at CMM Joint 2 52 with force Fn1. An internal compensating device 210 is provided at the CMM Joint 252 which provides a balancing moment Mn acting on the CMM Section 333 to compensate the force Fn2 of the remaining weight of the Manual CMM Arm behind the CMM Joint 353. In the state of the art, CMM segment 333 is subjected to relatively large bending moments of the order of 10 Nm in the horizontal spatial orientation shown. This causes the CMM segment 333 to bend and deflect significantly. This deflection cannot be measured by the CMM encoder 178 and results in a loss of measurement accuracy. This deflection can be reduced by making the CMM Section 333 more rigid, but at the expense of increased weight and cross-sectional size of the CMM Section 333. Referring now to FIG. 86B , a CMM Arm with Exoskeleton 800 is provided, and CMM Segment 3 33 is also shown with a vertical base axis and in a horizontal spatial orientation. The CMM section 333 is only supported at the CMM joint 252 by force Fx1, and supported by the transmission device 373 by force Fx2. Any deflection in the CMM Segment 333 is due to gravity or the remaining weight of the Internal CMM Arm 5. For the Manual CMM Arm invention with Exoskeleton 800, the deflection of CMM Segment 333 is at least 30 times less than the prior art Manual CMM Arm in Figure 86A. Referring now to FIG. 86C , a Manual CMM Arm with an Endoskeleton 840 is disclosed. The External CMM Arm 841 is external to the Endoskeleton 842 . Endoskeleton Segments 1-3 41-43 are disposed inside the External CMM Arm 841. Endoskeleton 842 also includes endoskeleton joints 1-2 61-62. Endoskeleton 842 is rigidly connected to Base 4 and supports External CMM Arm 841 with Transmission 373 at the distal end of CMM Segment 333. There are no other significant force transfer contacts between the Endoskeleton 842 and the External CMM Arm 841 . The endoskeleton joint 262 has a compensating device 210 attached thereto, which is preferably a machined spring but may be any other type of compensating device; the compensating device may also have a buffer 211. Exoskeleton segments 1-3 41-43 exhibit significant deflection, which can be on the order of several mms. These deflections are not important provided the deflected Endoskeleton Segments do not make contact with the interior of the External CMM Arm Segment. It should be noted that due to deflections, the endoskeleton segment joints 1, 2 61, 62 may undergo significant movement relative to the base 4 during use, wherein the spatial orientation of the arms changes. The CMM segment 333 is only supported at the CMM joint 252 with the force Fd1, and supported at the transmission device 373 with the force Fd2. Any deflection in CMM Segment 3 33 in the Manual CMM Arm with Endoskeleton 840 is due to gravity or residual weight of the External CMM Arm 841. For the Manual CMM Arm invention with Endoskeleton 840, the deflection of CMM Segment 333 is at least 30 times less than the state of the art Manual CMM Arm of FIG. 86A. It should be understood that a person of ordinary skill in the art to which the present invention pertains can provide a manual CMM arm with an endoskeleton 840 based on all the disclosures in this specification.

In another embodiment of this tenth embodiment, the endoskeleton 842 is shorter, includes two endoskeleton segments instead of three and is attached at one end to the CMM segment 222 instead of the base 4. It also supports the distal end of the CMM Segment 333 with the transmission 373. This shorter embodiment of endoskeleton 842 includes one joint instead of two: endoskeleton joint 2 62.

Eleventh embodiment

Robotic CMM Arm with Endoskeleton

In this eleventh embodiment, a Robot CMM Arm with an Endoskeleton is provided. This Robot CMM Arm with Endoskeleton embodiment includes an External CMM Arm guided by an Internal Endoskeleton. The Endoskeleton supports and steers the External CMM Arm through gearing so that it can be accurately measured. The present invention can be embodied in many layouts of a Robot CMM Arm with an Endoskeleton Articulated Arm. The Robot CMM Arm with Endoskeleton according to the eleventh embodiment of the present invention has two preferred layouts: 6-axis with 6 joints and 7-axis with 7 joints. The Robot CMM Arm with Endoskeleton can be portable or used in a fixed setup. This eleventh embodiment is actually the opposite of the first embodiment of the present invention.

