FUEL DOOR OPENING ASSEMBLY FOR USE WITH AUTOMATIC ROBOTIC REFUEUNG SYSTEM
Field of the Invention The present invention relates generally to an apparatus for refueling vehicles and more particularly to an automatic robotic refueling system for automotive vehicles which includes a fuel door opening apparatus to permit automatic opening and closing of the vehicle fuel door.
Description of the Related Technology
A great deal of effort has been expended to develop a system for robotically refueling automotive vehicles. Such systems may include an overhead gantry which supports a carriage upon which a robot is supported for appropriate movement relative to the vehicle to position the robot adjacent the fuel door on the vehicle. Alternatively, the robotic system may be supported on an island adjacent the vehicle and then moved to a position adjacent the fuel door. As another alternative, the robotic system may be stowed underground and, after positioning of the vehicle, retrieved and moved to a point adjacent the fuel door.
Irrespective of the position in which the robot is stored or the manner in which it is moved, all such robotic refueling systems require an appropriate mechanism to insert a hose assembly which includes a nozzle for delivery of fuel into the fuel tank of the vehicle. The fuel hose must be inserted through the vehicle fuel filler pipe and into a position internally of the vehicle fuel filler pipe such that the nozzle is appropriately positioned and so that fuel can easily flow from the nozzle into the vehicle fuel tank without obstruction. Typically, the fuel hose assembly is extended from the robot arm in accordance with appropriate signals received from a control mechanism. After refueling, the fuel hose assembly is extracted from the fuel filler pipe, the fuel filler door is closed, and the robot is returned to its stowed position. The refueled vehicle may then leave the robotic refueling station.
One form of robotic refueling apparatus is shown and described in the United States Patent Nos. 5,609,190; 5,628.351 and 5,634,503, which are assigned to the assignee of the present application, the disclosures of which are incorporated herein by reference. As is therein shown, a robot is stored on an overhead carriage which in turn is supported for
movement upon a gantry so that the robot may be positioned on either side of the vehicle in accordance with the position of the fuel filler door. After the robot is appropriately positioned, the fuel filler door is automatically opened by the robot and the fuel hose inserted into the fuel filler pipe on the vehicle so that fuel may be inserted into the vehicle fuel tank. After the vehicle fuel tank is appropriately filled, the fuel hose assembly is extracted from the fuel filler pipe, retracted into the robot arm, and the robot is then appropriately stored on the carriage and returned to its stowed position on the gantry until it is reactivated for refueling another vehicle.
It is important to automating the fueling process that a robotic refueling apparatus accommodate a wide range of fuel filler doors having various placements, opening and closing geometries, motions, and orientations relative to a vehicle and an associated fuel filler tube. Typically, the door opening mechanism is provided by a vacuum cup supported by a telescoping robotic arm assembly. The vacuum cup must be extremely manipulable over a wide range of motions and positions to accommodate the greatest number of fuel filler door configurations and required opening and closing motions. Further, since some fuel filler doors are self-closing, it may be necessary to hold the door open until the refueling operations are concluded. Even in those situations wherein the fuel filler door is designed to stay open by itself, it may be difficult to recapture an open door so that it can be closed. Therefore, it is generally the practice to retain a hold on the fuel door once captured and opened until completion of the refueling operation including closing the door. Therefore, so as to avoid interference with the robotic fueling apparatus, the door opening mechanism must be positionable out of the way of the end effector refueling apparatus while maintaining a hold on the fuel filler door. This may require substantial repositioning of the door opening mechanism and require a wide range of movement at a distal end of the arm.
A fuel door opening and closing apparatus is disclosed in U.S. Patent 5,609,190 above referred to and incorporated herein by reference. As is therein shown, the mechanism utilized to open a hinged fuel door over a vehicle=s fuel inlet includes a pneumatic cylinder supporting a vacuum cup. The vacuum cup is supported on the end of a push tube that is extendable by providing an inner tube that extends out of or retracts into an outer tube while maintaining a sealing relationship therewith. A vacuum is provided to the vacuum cup through the center of the push tube. A yaw positioning cylinder is also provided to turn the vacuum cup to the right or the left as may be required.
