COMPUTER NUMERICAL CONTROL ASSEMBLY OR PROCESSING OF COMPONENTS
20170227946 · 2017-08-10
Inventors
- Kenneth Wayne NICHOLSON (Kingston, CA)
- Philip David Munroe (Kingston, CA)
- Martin George SMITH (Kingston, CA)
- Robert David Almas (Kingston, CA)
Cpc classification
Y02P90/02
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G05B19/182
PHYSICS
G05B19/41815
PHYSICS
B23P21/004
PERFORMING OPERATIONS; TRANSPORTING
B23Q41/02
PERFORMING OPERATIONS; TRANSPORTING
G05B19/19
PHYSICS
B25J9/1669
PERFORMING OPERATIONS; TRANSPORTING
International classification
G05B19/19
PHYSICS
G05B19/414
PHYSICS
G05B19/418
PHYSICS
B23Q41/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention relates to a device, system and method of automated manufacture comprising: delivering a workpiece with a delivery device; receiving the workpiece with a receiving device, the delivering of the workpiece and the receiving of the workpiece being electronically synchronized; processing the workpiece with a processing tool while the workpiece is on the receiving device; transferring the workpiece to a completion device, the ejection of the workpiece and the transferring of the workpiece being electronically synchronized. In particular the workpiece may comprise: a platform with mounts supporting a first component in a selected orientation; and a locating surface, the method comprising: engaging and disengaging the locating surface of the workpiece with releasable connectors on the delivery device, on the receiving device and on the completion device.
Claims
1. A method comprising: delivering a workpiece with a delivery device by: loading the workpiece at an intake position of the delivery device; separating the workpiece by moving the workpiece from the intake position; accelerating the workpiece; and presenting the workpiece at a predetermined delivery time, delivery position, delivery speed and moving along a delivery trajectory; receiving the workpiece with a receiving device moving along a receiving trajectory configured to permit transfer of the workpiece at the delivery position from the delivery device to the receiving device, the delivering of the workpiece and the receiving of the workpiece being electronically synchronized; processing the workpiece with a processing tool while the workpiece is on the receiving device; presenting the workpiece at a predetermined ejection time, ejection position, ejection speed and moving along an ejection trajectory; transferring the workpiece to a completion device moving along a completion trajectory configured to permit transfer of the workpiece at the ejection position from the receiving device to the completion device, the ejection of the workpiece and the transferring of the workpiece being electronically synchronized.
2. The method according to claim 1 wherein, the workpiece comprises: a platform with mounts supporting a first component in a selected orientation; and a locating surface, the method comprising: engaging and disengaging the locating surface of the workpiece with releasable connectors on the delivery device, on the receiving device and on the completion device.
3. The method according to claim 2 wherein the platform has mounts supporting a second component, the method comprising: assembling the first and second components together with the processing tool while the workpiece is on the receiving device.
4. The method according to claim 2 wherein the platform and mounts include a fluid port, the method comprising: conveying fluid from the processing tool to the fluid port while the workpiece is on the receiving device.
5. A system comprising: a delivery device configured to deliver a workpiece by: loading the workpiece at an intake position of the delivery device; separating the workpiece by moving the workpiece from the intake position; accelerating the workpiece; and presenting the workpiece at a predetermined delivery time, delivery position, delivery speed and moving along a delivery trajectory; a receiving device configured to receive the workpiece by moving along a receiving trajectory configured to permit transfer of the workpiece at the delivery position from the delivery device to the receiving device, and to present the workpiece at a predetermined ejection time, ejection position, ejection speed and moving along an ejection trajectory; a processing tool configured to process the workpiece while the workpiece is on the receiving device; a completion device configured to accept transfer of the workpiece at the ejection position from the receiving device after processing, the completion device moving along a completion trajectory, a data processor; and a medium comprising machine-readable instructions executable by the data processor and configured to cause the data processor to generate signals useful in the synchronization of the: delivering of the workpiece and the receiving of the workpiece; processing of the workpiece; and transferring of the workpiece to the completion device.
6. The system as defined in claim 5, wherein the workpiece comprises: a platform with mounts supporting a first component in a selected orientation; and a locating surface; and wherein the machine-readable instructions are configured to cause the data processor to generate signals useful in the synchronization of the: engaging and disengaging the locating surface of the workpiece with releasable connectors on the delivery device, on the receiving device and on the completion device.
7. The system as defined in claim 5: wherein each of the delivery device, the receiving device, the processing tool and the competition device comprise actuators each with at least one axis of motion; and wherein the machine-readable instructions are configured to cause the data processor to generate signals useful in the controlling motion on each of the at least one axis of motion using a plurality of servo applications electronically cammed together on a standardized backplane of coded instructions.