Referring now to FIG. 87 , the Robot CMM Arm with Endoskeleton 850 includes an External CMM Arm 841 and an Internal Endoskeleton 851 . It should be understood that, based on the entire disclosure content in this specification, especially the disclosure content of the first embodiment, those of ordinary skill in the art of the present invention can provide a robot CMM arm with an endoskeleton.

other embodiments

This CMM arm with exoskeleton invention is not limited to the device of the disclosed embodiment, but can include any form of CMM arm with exoskeleton device applied to the following applications:

- In applications where the CMM Arm with Exoskeleton extends from very short to very long,

- In applications with payloads ranging from tens of grams up to hundreds of kilograms,

-Applications with precision ranging from the highest precision of today's industrial robots to the precision of today's conventional CMM machining,

- in applications located on Earth and in lower gravity environments such as space,

- preferably in applications with endoskeleton support with external CMM arms,

Applications where the object being measured can move in 6 degrees of freedom at any time during or between measurements and the CMM arm with exoskeleton and the object can each move simultaneously in 6 degrees of freedom during or between measurements .

Claims (120)

1. equipment comprises:

A) has the movable link of pedestal end, opposed sound end and the section more than three or three, it separate at the axle that rotatablely moves between described pedestal end and the described sound end by two or more, and wherein at least two described rotatablely moving spool can be not parallel;

B) has the movable position annunciator of pedestal end, opposed sound end and the section more than three or three, it separate at the axle that rotatablely moves between described pedestal end and the described sound end by two or more, and wherein at least two described rotatablely moving spool can be not parallel;

C) transmission device contacts with described movable position annunciator with described movable link, and the contact of wherein said transmission device and described movable link is in any position between the axle of rotatablely moving of described sound end and the most close described pedestal end;

So that make the motion of described movable link cause the motion of described movable position annunciator.

2. equipment according to claim 1, wherein said transmission device is between the sound end section of the sound end section of movable link and movable position annunciator.

3. equipment according to claim 1, wherein said transmission device comprise a plurality of separate type transmission devices.

4. equipment according to claim 3, wherein all described separate type transmission devices are rigidity.

5. equipment according to claim 3, wherein all described separate type transmission devices all are not rigidity.

6. according to each described equipment in the claim 1 to 4, wherein at least one described separate type transmission device is that rigidity and at least one described separate type transmission device are not rigidity.

7. according to each described equipment in the claim 1,2,3,5 and 6, each is radially or reverses or radially and reverse in the wherein said separate type transmission device.

8. equipment according to claim 5, the quantity of wherein said non-rigid separate type transmission device are one of two and described non-rigid separate type transmission device between the sound end section of the sound end section of movable link and movable position annunciator.

9. equipment according to claim 5, wherein the quantity of the described non-rigid separate type transmission device between described movable link and described movable position annunciator is three.

10. equipment according to claim 9, wherein said three non-rigid separate type transmission devices are positioned at:

A) on the pedestal end side surface of ancon;

B) on the pedestal end side surface of wrist;

C) on the pedestal end side surface of sound end.

11. according to claim 9 and 10 described equipment, wherein:

A) being positioned at described non-rigid separate type transmission device on the pedestal end side surface of sound end comprises and reversing and transmission device radially;

B) described other non-rigid separate type transmission device comprises radially transmission device.

12. equipment according to claim 6, the quantity of wherein said rigidity separate type transmission device are one and described rigidity separate type transmission device between the sound end section of the sound end section of movable link and movable position annunciator.

13., also comprise being used to stop the restraint device of rotation automatically according to each described equipment in the claim 1 to 12.

14. equipment according to claim 1, wherein said transmission device comprises the continous way transmission device.

15. according to each described equipment in the claim 1 to 3, wherein at least one described separate type transmission device comprises the controlled motion axle that at least one is other, its can change significantly described movable link the section with described movable position annunciator section between relative distance, the perhaps relative bearing between these sections, perhaps relative distance between these sections and relative bearing, first end that wherein has a described separate type transmission device of at least one other controlled motion axle is connected on the section of described movable link, and the other end that has a described separate type transmission device of at least one other controlled motion axle is connected on the section of described movable position annunciator.