When the end defector is placed adjacent to a vehicle=s fuel inlet and pointed to a fuel door covering the fuel inlet, the pitch is adjusted to center the fuel conduit on the expected position of the fuel inlet behind the fuel door and the vacuum cup is then laterally extended to meet the fuel door. Prior to the vacuum cup contacting the fuel door, the vacuum is applied and when a vacuum is detected at a sufficiently negative gauge pressure in the vacuum line going to the vacuum cup extension of the vacuum cup is reversed and the movement of the vacuum cup to swing the hinged fuel door open is initiated. The present invention is an improvement over the apparatus as disclosed in U.S. Patent No. 5,609,190 and as above briefly described.
SUMMARY OF THE INVENTION
A fuel door opening and closing assembly for use with an automatic robotic refueling system, the assembly including a movable arm having a vacuum cup mounted thereon. Means for moving the arm in a pitch motion, a yaw motion and for extending and retracting the vacuum cup and further including means for rotating the arm to first and second positions to accommodate fuel doers hinged in opposite sides.
In accordance with a more specific aspect of the present invention, the vacuum cup is mounted on the arm in such a manner that the vacuum cup revolves around its longitudinal axis and may also swivel in all directions about the longitudinal axis to accommodate the swinging motion of the fuel door opening about its hinge without losing contact of the vacuum cup to the fuel door.
In accordance with a still further aspect of the present invention, vacuum is applied to the vacuum cup centrally through a tube extending from the center thereof and through the arm while providing flexibility of the tube immediately adjacent the vacuum cup to accommodate the required movements of the vacuum cup.
Brief Description of the Drawings
FIGURE 1 is an elevational view of an end effector mechanism for use as part of a vehicle automatic robotic refueling system which includes a door arm opening and closing assembly constructed in accordance with the principles of the present invention; FIGURE 2 is a prospective view of the door arm opening and closing assembly of the present invention removed from the end effector;
FIGURE 3 is a view similar to FIGURE 2 but with the protective cowling and bellows removed therefrom;
FIGURE 4 is a side elevational view of the door arm assembly as shown in FIGURE 4;
FIGURE 5 is a partial cross-sectional view of the door arm assembly as shown in FIGURE 4 taken about the lines 5-5 thereof;
FIGURE 6 is a partial cross-sectional view of the vacuum cup assembly connected to the door arm opening and closing assembly taken about the lines 6-6 of FIGURE 5;
FIGURE 7 is a potential cross-sectional view of the vacuum assembly of Figure 6 taken about the lines 7-7 thereof;
FIGURE 8 is an block diagram illustrative of the control system for a fuel door opening assembly of the present invention; and
FIGURE 9 is a schematic illustration of a prior art system for refueling vehicles.
DETAILED DESCRIPTION
By referring now to Figure 9, there is shown as part of the prior art the general arrangement of components of a vehicle refueling system which utilizes a fuel door opening assembly constructed in accordance with the principles of the present invention. As is therein shown, an overhead gantry 101 having a set of longitudinal supports 102 and a cross member 103 is provided. The gantry can move a manipulator 105 to position the end effector on either side of the vehicle adjacent its fuel filler door.
The location of the vehicle fuel filler tube can be determined from data obtained from a transponder card disposed within the vehicle 107 to be refueled. The transponder card can be one of various types and preferably is an active radio frequency identification card which provides vehicle information to the automated refueling system thus allowing the system to know the location of the fuel filler tube and the fuel door which covers the
tube on the vehicle. Typically a customer interface 108 is provided. The customer interface allows the user to input various types of information to the system such as a credit card, type of fuel and other information as may be desired in any particular circumstance. The automated refueling system may also include a vision system with a camera 1 10 positioned above the expected location of the vehicle looking down at the vehicle. The camera produces an image that is captured and reduced to a digital format and communicated to a central processing unit. The central processing unit may be located in a convenient location for example, either in a building at the location of the automated refueling system or remotely. The vision system can determine from the data provided by the camera the location of the vehicle within the view of the camera. This information, along with the information provided by the transponder card, enables the system to issue command signals to cause the manipulator 105 to move to the appropriate position to accomplish the automated refueling.
By reference now to Figure 1, there is illustrated an end effector 10 which may be affixed by an appropriate bracket 12 to the manipulator 105 which can then position the end effector 10 to accomplish the automated refueling. The end effector 10 includes a fuel nozzle assembly 14 and a fuel door opening assembly 16. The fuel door opening assembly
16 is a modular assembly which is attached to a rotary actuator 18 which protrudes from the fuel nozzle assembly 14 and thus may be readily disconnected and connected. An appropriate cabling system 20 is provided and permits connection of various operational signals and energy sources from the refueling system through the manipulator 105 by way of appropriate connections 22 and cabling as illustrated to the fuel door opening assembly 16.
