Compliant cutoff saw assembly

Abstract

A cutoff saw assembly incorporates a robot assembly with a compliant cutting apparatus to remove various undesired metal extensions from a casting. The assembly cooperatively and conjunctively controls the position of the casting using the robot assembly and the force exerted by the cutting apparatus on the casting using a compliance control system. The compliance control system includes a compliance actuator that is connected to a compliance regulator. Both the robot assembly and the compliance control system are connected to a system controller. The compliance actuator is connected to the cutoff blade to actively vary the force of the cutting blade with respect to the casting. The compliance regulator, which is connected to the system controller, will measure and regulate the pressure in the compliance actuator, such that the robot assembly and compliance control system can apply the required force to cut the casting.

What is claimed is:  
     
         1 . A cutoff saw assembly for removing excess material from a casting, said assembly comprising: 
 a robot arm to hold the casting;    a system controller connected to said robot arm to control movement of said robot arm; and    a cutoff apparatus connected to said system controller, said cutoff apparatus including a compliant cutoff saw;    wherein said system controller cooperatively positions said robot arm with the casting proximately with said cutoff saw and determines the compliance of said cutoff saw.    
     
     
         2 . The cutoff saw assembly as described in  claim 1  wherein said cutoff apparatus further comprises a compliance control system connected to said frame.  
     
     
         3 . The cutoff saw assembly as described in  claim 2  wherein said compliance control system comprises an actuator controlling the force of said cutoff saw, said actuator further controlling the compliance of cutoff saw when engaged by the casting.  
     
     
         4 . The cutoff saw assembly as described in  claim 3  wherein said actuator is a hydraulic actuator.  
     
     
         5 . The cutoff saw assembly as described in  claim 3  wherein said actuator is a pneumatic actuator.  
     
     
         6 . The cutoff saw assembly as described in  claim 3  wherein said actuator is an electric actuator.  
     
     
         7 . The cutoff saw assembly as described in  claim 3  wherein said compliance control system further comprises a compliance regulator connected between said actuator and said system controller to control the operation of the actuator.  
     
     
         8 . The cutoff saw assembly as described in  claim 2  wherein said cutoff apparatus comprises: 
 a frame having a mounting assembly;  
 a support beam pivotally affixed to said mounting assembly, said support beam having a proximal end and a distal end;  
 a cutoff blade rotatably connected to said distal end; and  
 drive means for driving the rotation said cutoff blade, said drive means connected to said proximal end of said support beam.  
 
     
     
         9 . The cutoff saw assembly as described in  claim 8  wherein the drive means comprises a drive motor connected said proximal end of said support beam.  
     
     
         10 . A method for removing excess material from a casting comprising the steps of: 
 a) engaging the casting with a robot arm;    b) transporting the casting to a position proximate a cutoff blade;    c) controlling the force of said cutoff blade with a compliance control system; and    d) urging the casting into said cutoff blade with said robot arm.    
     
     
         11 . The method for removing excess material from the casting as described in  claim 10 , wherein prior to step a) including the step of: 
 programming a system controller to cooperatively manage said robot arm and said compliance system for removing the excess material from the casting.    
     
     
         12 . The method as described in  claim 10  wherein step c) further comprises the steps of: 
 positioning an actuator between said cutoff blade and a frame;  
 connecting said actuator to a compliance regulator;  
 connecting said compliance regulator to a system controller; and  
 controlling the pressure in said actuator with said compliance regulator.  
 
     
     
         13 . A compliance cutoff saw assembly for removing excess material from a casting comprising: 
 a robot to engage the casting;    a frame positioned opposite said robot;    a blade attached to said frame; and    compliance means mounted between said blade and said frame for supporting said blade with an adjustable force;    wherein said robot transports the casting into said blade to remove the excess material.    
     
     
         14 . The compliance cutoff saw assembly as described in  claim 13  further comprising a system controller connected to said compliance means and connected to said robot; said system controller regulating the concurrent operation of said robot and said compliance means.  
     
     
         15 . The compliance cutoff saw assembly as described in  claim 14  wherein said compliance means comprises: 
 a compliance actuator; and  
 a compliance regulator connected between said compliance actuator and said system controller;  
 wherein said compliance regulator controls the force exerted by said compliance actuator according to said system controller.  
 
     
     
         16 . The compliance cutoff saw assembly as described in  claim 15  wherein said compliance actuator is a pneumatic actuator.  
     
     
         17 . The compliance cutoff saw assembly as described in  claim 16  wherein said compliance actuator is a hydraulic actuator.  
     
     
         18 . The compliance cutoff saw assembly as described in  claim 15  wherein said frame includes: 
 a mounting assembly having a shaft and a pair of bearings; and  
 a support beam pivotally mounted to said mounting assembly, said support beam having a distal end and a proximal end;  
 wherein said blade is connected to said distal end of said support beam.  
 
     
     
         19 . The compliance cutoff saw assembly as described in  claim 18  wherein said blade is rotatably mounted to said distal end of said support beam, and wherein said assembly further comprises drive means for rotating said blade.  
     
     
         20 . The compliance cutoff saw assembly as described in  claim 13  wherein said robot comprises: 
 a multi-positional robot arm; and  
 a tooling clamp attached to said robotic arm to engage the casting.