16. according to each described equipment in the claim 1 to 15, the described pedestal end of wherein said movable link and the described pedestal end of described movable position annunciator are rigidly connected.

17. according to each described equipment in the claim 1 to 15, the described pedestal end of wherein said movable link is non-rigid the connection with the described pedestal end of described movable position annunciator.

18. according to each described equipment in the claim 1 to 15, the described pedestal end of wherein said movable position annunciator is rigidly connected on the section of described movable link.

19. there is relative motion in equipment according to claim 17 between the described pedestal end of wherein said movable link and the described pedestal end of described movable position annunciator.

20. equipment according to claim 19 is wherein measured described relative motion.

21. according to 1 to 20 each described equipment in the claim, the quantity of the kinematic axis in the wherein said movable position annunciator is 6.

22. equipment according to claim 21, wherein the type of the described kinematic axis the described movable position annunciator of listing from described pedestal end to described sound end is AOOAOA, and wherein A is an axially-movable axle and O is the orthogonal motion axle.

23. according to 1 to 20 each described equipment in the claim, the quantity of the kinematic axis in the wherein said movable position annunciator is 7.

24. equipment according to claim 23, wherein the type of the described kinematic axis the described movable position annunciator of listing from described pedestal end to described sound end is AOAOAOA, and wherein A is an axially-movable axle and O is the orthogonal motion axle.

25. equipment according to claim 23, wherein the described kinematic axis in the described movable position annunciator of listing in proper order according to shoulder, ancon and wrist is grouped into 3-2-2.

26. equipment according to claim 23, wherein the described kinematic axis in the described movable position annunciator of listing in proper order according to shoulder, ancon and wrist is grouped into 2-3-2.

27. equipment according to claim 23, wherein the described kinematic axis in the described movable position annunciator of listing in proper order according to shoulder, ancon and wrist is grouped into 2-2-3.

28. according to each described equipment in the claim 1 to 27, wherein said movable link and described movable position annunciator have the section and the kinematic axis of equal number.

29. according to each described equipment in the claim 1 to 27, wherein said movable link is a part, and compares section and the kinematic axis that has still less with described movable position annunciator.

30. equipment according to claim 29, the pedestal that wherein has a separate type transmission device to be positioned at ancon is distolateral.

31. equipment according to claim 29, wherein two separate type transmission devices pedestal of being positioned at ancon is distolateral and pedestal wrist is distolateral.

32. according to the described equipment of claim 21 to 28, wherein said movable link and described movable position annunciator have similar segment length, similar axle orientation and the similar axle centre of motion.

33. equipment according to claim 32, wherein said movable link and described movable position annunciator are roughly coaxial.

34. equipment according to claim 33, each kinematic axis of wherein said movable position annunciator is roughly coaxial with the corresponding sports axle of described movable link.

35. according to 1 to 34 each described equipment in the claim, wherein said movable link is positioned at the outside of described movable position annunciator.

36. equipment according to claim 35, the structure of wherein said movable link are open type.

37. equipment according to claim 35, the construction packages of wherein said movable link described movable position annunciator.

38. according to 1 to 37 each described equipment in the claim, wherein said movable link can be from described movable position annunciator dislocation.

39. according to the described equipment of claim 38, wherein said movable link is by it being moved vertically leave described movable position annunciator and by dislocation.

40. according to the described equipment of claim 38, wherein said movable link leaves described movable position annunciator and by dislocation by opening it and it radially being moved.

41. according to each described equipment in the claim 1 to 40, wherein axially-movable axle and respective drive device are placed so that the inertia of described movable link is minimized towards the described pedestal end of each long section.

42. according to each described equipment in the claim 1 to 41, wherein on described movable link, the distance between shoulder orthogonal motion axle and the ancon orthogonal motion axle is than the distance big at least 5% between ancon orthogonal motion axle and the wrist orthogonal motion axle.

43., also comprise the hard joint restraint device that is positioned on the described movable link so that make described hard joint restraint device prevent that the intrinsic stop on the joint of described movable position annunciator and described movable position annunciator from contacting according to each described equipment in the claim 1 to 42.