It will be understood by those skilled in the art that the manipulator arm 105, in response to appropriate command signals, will rotate the fuel nozzle assembly 14 of the end effector 10 to provide a yaw motion to properly position the nozzle assembly 14 to accomplish refueling of the vehicle. By way of the connection of the fuel door opening assembly 16 to the nozzle assembly 14. such yaw motion will be transmitted to the fuel door opening assembly as well.
By reference now to Figures 2-4, the fuel door opening assembly constructed in accordance with the principles of the present invention is illustrated in greater detail. In Figure 2, the assembly is shown in its fully assembled condition which includes an
appropriate cowling such as illustrated at 24 which covers the forward portion of the assembly and at 26 which covers the rear portion of the assembly. An appropriate bellows 28 surrounds the assembly between the cowlings 24 and 26 and accommodates extension and retraction of the vacuum cup 30 as will be described more fully below. As is also clearly illustrated in Figure 2, the cable 20 terminates with appropriate connectors as shown at 32 and 34 which provide air under pressure to operate actuators utilized within the assembly as well as electrical connections for transmitting electrical power and electrical signals to and from various transducers and other electrical apparatus housed within the assembly 16. As is evident particularly from Figure 2 by disconnecting the fuel door opening assembly from the fuel nozzle assembly by removal of appropriate connecting pins from openings 36 in bracket 38 and by disconnecting the connectors 32 and 34, the door arm opening assembly may be removed from the end effector 10 quickly and easily. Such modular construction provides for easy installation of the fuel door opening assembly as well as its removal and replacement for appropriate repair and maintenance as such as required. By such modular construction downtime of a robotic refueling system constructed in accordance with the principles of the present invention is radically reduced.
By reference more particularly to Figure 3, the structure of Figure 2 is illustrated with the cowlings 24 and 26 and the bellows 28 removed. As is better illustrated in Figure 3, the fuel door opening assembly 16 includes a pitch actuator 40 pivotally connected to the bracket 38 by an appropriate pivot connection 42. At the opposite end, a clevis 44 is utilized to pivotally attach the piston rod 46 of the actuator 40 at fitting 48 formed as part of the slide bracket 50. A protective bellows 52 covers a wrist assembly 54 (Fig. 5) which provides universal motion for the vacuum cup 20 as will be described more fully hereinafter.
An extend/retract actuator 55 is connected to the slide bracket 50 and is anchored at a tie bracket 56. The extend retract actuator 54 positions the vacuum cup 30 by laterally extending it to the right as viewed in Figure 3 to cause it to come into contact with the vehicle fuel door for opening and closing the fuel door as will be described more fully below. A tube assembly 58 is connected between the vacuum cup 30 and the vacuum pump assembly 60 which is affixed to the bracket 38. The vacuum pump assembly is an in-line vacuum pump thus allowing vacuum to be drawn and exerted through the opening 62 in the vacuum cup 30 by way of exhausting air through the tube 58 and out the rear (to the left as viewed in Figure 3) of the vacuum pump assembly 60. This allows any type of foreign
matter which may have collected within the opening 62 or the tube 58 to be easily exhausted from the system without interfering with the operation thereof. The tie bracket 56 is connected by way of a pivot pin 64 to the bracket 38. Also provided as part of the tube assembly 58 is a flexible or corrugated hose 66 which permits the vacuum cup 30 to be moved up and down in a pitch motion as shown by the arrow 68 in response to signals applied to the pitch actuator 40 to properly position the vacuum cup with respect to the vehicle fuel door. The pitching motion of the vacuum cup occurs about the pivot point 64. A Hall effect housing assembly 70 (Figure 4) is also provided about the pivot point 64. The assembly 70 is adapted such that there is an appropriate magnet and Hall sensor devices disposed within the housing assembly 70 to provide a pitch transducer developing an electrical signal representative of the pitch position of the vacuum cup 30 which signal is connected by way of an appropriate cable 72 to a control signal generator (Figure 8).
