DETAILED DESCRIPTION OF THE INVENTION

[0077] The test head is held and supported by apparatus that is attached to the main arm of the manipulator. The main arm is slidingly attached with a sliding mechanism, such as a linear rail and bearing combination, to a vertical arm support that is driven in the up-down direction by a non-compliant drive mechanism, such as a motor-driven or a hand-crank driven screw. The amount of vertical motion of the main arm relative to the vertical arm support is physically limited to an amount sufficient to allow docking of the test head; this is typically plus or minus one inch. This is referred to as vernier vertical motion. A coupling mechanism that has a mechanical advantage greater than one is used to couple the main arm to the vertical arm support. This device has a fixed part directly connected to the vertical arm support (e.g. the fulcrum in the case of a lever), a load bearing part coupled to the main arm, and an input part to which counter weights are attached. If the mechanical advantage is MA, then the weight of the counter weights is the weight of the load (test head, main arm and mechanical supports, and test head's share of the cable weight) divided by MA. This allows the main arm and its load to move virtually weightlessly in its vertical vernier motion; the only resistance to said vertical vernier motion being that of friction in coupling mechanism, friction in the sliding mechanism, and forces arising from any cable movement. If the cable is positioned essentially in the horizontal plane at approximately the same height as the center of gravity of the test head, then the forces due to the changing of cable position will be negligible over the plus or minus one inch of vertical test head travel. A telescopic cable support arm with a horizontal-leveling device as disclosed in U.S. Patent Application Serial No. PCT/US00/00704 provides this capability.

[0078] A preferred coupling device is a high-pitch, low-friction, back-drivable ball screw. Such a device is known to be a compact and highly efficient converter of rotational to linear motion that can readily provide a suitable mechanical advantage. An exemplary embodiment based on such a device is described later. The ball screw is used to effect motion of main arm by driving the main arm, but it should be noted that the ball screw is a driven mechanism in the sense that the counterweights drive the ball screw, and the main arm back-drives the ball screw. Therefore, the use of the term “drive” when applied to the ball screw means that force is transferred through the ball screw, and that the ball screw is used as a mechanical advantage device. The driving force transferred through the ball screw typically would be from a torque-limited motor, force applied by hand, external force, or the counterweights.

[0079] The vertical arm support to which the main arm is attached may be the distal movable section of a telescoping column; or it may be a structure that slides along one or more shafts attached to a fixed-height column or one or more linear rails attached to a fixed-height column. Thus, the vertical column may be either of the telescoping type or of the fixed height type.

[0080] One or more linear actuators are used to drive the vertical motion of the vertical arm support and its load (hereinafter “system load”), which comprises the main arm, the test head support apparatus, the test head, the test head's share of the cable and cable support weight, and the counter weights. The actuators are typically motor-driven screw mechanisms that have a thread pitch and internal friction sufficient to prevent back driving under the full load. Thus, the screw is sufficient to support the full system load at any height within the range of the system. Furthermore, the screw mechanism is selected to have a total load rating greater than approximately 3.5 times the system load without breaking. Also the lower physical stop for the vertical arm support is designed so that it can bear the entire system load with a safety factor of at least approximately five. The combination of these aspects yields assurance that the first safety objective; namely, to provide adequate structural support for test head so that it cannot fall to the ground or through a distance of more than approximately two inches in the event that the counterbalance mechanism fails or becomes unbalanced, is reasonably achieved.

[0081] With the load properly counterbalanced, the main arm typically should never significantly move with respect to the vertical arm support except when driven by the dock actuator during docking and undocking. If such motion does occur, then it is probably indicative of an accidental event.

[0082] The vertical vernier axis is further equipped with position-sensing means, and it may also be equipped with motion sensing means. Also, if desired, a torque-limited drive motor coupled via a clutch as described previously in U.S. Patent Application Serial No. PCT/US00/00704 may be provided. It is recognized that in some embodiments it will be possible to combine position and motion sensing devices in that the two quantities are mathematically related. The purpose of the motion sensing means is to detect when there is motion of the main arm relative to the vertical arm support; unless the docking actuator is being operated, such motion would indicate that an obstacle or other unsafe condition has been encountered. The position sensor desirably indicates when the main arm is approximately centered within its range of vertical vernier motion. Aspects of an overall control methodology include:

[0083] The main arm is desirably approximately centered within its range of vertical vernier motion before the main vertical motion screws can be actuated. This insures that if an obstacle or other unsafe condition is encountered it will be detected.