44. according to the described equipment of claim 43, wherein be arranged in described hard joint restraint device on one or more orthogonal motion axles and be arranged for and prevent described orthogonal motion axle any one becomes straight type, wherein straight type is restricted on the straight line between two adjacent kinematic axis that described orthogonal motion axle is located substantially on described straight type orthogonal motion axle.

45. according to the described equipment of claim 43, its flexibility increases, and wherein is arranged in described hard joint restraint device on one or more orthogonal motion axles and is configured to allow described orthogonal motion axle any one is operated in the both sides of straight type basically.

46. according to 1 to 34 each described equipment in the claim, wherein said movable position annunciator is positioned at the outside of described movable link.

47. according to 1 to 45 each described equipment in the claim, but wherein said movable link manual operation.

48. according to the described equipment of claim 47, wherein, in any one dimensional orientation, act on common on the described movable link and hold the location and hold for the moment for various with common, the static load that acts on the described movable position annunciator is substantially the same.

49. according to 1 to 46 each described equipment in the claim, wherein said movable link is a robot.

50. according to the described equipment of claim 49, the artificial anthropomorphic formula of wherein said machine and comprise a series of kinematic axis.

51. according to 1 to 50 each described equipment in the claim, wherein said movable position annunciator is the CMM arm.

52., also comprise being used to make the controller of the described sound end of described movable link with respect to the described pedestal end motion of described movable link according to each described equipment in the claim 1 to 51.

53., comprise individual unit and for portable according to the described equipment of claim 52.

54., comprise the separate type control box according to the described equipment of claim 52.

55., also comprise the angular encoder that is positioned on the described movable position annunciator according to each described equipment in the claim 1 to 54.

56., also comprise having the CD-ROM drive motor that is positioned at the rotary encoder on the movable link according to each described equipment in the claim 1 to 54.

57. according to claim 55 and 56 described equipment, wherein provide the High-speed Control of using described rotary encoder ring, and the pinpoint accuracy of using described angular encoder control loop be provided.

58. according to each described equipment in the claim 1 to 56, wherein provide single control loop, and unique form of the rotary encoder that provided is provided the angular encoder that is positioned on the described movable position annunciator.

59. according to each described equipment in the claim 52 to 58, wherein said controller can control one or more other kinematic axis in case dislocation following any one:

D) described pedestal end;

E) described object.

60., comprise that also the one or more probes that place on the described movable position annunciator are so that collect probe data according to each described equipment in the claim 1 to 59.

61., comprise that also the one or more probes that place on the described movable link are so that collect probe data according to each described equipment in the claim 1 to 60.

62. according to each described equipment in the claim 1 to 61, any one is a non-contact probe in wherein said one or more probes.

63. according to the described equipment of claim 62, wherein said non-contact probe is the striped probe.

64. according to the described equipment of claim 62, wherein said non-contact probe is the area probe.

65. according to each described equipment in the claim 1 to 62, any one is a contact probe head in wherein said one or more probes.

66. according to the described equipment of claim 65, wherein any described contact probe head is hard probe.

67. according to the described equipment of claim 65, wherein any described contact probe head is a trigger probe.

68. according to the described equipment of claim 65, wherein any described contact probe head is a pressure probe.

69. according to each described equipment in the claim 1 to 61, any one is the parameter measurement probe in wherein said one or more probes.

70., also comprise the probe cover device that is connected on the described movable link according to each described equipment in the claim 1 to 69.

71., comprise that also the one or more instruments that place on the described movable position annunciator are so that executable operations according to each described equipment in the claim 1 to 70.

72., comprise that also the one or more instruments that place on the described movable link are so that executable operations according to each described equipment in the claim 1 to 71.

73. according to each described equipment in claim 71 and 72, wherein said instrument is a milling cutter, provides position feedback at control loop so that make described milling cutter follow program control cutter path exactly and be arranged in described angular encoder on the described movable position annunciator.

74. according to each described equipment in the claim 1 to 73, also comprise data processor, its retrieval is from the described probe data of described one or more probes with from the location of described movable position annunciator.

75. according to each described equipment in the claim 1 to 74, wherein said probe data and describedly orientate time synchronized as or carried out time mark.

76. according to each described equipment in the claim 1 to 75, wherein lock-out pulse indicates the system change sign.

77. according to each described equipment in the claim 1 to 76, wherein said probe data is collected from object.