The vacuum pump assembly 60 includes an in-line vacuum pump 74 which is coupled to a check valve assembly 76 which is followed by a muffler 78 used to reduce the noise which may be generated by the vacuum pump 74. The check valve assembly 76 is utilized to block the conduit provided by the tube assembly 58, 66 and the pump 74 from the entry of unwanted materials when the door arm assembly is in its stowed positions, with the vacuum cup 30 facing upwardly.
As is shown particularly in Figure 4, there are various electrical lead connectors and conduits for application of power and signals to the door arm assembly or from the various transducers of the door arms assembly back to the control signal generator of the system.
Such is shown, for example, as a pneumatic conduit 80 for operating the actuator 55. at 82 and 84 for operating the retract and extend positions of the pitch actuator 40, electrical conduit 86 which connects to a linear potentiometer 88 which provides a signal proportional to the position of the vacuum cup 30 as it is extended and retracted. The specific conduits and cables are collected together into the protective sheath 20 and routed as shown in Figure 1 to be coupled by way of the connectors 32 and 34 (Fig. 2) to the fuel nozzle section of the end effector. A protective cover 90 is placed over the exit area where the cables go into the protective cable sheath 20 as is shown particularly in Figs. 1 and 4.
Referring now more particularly to Figure 5, the tube assembly is shown as including an outer tube 92 and an inner tube 94. The inner tube 94 is disposed to slide internally within the outer tube 92 and includes a bearing 96 which provides a support for
the inner tube 94 and is constructed of material such that the inner tube 94 can easily slide and at the same time maintain a seal to enable generation of the desired vacuum which is applied through the hollow interior 98 of the tubes 92 and 94 to the vacuum cup 30. As is clearly shown, there is also provided a flexible tube 100 having a spring 106 disposed over the exterior surface thereof which is coupled between the end of the inner tube 94 and the vacuum cup 30. The flexible tube 100 is utilized to conduct the vacuum through the universal wrist assembly 54 in a continuous and uninterrupted fashion even during the time that the vacuum cup is universally manipulated to contact, open and close the fuel door on the vehicle. As is also illustrated, the slide bracket 48 receives a bearing 104 so that the inner tube 94 can readily slide through the slide bracket 48. The piston 112 of the extend retract actuator 55 is coupled to a vacuum cup coupling bracket 114 through utilization of the nut 116 and the lock nut 118 upon the application of the pneumatic pressure internally of the extend retract actuator 55 the piston rod 112 will extend carrying with it the vacuum cup 30 and the universal wrist assembly 54 to position it adjacent the fuel door. As is also seen, the slide tube 94 is coupled to the coupling bracket 114 and also moves as the vacuum 30 is caused to extend or retract. In this fashion, the hollow interior 98 always remains in communication with the vacuum cup 30.
The wrist or universal assembly 54 includes a first hinge assembly 120 and a second hinge assembly 122. The first hinge assembly 120 permits the vacuum cup 30 to move into and out of the plane of the paper as viewed in Figure 5 while a second hinge assembly 122 permits the vacuum cup to move as illustrated by the arrow 124. The combination of these two hinge assemblies permits effective universal movement of the vacuum cup 30 in all directions without interfering with the application of the vacuum as a result of the flexible tubes 100 and 66 as previously described. The wrist assembly 54 is shown in greater detail in Figures 6 and 7 to which reference is hereby made. The wrist assembly is specifically described and claimed in co- pending application identified by attorney docket TH1620 entitled Wrist Assembly for Robotic Refueling Systems and is incorporated herein by this reference.
As is illustrated more clearly in Figures 6 and 7, the hinge 122 is in the form of a U- shaped stirrup member which is secured to a pair of arms 124 and 126 extending from a hinge base 128 by a pair of pivot pins 130 and 132, respectively. Secured at the center of
the stirrup shaped hinge 122 is the vacuum cup hinge 120 which includes an encircling portion 134 within which the vacuum cup assembly is secured. As is illustrated, the vacuum cup hinge 120 is pivotly secured at 136 to the central portion of the stirrup shaped hinge 122. Through the pivotal attachment of the hinge 122 to the arms 124 and 126, the vacuum cup 30 is permitted to move as illustrated by the arrow 138. By the pivotal attachment of the vacuum cup hinge 120, as illustrated in Figure 7, the vacuum cup is permitted to move as is illustrated by the arrow 140. Appropriate springs 142 and 144 are secured about the ends of the pivot pins 130 and 132 and to the arm 146 of hinge 120 thereby retaining the vacuum cup centrally disposed in the absence of forces applied thereto.