[0084] The motion sensor is used to detect such relative motion and to provide a warning signal that can be utilized by the overall system to stop motion or to take other safety related action. The preferred action taken upon detection of such an event is to remove power from the vertical actuator and from any other axes, which might be simultaneously under powered motion.

[0085] The vertical vernier axis drive motor is used to center the main arm with respect to the vertical arm support before main vertical motion is energized. The clutch is engaged only when the drive motor is called upon to drive the vernier axis. Thus, the motor is normally decoupled and does not interfere in any way with either docking or obstacle detection. Because the motor is torque limited, damage will be prevented if an obstacle is encountered during the centering motion. A timer may be incorporated to detect this condition.

[0086] The torque-limited motor can be located on either side of the ball screw mechanism; however the gearing and torque limitations must take into consideration the mechanical advantage of the ball screw mechanism.

[0087] In order to provide freedom of motion in all six axes simultaneously, the above innovations are preferably used with a suite of techniques, which have been previously patented and/or disclosed. These include:

[0088] A test head cable pivot and associated apparatus as described in U.S. Pat. Nos. 5,030,869, 5,450,766 and 5,608,334.

[0089] A telescoping cable support arm as disclosed in U.S. Pat. No. 4,893,074 in conjunction with a cable support arm leveler as described U.S. Patent Application Serial No. PCT/US00/00704.

[0090] A base for the column that provides in-out, side-to-side, and swing motion where the center of swing motion is at a point between the column and tester cabinet and preferably near the point where the cable exits the tester cabinet as further described in U.S. Patent Application Serial No. PCT/US00/00704.

[0091] FIG. 1 is a perspective drawing of a manipulator 11 incorporating the present invention. Earlier patents and publications have described some elements of the manipulator 11 , and these are noted in the descriptions. Referring to FIG. 1 the manipulator 11 includes a base 15 that provides swing motion, in-out motion, and side-to-side motion. This base is described in further detail in U.S. Patent Application Serial No. PCT/US00/00704. The three axes of the base may or may not be powered depending upon the application. Mounted on the base is the manipulator column. 17 The column 17 may be either of the fixed height type or of the telescoping type (shown in FIG. 1 ).

[0092] As shown in FIG. 1 , the telescoping column 17 is comprised of three telescoping segments: a lower segment 21 , a middle segment 22 , and an upper segment 23 . In this case the upper segment 23 is also the vertical arm support, and a main arm 25 is slidingly attached to it. The main arm 25 supports a horizontal arm assembly 27 that in turn supports a cradle pivot assembly 29 , a cable pivot assembly 31 , and a test head yoke 33 . A test head (not shown) is attached to the test head yoke 33 and is normally carried by the test head yoke 33 as the load. It is noted that any of a wide variety of other types of attachment mechanisms can be substituted. Vertical vernier relative motion between the main arm 25 and the vertical arm 23 support has a range of approximately plus or minus 1 inch (25 mm) and is enabled by a mechanism that includes a ball screw and counter weights (not shown in FIG. 1 ). A telescopic cable support arm 18 provides effectively balanced roll motion through the telescopic cable support arm leveling mechanism 18 a.

[0093] FIGS. 2 and 3 illustrate the coordinate systems and nomenclature used to describe the manipulator, test head, and their motions. As described in U.S. Pat. Nos. 5,030,869, 5,450,766 and 5,608,334, the cradle pivot assembly 29 , a cable pivot assembly 31 , and test head yoke 33 support the test head in a manner that provides simultaneous degrees of freedom in pitch and roll. Following known practices described in these patents as well as the inTEST Handbook, the pitch and roll motions are balanced for low effort docking. Depending upon specific application requirements additional degrees of freedom may also be provided in the horizontal arm 27 structure including swing, in-out, and side-to-side. These additional degrees of freedom in the horizontal plane may occur either singly or in combinations, and furthermore these additional motions may be redundant to motions provided elsewhere in the manipulator. Examples include, but are not necessarily limited to, the following:

[0094] The horizontal arm assembly 27 may be comprised of a single upper arm rigidly attached to both the main arm 25 and cradle pivot assembly 29 . This configuration provides no additional degrees of freedom.