78. according to each described equipment in the claim 1 to 76, wherein said operating on the object carried out.

79., also comprise one or more movable transmission devices according to each described equipment in the claim 1 to 78.

80. according to the described equipment of claim 79, wherein one or more described movable transmission devices provide axial expansion bearing.

81. according to the described equipment of claim 79, wherein one or more described movable transmission devices provide axially and expansion bearing radially.

82., also comprise expansion bearing control software according to each described equipment in the claim 79 to 81.

83., also comprise air bearing according to each described equipment in the claim 79 to 82.

84. according to each described equipment in the claim 77 to 78, wherein said pedestal end is rigidly connected on the described object.

85. 4 described equipment according to Claim 8, wherein said object is pipe.

86. according to each described equipment in the claim 1 to 83, wherein said pedestal end is installed on the supporting arrangement so that make described probe data to be collected or the described operation of execution on the described object that is positioned to small part under the described supporting arrangement.

87. 6 described equipment according to Claim 8, wherein said supporting arrangement is the rigidity bridge.

88. 7 described equipment according to Claim 8, wherein said rigidity bridge also comprises linear track, and described pedestal end is installed on the linear track so that make described pedestal end can cross described linear track.

89. according to each described equipment in the claim 1 to 83, wherein said object is positioned on the accurate displacement.

90. according to each described equipment in the claim 1 to 83, wherein said pedestal end is positioned on the accurate displacement.

91. according to each described equipment in the claim 1 to 83, wherein said object is positioned on the accurate displacement and described pedestal end is positioned on the accurate displacement.

92. each described equipment in 9 to 91 according to Claim 8, any one all comprises one or more kinematic axis in the wherein said displacement, and wherein each axle is rotary or linear.

93. each described equipment in 9 to 92 according to Claim 8, wherein said displacement is manual or automatic dislocation formula.

94. according to each described equipment in the claim 1 to 93, wherein said pedestal end is oriented in the direction that out of plumb makes progress.

95., also comprise the mobile vehicle of the pedestal end connection of movable link according to each described equipment in the claim 1 to 83.

96. according to the described equipment of claim 95, wherein mobile vehicle also comprises the pin that can lift automatically and put down.

97. according to each described equipment in the claim 1 to 96, wherein one or more longitudinal joints comprise that also slip ring and described one or more longitudinal joints can unrestrictedly rotate.

98. according to each described equipment in the claim 1 to 97, wherein said movable link is driven so that make slip ring can be used for providing the unconfined rotation in the longitudinal joints by intelligent driver and high-speed bus device.

99. according to the described equipment of claim 47, wherein removable driver element is assemblied on the described movable link so that calibration automatically.

100. according to the described equipment of claim 47, wherein second movable link is connected on the described movable link, described second movable link also comprises the drive unit that is used for automatic calibration.

101., also comprise automatic movable link so that make according to the described equipment of claim 47:

Described can manually operated movable link or one of described automatic movable link can be connected on the described movable position annunciator;

Described automatic movable link is connected on the described movable position annunciator so that calibration automatically;

Describedly can be connected in described movable position annunciator so that can be used for one or more purposes that it provides by manually operated movable link.

102. according to the described equipment of claim 49, wherein:

Described robot is connected on the described movable position annunciator so that calibration automatically;

Described robot can dismantle from described movable position annunciator;

Described movable position annunciator is that the manual CMM arm of conventional type is so that use under the situation that does not connect described robot.

103. according to each described equipment in the claim 1 to 102, the bearing arrangement in the one or more joints in the wherein said movable position annunciator comprises a pair of prestressed ceramic ball bearing.

104. according to each described equipment in the claim 1 to 103, wherein one or more drivers also comprise the automatic anti-fault brake apparatus.

105. according to each described equipment in the claim 1 to 104, also comprise the cooling system device, wherein air is through between described moveable arm and the described movable position annunciator.

106., also comprise bascule according to each described equipment in the claim 1 to 105.

107., also comprise the temperature-detecting device and the thermal compensation device that are at least one position along described movable position annunciator according to each described equipment in the claim 1 to 106.

