Three dimensional wire bending apparatus

Abstract

An improved system for automatically shaping wires includes two movable robotic arms each having a certain degree of freedom of movement, and each having a mechanism for holding a wire in place and a rotational bending unit for creating the desired shape on the wire. Each of the two robotic arms is positioned on a movable unit to enable their linear motion, while various pulleys connected to motors provide for movement of various links that form each arm. The system enables an operator to move the workpiece wire in three-dimensional space using a controller. By positioning the workpiece in the desired position and using a rotational bending unit, highly precise angular bends can be created on the workpiece.

What is claimed is: 
     
         1 . A system for automatically shaping wires comprising:
 a base support;   a straightening mechanism positioned on one end of the base support for receiving and straightening an input wire;   two articulated robotic arms having approximately the same size and the same shape, each robotic arm including a plurality of pivotable links;   two railing mechanisms, each positioned on one longitudinal side of the base support and each connected to one of the two articulated robotic arms for enabling linear movement of the two articulated robotic arms;   a clamping mechanism attached to one of the plurality of pivotable links for holding the input wire in place;   a bending unit located adjacent to the clamping mechanism for shaping the input wire;   a cutting mechanism for cutting the shaped wire as needed; and   a controller for controlling the operation of the system,   wherein each robotic arm is movable in a longitudinal linear direction along the base support and each robotic arm has a predetermined degree of freedom of movement.   
     
     
         2 . The system of  claim 1 , wherein the plurality of pivotable links include three pivotable links. 
     
     
         3 . The system of  claim 2 , wherein the three pivotable links include an effector link. 
     
     
         4 . The system of  claim 3 , wherein the clamping mechanism is located on the effector link. 
     
     
         5 . The system of  claim 1 , further comprising a motor for applying a rotational force to a shaft connected to one of the plurality of pivotable links for pivoting the one of the plurality of pivotable links. 
     
     
         6 . The system of  claim 5 , further comprising a plurality of pulleys, at least one of which is connected to the one of the plurality of pivotable links, the pulleys being connected via a belt for pivoting one or more of the plurality of pivotable links. 
     
     
         7 . The system of  claim 1 , wherein the clamping mechanism includes a stationary unit and a movable unit. 
     
     
         8 . The system of  claim 7 , further comprising a motor for moving the movable unit when needed. 
     
     
         9 . The system of  claim 1 , wherein the clamping mechanism is configured to clamp and hold the input wire along the longitudinal axis of the system when the wire enters the system through the straightening mechanism. 
     
     
         10 . The system of  claim 1 , wherein the clamping mechanism is configured to pick up the input wire from a first designated location and drop off the shaped wire to a second designated location. 
     
     
         11 . The system of  claim 1 , further comprising two movable platforms, each attached to one longitudinal side of the base support and each carrying one of the two robotic arms on one of the two railing mechanisms. 
     
     
         12 . The system of  claim 1 , wherein the cutting mechanism comprises:
 a cutting die for holding the input wire;   a cutting arm for cutting the input wire; and   a motor for controlling the movement of the cutting arm.   
     
     
         13 . The system of  claim 12 , wherein the base support includes an opening through which the cutting arm can pass. 
     
     
         14 . The system of  claim 13 , further comprising a shaft connected on one side to the motor and on the other side to a flywheel, the flywheel being attached to the cutting arm. 
     
     
         15 . The system of  claim 1 , further comprising a control panel, the control panel comprising the controller, a motor driver, a memory, one or more power ports and one or more communications ports. 
     
     
         16 . The system of  claim 15 , wherein the system can be connected to a computing device via at least one of the communications ports. 
     
     
         17 . The system of  claim 16 , wherein a program to control the operation of the system may be transferred to the control panel from the computing device via the at least one communication port. 
     
     
         18 . The system of  claim 17 , the program controls an operation of at least one of the two articulated robotic arms, the clamping mechanism, the bending unit, and the cutting mechanism. 
     
     
         19 . The system of  claim 15 , wherein at least one of the power ports is for providing power to the system. 
     
     
         20 . The system of  claim 1 , wherein the bending mechanism is configured to shape the input wire on two sides of the clamping mechanism and in both clockwise direction and counterclockwise directions.