[0095] The horizontal arm assembly 27 may consist of a single upper arm that is rigidly attached to the cradle pivot assembly 29 and attached in a hinged fashion to the main arm 25 to enable swing motion in the horizontal plane.

[0096] The horizontal arm assembly 27 may consist of an upper arm hinged to the main arm 25 , a forearm hinged to the upper arm, and a hinged connection to the cradle pivot assembly 29 in a manner to allow simultaneous in-out, side-to-side, and swing motions in the horizontal plane.

[0097] The horizontal arm assembly 27 may consist of two upper arms of equal length and two forearms also of equal length arranged in a quadrilateral. Both upper arms are hinged to the main arm 25 , each forearm is hinged to its respective upper arm, and both forearms are hinged to the cradle pivot assembly 29 . This structure would enable simultaneous in-out and swing motion in the horizontal plane while inhibiting side-to-side motion.

[0098] Those skilled in the art will recognize that there are many possible ways to construct a horizontal arm assembly 27 .

[0099] A configuration using a single upper arm 43 attached to the main arm 45 and rigidly attached to a cradle pivot assembly 49 and attached in a hinged fashion is shown in FIG. 4 . This generally corresponds to the second possibility in the above list. In particular the main arm 45 engages the upper arm 43 that is directly connected to the cradle pivot assembly 49 such that this connection allows the upper arm 43 to articulate with respect to the main arm 45 and thereby provide a limited plus/minus (approximately) 5 degrees of secondary or vernier swing motion. This means that the plus/minus 5 degrees of motion is in a horizontal plane. This plus/minus 5 degrees of swing motion is designated as 401 in FIG. 4 . As described in U.S. Pat. Nos. 5,608,334, 5,450,766, and 5,030,869 and “The inTEST Handbook,” the upper arm 43 engages (typically) the cradle pivot assembly 49 to provide an approximate plus/minus 5 degrees of balanced pitch motion. This plus/minus 5 degrees of pitch motion is designated as 403 in FIG. 4 . The cradle pivot assembly 49 comprises an outer cradle back 407 that is connected via a cradle pivot shaft 411 to an inner cradle back 409 (not shown) that is in turn connected with a cradle side 413 . It is noted that any of a wide variety of other types of attachment mechanisms can be substituted for the cradle in the cradle pivot assembly 49 shown in FIG. 4 . A cable pivot assembly 31 comprising a cable pivot housing 415 , which is attached to the cradle side 413 , that is rotationally engaged with test head adapter ring 417 , which is fixedly attached to the test head (not shown) via a test head yoke 33 , provides approximately plus/minus 95 degrees of roll motion in most applications. This plus/minus 95 degrees of roll motion is designated as 405 in FIG. 4 . Total roll motion of typically up to plus or minus 95 degrees (190 degrees total) can be provided in certain situations. Typically and preferably a telescopic cable support arm 18 is used to provide effectively balanced roll motion and by the use of a telescopic cable support arm leveling mechanism 18 a (see FIG. 1 ) as is described in U.S. Pat. No. 4,893,074 and U.S. Patent Application Serial No. PCT/US00/00704. In combination the cable pivot 31 , the telescoping cable support arm 18 , and the leveling mechanism 18 a effectively minimize variations in forces exerted by the cable on the test head as the manipulator is moved through its motion envelope. Alternatively, a tumble mode test head support mechanism may be utilized which provides, for example, plus/minus five degrees of roll motion and plus/minus 95 degrees (or more if need be) of pitch motion. Optionally, the roll (or—for a tumble mode—the pitch) axis may be powered and clutched in the manner described in earlier disclosures. The remaining axes that are supported by the main arm may also be powered in a similar manner if desired.