Appropriate additional springs such as shown at 148 are also attached to the hinge 122 and to the pivot base 128 to cause the hinge 122 to remain in a neutral position in the absence of forces being applied to the vacuum cup 30.
An important feature of the present invention is that the vacuum cup 30 is adapted to rotate or extend about its longitudinal axis 150. This is accomplished by having the vacuum cup 30 seated upon a Teflon bushing 152. The Teflon bushing is then positioned upon the outer surface of the tube 100 and is retained in place by a retaining ring 154 and a washer 156. The wrist assembly bellows 52 is secured to a collar 158 which seats upon a shoulder 160 formed upon the terminal portion of the vacuum cup hinge 120 through which the tube 100 passes. The Teflon bushing 152 is also utilized to secure the bellows 52 in position. Since the bushing 152 is constructed of Teflon or a similar material having high lubricity the vacuum cup 30 is allowed to freely rotate or spin upon its longitudinal axis 150.
In operation the door arm opening assembly of the present invention is capable of being positioned adjacent the fuel door, moved into position such that the vacuum cup can engage the fuel door, open the fuel door while remaining attached thereto during the refueling operation then close the fuel door and detach itself from the fuel door followed by re-stowing of the endefector. This operation can be accomplished irrespective of whether the fuel door is hinged on the right or the left and irrespective of the exact positioning of the hinge simply because the vacuum cup 30 has the ability to universally move through the pivoting as above described and is also capable of rotating or spinning about its longitudinal axis. By the ability for such freedom of movement, the vacuum cup is thus capable of remaining attached to the fuel door during the entire refueling operation. Thus, enabling the fuel door to be returned to its closed position after the vehicle has been refueled.
When the identification tag information is communicated to the control system for the robotic refueling system, not only is the position of the fuel door communicated, but also whether the fuel door is hinged on the right or the left. If the fuel door is hinged on the right, then the door arm opening assembly as viewed in Figure 1 is rotated by the rotary actuator 18 so that it would move in a counter-clockwise direction when viewed toward the left as illustrated in Figure 1 or into the plane of the paper. Alternatively, if the fuel door hinge is on the left when facing the fuel door, the rotary actuator 18 will rotate the door arm opening assembly 16 in a clock-wise direction when viewed toward the left as shown in Figure 1 or outwardly from the plane of the paper. As the vision system mounted upon the endefector acquires the outline of the fuel door, the control system through appropriate command signals positions the door arm opening assembly, actuates the yaw and pitch control of the endefector and the extend-retract actuators of the door arm opening assembly to cause the vacuum cup to engage the surface of the fuel door and become attached thereto as a result of the vacuum which had previously been activated. Retraction of the extend retract actuator 55 will then cause the fuel door to open with the vacuum cup rotating about its axis and universally bending in the directions required to accommodate the opening of the fuel door. Thereafter, the fuel nozzle is inserted into the fuel pipe, the car is refueled and the fuel nozzle is retracted. Thereafter, the extend- retract actuator 55 is extended thus returning the fuel door to its close position at which time the vacuum is removed and the vacuum cup again retracted after which the endefector is appropriately stowed by the manipulator 105. The movement of the endefector and the door arm assembly is accomplished by a control system generally shown in block diagram in Figure 8. As is therein shown, there is provided a command signal generator 162 which receives signals from the radio frequency identification tag 164 which is disposed within the vehicle and is activated by a radio frequency signal from the supporting system such as the gantry as shown in Figure 9. The signals from the vision system 166 are also fed into the command signal generator 162. The vision system may include an overhead camera 1 10 as well as a camera mounted upon the endefector 10 as above generally described. This information causes the command signal generator 162 to issue appropriate commands to the manipulator 105 to position the endefector at the proper position with regard to the vehicle so that the door arm opening assembly and the fuel nozzle assembly are disposed adjacent the fuel pipe for refueling. The
positioning of the endefector and particularly the door arm opening assembly is detected by the pitch transducer 168, the yaw transducer 170 and the extend retract transducer 172. The signals generated by these transducers are then applied as feedback signals to the command signal generator 162. By the combination of the signals from the vision system and the feedback transducers, the positioning of the endefector is fine tuned so that the vacuum cup can be accurately attached to the fuel door and the appropriate signals generated to cause the fuel door to be opened and closed and the car to be refueled as above described.