8. An automated device comprising: a delivery device having a numerically controlled delivery drive for: loading a workpiece at an intake position of the delivery device; separating the workpiece by moving the workpiece from the intake position; accelerating the workpiece; and presenting the workpiece at a predetermined delivery time, delivery position, delivery speed and moving along a delivery trajectory; a receiving device having a numerically controlled receiving drive for moving along a receiving trajectory configured to permit transfer of the workpiece at the delivery position from the delivery device to the receiving device; a processing device having a numerically controlled processing drive for processing the workpiece with a processing tool while the workpiece is on the receiving device; the numerically controlled receiving device being configured for presenting the workpiece at a predetermined ejection time, ejection position, ejection speed and moving along an ejection trajectory; a completion device having a numerically controlled completion drive for moving along a completion trajectory configured to transfer the workpiece at the ejection position from the receiving device to the completion device, the delivering of the workpiece and the receiving of the workpiece being electronically synchronized by the numerically controlled delivery and receiving drives, the processing of the workpiece being electronically synchronized by the numerically controlled processing drive, and the ejection of the workpiece and the transferring of the workpiece being electronically synchronized by the numerically controlled delivery and receiving drives.
9. The automated device according to claim 8, wherein, the workpiece comprises: a platform with mounts supporting a first component in a selected orientation; and a locating surface; and the delivery device, the receiving device and the completion device include releasable connectors for engaging and disengaging the locating surface of the workpiece.
10. The automated device according to claim 9 wherein, the platform has mounts supporting a second component; and the processing tool comprises an assembly tool for assembling the first and second components together with while the workpiece is on the receiving device.
11. The automated device according to claim 9 wherein, the platform and mounts include a fluid port; and the processing tool includes an outlet port for conveying fluid to the fluid port while the workpiece is on the receiving device.
12. The automated device according to claim 9 wherein, the locating surface comprises a pin with a locating groove; and the releasable connectors comprise grip fingers actuated between an open position and a closed position engaging the pin and locating groove.
13. The automated device according to claim 12 wherein the workpiece comprises a base joined to the platform with the pin.
14. The automated device according to claim 8 comprising a rotary engine wherein: the delivery device comprises a rotary actuated input indexing platform configured to pick the workpiece from an input stream of like workpieces; the receiving device comprises a rotary tool platform on which the processing tool is mounted; and the completion device comprises a rotary actuated input indexing platform configured to place the workpiece from the receiving device into an output stream of like workpieces.
15. The automated device according to claim 8 comprising a pick and place engine wherein: the workpiece comprises an individual component; the delivery device comprises a rotary actuated input indexing platform configured to pick a component from an input stream of like components; the receiving device comprises a pick and place robot; and the completion device comprises a linear actuated conveyor configured to accept the component from the pick and place robot.
16. The automated device according to claim 15 wherein the processing tool comprises an optical scanner configured to scan the component to identify a surface feature and determine an input orientation based on the surface feature; and the pick and place robot includes a rotary grip in communication with the optical scanner configured to rotate the component from the input orientation to an output orientation.
17. The automated device according to claim 16 wherein the linear actuated conveyor comprises a platform with multiple mounts supporting multiple components in the output orientation as placed by the pick and place robot.
18. The automated device according to claim 8 comprising a multiplex engine wherein the delivery device comprises a rotary actuated input indexing platform; the receiving device comprises a pick and place robot; and the completion device comprises a linear actuated conveyor configured to present the workpiece to the pick and place robot before processing and to accept the workpiece from the pick and place robot after processing.
19. The automated device according to claim 18 wherein the processing tool is mounted to a stationary base.
Description
DESCRIPTION OF THE DRAWINGS
[0013] In order that the invention may be readily understood, embodiments of the invention are illustrated by way of examples in the accompanying drawings.
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[0024] Further details of the invention and its advantages will be apparent from the detailed description included below.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] This description employs the terms “delivery device”, “receiving device, and “completion device” merely to imply a progression of the workpiece or processing from delivery to receiving to completion. Alternative terms could be used such as first, second and third to imply the same progression. Any of the devices can simply transfer workpieces from one location or position to another without processing or changing the workpiece. Any of the devices can also be a platform that includes tools or processing to perform some value-added function to the workpiece for example scanning, forming, welding, assembling, changing orientation or applying adhesives. Further although many of the devices are shown as rotating, the description herein uses general terms which are meant to also include devices that translate in a linear motion, in x-y-z Cartesian motion, in a curved trajectory or any other motion.
[0026] The rotary engine embodiment shown in
[0027] Referring to
[0028] The POD 1 in the example shown in
[0029] An advantage using PODs 1 is that, once the other machinery has been set up to process the PODs 1 as workpieces, to process different sized or shaped components (2, 3) the major portion of the machinery need not be extensively modified. Modification is limited to the mounts 4 and to other replaceable tools or parts that contact the components (2,3). The costs and downtime involved in retooling a system to process different components is greatly reduced in many cases.
[0030] Referring to
[0031] The POD 1 is delivered to the rotating receiving device 12 by the delivery device 11 in a synchronized manner by bringing the stationary POD 1 on the input conveyor 10 up to a rotary speed that matches the rotary speed of the receiving device 12 at the time when the pod 1 is transferred.