[0100] FIGS. 5A through 5C are perspective drawings of the test head positioner 11 and illustrate the interaction of all of the manipulator axes of FIG. 2 . The positioner permits movement in all six degrees of freedom. FIG. 5A shows the base 15 with an upper platform 61 rotated 30 degrees clockwise and the column 17 pushed all the way back and all the way to the left. FIG. 5B shows the base 15 with the upper platform 61 in a straight-ahead alignment with the column 17 at mid-stroke in both in-out and side-to-side axes. FIG. 5C shows the base 15 with the upper platform 61 rotated 10 degrees counterclockwise with the column 17 positioned all the way forward and all the way to the right. It is seen that all axes may be individually controlled or that all may be moved simultaneously as is generally needed in docking.

[0101] Referring again to FIG. 1 , the telescoping column 17 is mounted to the base 15 and is comprised of the three vertical segments 21 , 22 , 23 , and these segments 21 , 22 , 23 are approximately equal in length. The length of each vertical segment 21 , 22 , 23 is approximately four feet (120 cm). This provides a height of approximately four feet above the top of the base 15 , when the column is fully retracted, and approximately eight feet (240 cm) above the top of the base 15 , when it is fully extended. The vertical structure is not necessarily limited to three segments 21 , 22 , 23 ; fewer or greater numbers of segments could be utilized according to needs and available technology. The three segments 21 , 22 , 23 in this example all have “H” cross sections for stiffness, with the uppermost section 23 having additional vertical fins for additional stiffness. Other cross sections could also be used; for example, the nestable cross section utilized in U.S. Pat. No. 5,931,048, to Slocum et al. and referenced above. The three segments are as follows:

[0102] Main (or first or bottom) segment 21 —fixed to the base 15 .

[0103] Second (or middle) segment 22 —slides up and down the main segment 21 by means of linear guide rails 81 (not shown in FIG. 1 ) attached to the main segment 21 engaged by mating ball slides 83 (not shown in FIG. 1 , see FIG. 12 ) attached to the second segment 22 .

[0104] Third (or upper) segment 23 —slides along the second segment 22 by means of linear guide rails 81 (not shown in FIG. 1 ) attached to the second segment 22 engaged by mating ball slides 83 (not shown in FIG. 1 , see FIG. 12 ) attached to the third segment 23 . This segment also functions as the vertical support arm 25 .

[0105] The three vertical segments 21 , 22 , 23 are arranged so that motor-driven linear actuators 75 , one for each moving segment, can raise and lower the top of the column 17 . The linear actuators 75 are coupled to standard trunions 76 (one of two shown in FIG. 1 , see also FIGS. 10A and 10B ). Actuators having ball screws are preferred; however, other screw types, such as an ACME screw, could alternatively be used depending upon cost, availability, speed variables and power requirements. The first such linear actuator 75 moves the second segment 22 with respect to the main segment 21 . The second such linear actuator 75 moves the third segment 23 with respect to the second segment 22 . The second 22 and third 23 segments move in proportion such that a total vertical motion is made up of 50% motion of the second segment 22 with respect to the first 21 and 50% motion of the third 23 with respect to the second 22 .

[0106] A standard Saginaw linear actuator 75 is typically utilized. This unit provides a maximum extension of 24 inches (61 cm). The two actuators 75 together provide a total vertical travel of 48 inches (122 cm), and it is observed that each of the movable segments 21 , 22 , 23 moves approximately one-half its length with respect to the segment that is immediately below it. Thus at full extension there remains an approximate 50% overlap between adjacent segments which helps to maintain structural rigidity. In a preferred embodiment each actuator 75 has a speed of approximately 0.4 inches/second (1 cm/sec) to provide a combined vertical speed of approximately 0.8 inches per second (2 cm/sec) or 4 feet/minute. The combination of two standard off-the-shelf actuators 75 together with two movable segments provides the most economical overall solution providing 48 inches (120 cm) of vertical travel. Should other actuators with different ranges become available at reasonable costs, then the economics may suggest a different number of movable segments to achieve the same result.