108. according to each described equipment in the claim 1 to 107, wherein movable link comprises that also at least one external impact absorption plant is so that provide protection under situation about bumping.

109., also comprise the network connection device that leads to the production control system device according to each described equipment in the claim 1 to 108.

110., also comprise the parameter measurement device according to each described equipment in the claim 1 to 109.

111., also comprise the one or more strain gauge arrangement that are fixed on the described movable position annunciator according to each described equipment in the claim 1 to 110.

112., also comprise one or more holding devices that act on the described kinematic axis that is positioned on the described movable link according to each described equipment in the claim 1 to 111.

113., also comprise according to each described equipment in the claim 1 to 112:

The transport case device;

Be connected in the extension apparatus on the described pedestal end of the described pedestal end of described movable link or described movable position annunciator.

114., also comprise the wireless buttons cell arrangement according to each described equipment in the claim 1 to 113.

115., also comprise according to each described equipment in the claim 1 to 114:

-calibration artifact

One or more calibration of axes are for use in the relative motion that provides between described pedestal and the described calibration artifact.

116. a method that is used for locating automatically the movable position annunciator, it may further comprise the steps:

Controller causes that drive unit generates driving torque;

Described driving torque puts on the movable link, thereby makes described movable link motion;

Described movable link causes described actuator movement;

Described transmission device is exerted all one's strength and is put on the rigid element of described movable position annunciator, so that make described movable position annunciator motion;

Wherein said movable link and described movable position annunciator both have pedestal end, opposed sound end and the section more than three or three, these sections are separated by two or more axles that rotatablely move between described pedestal end and described sound end, wherein at least two described axles that rotatablely move are not parallel, and the contact position of wherein said transmission device and described movable link is in any position between the axle of rotatablely moving of described sound end and the most close described pedestal end.

117. a method that is used to manually locate the movable position annunciator may further comprise the steps:

Operating personnel move described movable link;

Described movable link causes described actuator movement;

Described transmission device causes that power puts on the rigid element on the described movable position annunciator, thereby makes described movable position annunciator motion;

Wherein said movable link and described movable position annunciator both have pedestal end, opposed sound end and the section more than three or three, these sections are separated by two or more axles that rotatablely move between described pedestal end and described sound end, wherein at least two described axles that rotatablely move are not parallel, any position of the contact position of wherein said transmission device and described movable link between the rotating shaft motion of described sound end and the most close described pedestal end.

118. a method that is used to locate the movable position annunciator that has the probe that places being used on the movable position annunciator to determine object data, it may further comprise the steps:

Controller causes that drive unit generates driving torque;

Described driving torque puts on the movable link, thereby produces the motion of described movable link;

Described movable link causes described actuator movement;

Described transmission device causes that power puts on the rigid element on the described movable position annunciator, thereby makes described movable position annunciator produce motion;

Described probe is collected the data of described object;

Data processor receives the position from described movable position annunciator;

Described data processor receives the data from described probe.

119. a method that is used to locate the movable position annunciator that has the probe that places being used on the movable position annunciator to determine object data may further comprise the steps:

Controller causes that drive unit generates driving torque;

Thereby described driving torque puts on the motion that produces described movable link on the movable link;

Thereby described movable link causes that power puts on makes described transmission device produce motion on the transmission device;

Described transmission device causes that power puts on the rigid element of described movable position annunciator, so that make described movable position annunciator motion;

Described probe is collected the synchrodata of described object and is sent synchronizing signal to described movable position annunciator simultaneously;

Data processor receives the synchronous location from described movable position annunciator;

Described data processor receives the described synchrodata from described probe.

120. a method that is used to locate the movable position annunciator that has the probe that places being used on the movable position annunciator to determine object data may further comprise the steps:

Controller causes that drive unit generates driving torque;

Described driving torque puts on and causes described movable link to produce motion on the movable link;

Described movable link causes that power puts on the transmission device, thereby causes described actuator movement;

Described transmission device causes that power puts on the rigid element of described movable position annunciator, so that make described movable position annunciator motion;

Described probe is collected the data of being carried out the described object of time mark by the clock in the described probe;

Data processor receives the clock in the free described movable position annunciator to carry out the location of the described movable position annunciator of time mark;

Described data processor receives the described timestamp data from described probe.

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