[0032] The steps of doing so can be summarized as “rapid speed matching” (RSM) which includes: loading the workpiece POD 1 at the intake position; separating the workpiece POD 1 from other PODs 1 and the input conveyor 10 by moving the POD 1 from the intake position; rotationally accelerating the POD 1; and presenting the POD 1 to the open grip fingers 9 of the rotating receiving device 12 at a predetermined delivery time, delivery position, delivery speed and moving along a delivery trajectory. The POD 1 is released by opening the grip fingers 9 of the rotating delivery device 11 and engaged by closing the grip fingers 9 of the rotating receiving device 12 at the predetermined delivery time. Instantaneous coordination of these movements is provided by electronic camming software controlling all of the required actuators. To do so the receiving device 12 moves along a receiving trajectory configured to permit transfer of the POD 1 at the delivery position from the delivery device 11 to the receiving device 12, where the delivering of the POD 1 and the receiving of the POD 1 are electronically synchronized.
[0033] At this point the POD 1 is secured to the rotating receiving device 12 by the grip fingers 9 as shown in
[0034] As shown in
[0035] Referring to
[0036] As shown in
[0037] In the example shown, when considered relative to the axis of the receiving device 12, the angular spacing between the delivery device 11 and the completion device 17 is less than 90° which leaves more than 270° of rotation during which the receiving device 12 and processing tool 13 have time to test and assemble the components (2, 3). However it will be understood that the rotation speed of the receiving device 12 need not be constant. Electronic camming software can be coded to speed up and slow down rotation in any manner desired to provide sufficient time for testing and assembly actions.
[0038] Once assembly or processing is completed, using the processing tool 13 while the POD 1 is on the receiving device 12, the POD 1 is presented at a predetermined ejection time, ejection position, ejection speed and moving along an ejection trajectory by computer numerical control of the rotary driver of the receiving device 12. The POD 1 is transferred from the grip fingers 9 of the rotating receiving device 12 to the open grip fingers 9 of the rotating completion device 17. The rotating completion device 17 moves along a completion trajectory configured to permit transfer of the POD 1 at the ejection position from the receiving device 12 to the completion device 17, the ejection of the POD 1 and the transferring of the POD 1 being electronically synchronized. The completion device 17 is a rotary actuated input indexing platform with grip fingers 9 configured to place the POD 1 from the receiving device 12 into an output stream of like PODs 1 on the output conveyor 18. To do so the rotary speed of the completion device 17 must change from matching the rotary speed of the receiving device 12 to match the speed of the output conveyor 18. Of course all devices could be programmed to rotate continuously like meshed gears, however with separate electronic camming controls each device is able to change rotational velocity and even direction to suit any desired timing and processing plan.
[0039] All of the movements described above are controlled by electronic camming software and other software dedicated to the rotary engine. The rotary engine is an example of the grouping of electronically cammed devices which together can be integrated as a unit into various larger systems as a sub-system. The electronically cammed system includes a data processor and a information storage medium to record machine-readable instructions executable by the data processor and configured to cause the data processor to generate signals to synchronize the: delivering of the workpiece (POD 1 or individual components 2, 3) and the receiving of the workpiece; processing of the workpiece; transferring of the workpiece to the completion device 17; engaging and disengaging the locating pins 7 of the PODs 1 with releasable connectors or grip fingers 9 on the delivery device 11, on the receiving device 12 and on the completion device 17.
[0040] Besides the “rotary engine” described above, the benefits of grouping devices together into standardized “engines” or sub-systems has been found useful in designing and assembling larger more complex manufacturing systems. Each sub-system provides for common functions and can be built and tested separately. As suggested by the system shown in
[0041] A system may be conceptualized as a n-axis system level robot having a potentially limitless or n-axes of motion distributed throughout all integrated devices. A central device such as a servo conveyor can act as a master axis device with auxiliary devices around the conveyor acting as slave devices with their own slave axes in coordination with the master axis device. The system has a central control where software generates signals for synchronizing of the: delivering of the workpiece and the receiving of the workpiece; processing of the workpiece; and transferring of the workpiece to the completion device, as well engaging and disengaging the grip fingers 9 and all other motions. Each of the delivery device, the receiving device, the processing tool and the competition device comprise actuators each with at least one axis of motion; and software generates signals to control motion on each axis of motion using standarized servo applications electronically cammed together on a standardized backplane of coded instructions. The common servo application software leads to common software for groupings of devices into sub-systems, named “engines” herein. Common engine or sub-system software combined in an electronically cammed n-axis system level robot, leads to efficiencies in designing and building through standardization.
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[0044] The pick and place robot 24 (receiving device) rotates and orients components from the indexing platform 21 to transfer the components on the mounts 4 of the PODs 1 disposed on a linear actuated screw conveyor 25 (completion device). Therefore the pick and place engine or sub-system is made up from a delivery device comprising a rotary actuated input indexing platform 21 configured to pick a component (such as a cap 2 or body 3) from an input stream of like components supplied by the linear conveyor 20. The receiving device comprises a pick and place robot 24 and the completion device comprises a linear actuated conveyor 25 configured to accept the components (2, 3) from the pick and place robot 24 onto a POD 1.
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[0048] Referring to the integrated system of
[0049] Although the above description relates to a specific preferred embodiment as presently contemplated by the inventors, it will be understood that the invention in its broad aspect includes mechanical and functional equivalents of the elements described herein.