[0107] In contrast to many other contemporary manipulators, this main vertical motion is typically powered; there are no associated counterbalancing mechanisms. The linear actuators 75 are responsible for fully supporting the entire system load (previously defined) regardless of whether the actuators 75 are energized to either raise or lower the load or whether power to the actuators 75 has been turned off. Accordingly, the thread pitch angle of the linear actuators 75 is chosen to prevent back driving; i.e., so that if a motor is disabled or removed, the load will stay at a fixed vertical position and not fall. No mechanical brakes or locks are required. The actuators 75 are therefore considered to be non-compliant drives. The ultimate static load rating of the mechanisms is chosen with a safety factor greater than three so that structural integrity is maintained in all situations.

[0108] FIG. 6 is a cut-away perspective illustration and shows details of the main arm 25 and the use of vernier vertical motion. As shown, the main arm 25 is slidingly attached to the third segment 23 (vertical arm support) using linear guide rails 81 a that are attached to the vertical arm support 23 and that are engaged by mating ball slides 83 a (not visible in FIG. 6 , see FIGS. 7 a through 7 c ) attached in turn to the main arm 25 . Third segment 23 attaches to second segment (not shown) by means of linear guide rails 81 and linear bearing blocks 83 . Resilient bumpers 85 are attached at the upper and lower ends of the main arm 25 . These bumpers 85 contact structural elements of the vertical arm support 23 in a manner to restrict the vertical motion of the main arm 25 to approximately plus or minus one inch (2.5 cm) with respect to the vertical arm support 23 for docking and undocking. This provides a vertical vernier motion that is fully independent of the main vertical motion provided by the previously described linear actuators 75 .

[0109] The main-arm vernier vertical motion is relative to the third segment or vertical arm support 23 . It is fully balanced to enable smooth docking and undocking and to absorb motion and vibration during testing. Balance is achieved using a vertical counter weight mechanism 91 with a mechanical advantage (MA) greater than one. Typically, the mechanical advantage is 10. This embodiment achieves this using a low friction ball screw mechanism 90 having a 20 mm×20 mm (or similar) thread pitch angle to allow low-friction, free motion in either direction. This permits the main arm 25 to be readily back driven without undue force. Ball screws are well known as being efficient devices to provide linear motion with mechanical advantage. An upper end of the ball screw 95 is mounted to the upper end 96 of the vertical arm support 23 using a support unit comprising an appropriately sized contact ball screw support bearing assembly 103 (not shown in FIG. 6 , see FIGS. 7 A- 7 C), in which the ball screw 95 is free to rotate. The ball screw shaft extends upwards through the bearing, and a cable drum 97 is coaxially and rigidly attached to the ball screw 95 so that the ball screw 95 and drum 97 rotate in unison. The top of the cable drum 97 is above the top of the vertical arm support 23 . The ball screw 95 is used to effect motion of main arm 25 by driving the main arm 25 , but it should be noted that the ball screw 95 is a driven mechanism in the sense that the counterweights (not shown) drive the ball screw 95 , and the main arm 25 back-drives the ball screw 95 .

[0110] One end of a cable 98 is fixed to the cable drum 97 . The cable 98 is wound around the drum 97 , extends over the top of the vertical arm support 23 , and is led towards the rear of the manipulator 11 . The cable then passes over a sheave 99 attached to a bracket 101 mounted on top of the vertical arm support 23 . The cable 98 then extends downwards from the sheave 99 and connects to and supports a weight holder 100 that contains an appropriate amount of counter weights (not shown). The cable drum 97 is provided with a helical grove in which the cable 98 rides to prevent the cable from overriding itself and causing the system to jam.

[0111] A ball screw nut 111 having mating threads to the ball screw 95 is attached with machine screws to the upper end of the main arm 25 . The ball screw 95 is threaded through this nut 111 . The ball screw 95 supports the main arm 25 and its entire load. As the main arm 25 moves vertically with respect to the vertical arm support 23 , the motion of the ball screw 95 through the nut 111 will cause the ball screw 95 to rotate along its axis. As the ball screw 95 rotates, the cable drum 97 will turn and the counter weights (on weight holder 100 ) will be raised or lowered. It is seen that the bearing assembly that attaches the ball screw 95 to the vertical arm support 23 must both bear the full axial load applied by the main arm 25 and allow low friction rotation of the ball screw 95 . Commercially available ball screw support bearings are employed for this function.

[0112] As mentioned, a mechanical advantage (MA) greater than one is typically provided. Neglecting friction, the mechanical advantage is determined by the formula:

MA=π·D·P

[0113] Where: D is the effective diameter of the drum 97 ,

[0114] And P is the ball screw pitch in turns per unit length

[0115] (Note: units of length used in both quantities must be the same)

[0116] The counter weights weigh 1/MA (10% with MA=10) of the combined weights of the test head (not shown), main arm 25 and interconnecting manipulator structure, and the test head's share of the telescopic cable support and cable. The counter weights move MA times the distance of the main arm motion with respect to the third segment 23 (i.e., approximately +/−10 units for each one unit with MA=10). Because there is very little friction in the system, the main arm 25 behaves as if it were directly counterbalanced with a simple cable and pulley arrangement as first described for example in U.S. Pat. No. 4,527,942.

[0117] FIGS. 7A, 7B and 7 C are cross sectional views of the upper portion of the manipulator column 17 showing the main arm 25 in its uppermost position, and intermediate position, and lowest position respectively. These serve to illustrate the relative motions of the main arm 25 , ball screw 95 , and counter weights (weight holder 100 ). In FIGS. 7 A- 7 C, the ball screw support bearing assembly 103 is also shown. In each of FIGS. 7 A- 7 C, the upper segment 23 is cut away and the middle segment 22 is not shown to illustrate operation of the main arm counterbalance mechanism.

[0118] FIGS. 8 and 9 are views depicting a non-telescoping embodiment of a positioning system constructed according to one aspect of the present invention. The arrangement previously described may also be applied to the positioning system in which a fixed height column is used. In prior art manipulators having a fixed height column, the main arm slides along rails or one or more shafts supported by the column; typically the main arm and its load are fully counterweighted, so that little force is required to move the test head over the full range of vertical motion. The total weight of the counterweights is approximately equal to the weight of the system load (i.e., the main arm and everything supported by it including the test head). The present invention can be adapted to allow the total weight of the counterweights to be approximately equal to the system load divided by the mechanical advantage MA.

[0119] In FIGS. 8 and 9 , a fixed height column manipulator 141 is shown without a base. The manipulator 141 has a column 143 which may be mounted on either a fixed base or on a base that provides horizontal motion in selected axes, both approaches being known and having been described in earlier patents and disclosures. Additionally, the fixed column 143 may be a stationary column extending between and being attached to floor and ceiling.

[0120] A vertical arm support 145 is slidingly coupled to the column 143 using, preferably, linear guide rails 147 fixed to the column 143 engaged by ball slides (not shown) attached to the vertical arm support 145 . A linear actuator 75 (not shown) is used to drive the vertical arm 145 vertically along the column 143 .

[0121] A main arm 155 of the manipulator 141 is slidingly coupled to the vertical arm support 145 in a similar manner as with the telescoping column manipulator 11 . A similar ball screw mechanism 161 is utilized in a similar manner to provide a balanced vernier vertical motion and to reduce the amount of counter weights required. In this embodiment, a cable 165 supporting the counter weights is treated somewhat differently. In particular, the cable 165 is first led from a cable drum 167 and passed under a sheave 169 that is fixed to the upper end of the vertical arm support 145 . The cable 165 then extends toward the top of the column 143 and passed over a sheave 171 that is fixed to the top of the column 143 . The cable 165 is then led down the rear of the column 143 where it is attached to a weight holder 100 that holds the counter weights (not shown).

[0122] It is apparent that as the vertical arm support 145 is driven up and down the front of the manipulator column 143 , the counter weights will fall and rise along the rear of the column 143 . The total travel of the counter weights will be nominally equal to the distance traveled by the vertical arm 145 support plus or minus the mechanical advantage, MA, multiplied by the travel of the main arm 155 with respect to the vertical arm support 145 . The physical height of the counter weights, the diameters and locations of the sheaves 169 , 171 , and the space required by the physical extension available in the linear actuator 75 will all impose limits on the total available vertical motion available in a manipulator of a given fixed height.

[0123] FIGS. 10 A- 13 are different views of a telescoping positioner 11 constructed according to the present invention. The views illustrate the relative motions of the main arm 25 , ball screw 95 , and counter weights (weight holder 100 ). FIGS. 10A and 10B are perspective views of the front of a telescoping column assembly 11 . FIGS. 11A and 11B are perspective views of the back of the telescoping column assembly 11 . FIGS. 11A and 11B provide a view of the screw 75 a of the linear actuator 75 , with one end of the screw 75 a coupled to fork 75 b. FIG. 12 is a plan view of the telescoping column assembly 11 and FIG. 13 is a top perspective view of the telescoping column assembly 11 .

[0124] Safety features and system control features can be used in both the telescoping column and fixed height column embodiments. The vertical vernier axis is powered in a manner similar to that disclosed in U.S. Patent Application Serial No. PCT/US00/00704. A dc motor is combined with an appropriate gear box, clutch, and drive mechanism to apply power to the ball screw cable sheave in the case of the telescoping column manipulator and to either the ball screw cable sheave or the column cable sheave in the case of the fixed height manipulator. The clutch is only engaged when it is desired to use the motor to drive the vertical vernier axis, at all other times this axis is free to move relative to the vertical support arm by the application of any external forces.

[0125] The current applied to the dc motor is typically limited to a fixed value to limit the motor torque to a level sufficient to slightly overcome friction and allow motion. If obstacles or significant external forces are encountered, the motor will safely stall.

[0126] There are two cases of external forces:

[0127] 1) During docking and undocking the vernier vertical axis must be free to move due to the forces applied by the docking actuator. While docked, the vernier vertical axis should be free to move to absorb vibrations due to the handler, prober or other test station apparatus (TSA) operation.

[0128] 2) When not docked, or in the process of being either docked or undocked, any non-driven vertical vernier motion is a sign that external forces have been applied and/or an obstacle has been encountered in positioning the test head vertically. Generally, these may be taken as unsafe or hazardous conditions.

[0129] Accordingly, a means for sensing relative motion between the main arm 25 and the vertical arm support 23 is provided. The output of this sensor provides a useful signal for both control and safety. Additionally, sensors are employed to sense the relative position of the main arm 25 with respect to the vertical arm support 23 . A variety of sensor types can be used according to the sophistication of the overall control system that is to be used with the manipulator 11 . For example an absolute encoder that provides precise position information could be utilized in a system having a high degree of automation. The output of such an encoder may be readily differentiated in a data processing unit to provide motion detection. In a simpler system, one or more limit switches may be used to detect certain relative positions and a simple photoelectric or other device could be utilized to detect relative motion.

[0130] A most basic system is now described to illustrate the safety features incorporated in the invention. Those skilled in the art will readily apply these features to more sophisticated systems. In this basic system limit switches and limit switch actuators are used in known ways to provide the following binary-valued signals:

[0131] Main Arm Up (MAU): true when the main arm 25 is in the upper half of its range of relative travel. That is, it is true from approximately the center of travel through the upper limit of travel.

[0132] Main Arm Centered (MAC): true when the main arm 25 is in the central region of its range of relative travel. Typically, for reasons discussed below, when the main arm 25 is approximately within plus or minus ⅛ to ¼ of an inch of being exactly centered.

[0133] Main Arm Down (MAD): true when the main arm 25 is in the lower half of its range of relative travel.

[0134] In addition there is a motion sensor that provides a signal whenever relative motion occurs. In the present system an incremental shaft encoder having a resolution of 1024 parts per revolution (such as a Hohner Corporation Series 01 encoder) is coupled to the cable sheave 99 . If the sheave 99 has a six-inch diameter and if the ball screw mechanism 90 provides a mechanical advantage of ten, then the incremental encoder will detect a relative motion change of approximately 0.018 inches. The encoder output may be readily connected to electronic circuitry to provide a pulse whenever such an increment motion is detected. To achieve a coarser resolution, a digital counter circuit can divide the train of pulses appropriately.

[0135] There are two modes of operation in a basic system: a “normal” mode and a “maintenance” mode. A key operated switch is provided and arranged so that the system is in normal mode when the key is not inserted in the switch. A skilled operator, who possesses a key, may insert the key and switch the system to maintenance mode when necessary. Those skilled in the art will recognize that there are other methods that could be implemented to ensure that only qualified, skilled personnel are able to place the system in maintenance mode.

[0136] In normal mode the safety features to be described are enabled allowing a person of relatively low skills and experience to operate the system. Maintenance mode is provided to help a skilled, qualified operator clear the system from the effects of obstructions, collisions, or other unsafe situations and also to enable system maintenance, repair, and set-up operations where balanced motion might not always be available or possible.

[0137] A handheld control unit is provided that has (in addition to other possible controls not pertinent to the present invention) a three-position momentary on-off-on switch to control the major vertical motion. One of the on positions is used to request the linear actuators 75 to move the vertical arm support 23 in the up direction. The other on position requests the linear actuators 75 to move the vertical arm support 23 in the down direction. In either maintenance or normal mode, vertical motion will always stop whenever the operator control is released, whereupon it reverts to the off position.

[0138] In maintenance mode, the vertical arm support actuators 75 will always be energized in response to the motion request. It is up to the skilled operator to ensure safety of operation.

[0139] In normal mode safety features are enabled, and these are now described in the following paragraphs.

[0140] Before either up or down motion can begin in normal mode, it is required that the main arm 25 be in a position where it can detect an abnormal condition effecting motion. There are several possible simple control embodiments. Two are described herein, and others will be apparent to those skilled in the field. In the first embodiment, if MAC is true, signifying that the main arm 25 is in the “central region” of its range of relative travel, when either up or down motion is requested, then power is appropriately applied to the vertical actuators 75 and the requested motion commences. If MAC is false when the operator actuates either the up control or the down control, the system will automatically attempt to center the main arm 25 . In particular if MAU is true, the system will use the vernier vertical drive motor and clutch to drive the main arm 25 in the down direction until MAU switches to false. At this point the main arm 25 will be very nearly in the center of the central region. Vertical arm support motion is then allowed to begin. Similarly, if MAD is true, the system will drive the main arm 25 in the up direction until MAD switches to false where the main arm 25 will be very nearly in the center of the central region. Vertical arm support motion is then allowed to begin.

[0141] In the second embodiment, it is reasonably assumed that if an obstruction is encountered during vertical motion, it will cause the main arm 25 to move in the opposite direction of the requested motion. For example, an obstruction encountered while moving in the up direction will cause a downwards relative motion of the main arm 25 relative to the vertical arm support 23 . In this embodiment Up (Down) vertical motion is allowed if either MAU (MAD) or MAC are true when the up motion is requested. If neither is true, then MAD (MAU) is necessarily true and the main arm 25 is driven up with respect to the vertical arm support 23 until MAD (MAU) becomes false, indicating that the main arm 25 is centered with respect to the vertical arm support 23 . As stated previously, the manipulator 11 can be configured so that vertical motion always halts whenever the operator control is released.

[0142] In either embodiment, whenever the system begins to automatically center the main arm 25 , a timer can be started. The timer is stopped when the main arm 25 arrives at its centered position. If an obstacle, obstruction, or other malfunction prevents the main arm 25 from becoming centered within a predetermined amount of time, the timer gives an output signal that shuts off the power sources to all drive mechanisms and alerts the operator to the situation. The power sources to the drive mechanisms must be manually turned back on by a skilled, qualified operator after the situation has been fixed. It may be necessary for the skilled, qualified operator to utilize maintenance mode to clear the situation. A key-operated switch or other secure means may also be readily employed to restore the power to the actuators 75 f