METHOD AND ASSEMBLY UNIT FOR ASSEMBLING NON-ELECTRIC COMPONENTS ONTO A COMPONENT CARRIER

Abstract

A pick & place operation picking a non-electric component and placing the picked component onto a component-carrier and a connect operation connecting the placed component with the component-carrier by implementing a connection technology on a hybrid, at least reactive and deliberative machine architecture based on a “machine world model” as a digital twin to formulate correct machine-behavioral sets being used during machine run-time as well as an “machine workflow”, and executing by machine motion generation including a collision-free motion or path planning of a machine within a machine workspace primary kinematic machine-movement-sequences enabling the pick & place operation and secondary kinematic machine-movement-sequences enabling the connect operation, and enabling the execution via the machine motion generation by initializing the “machine world model” according to a configuration file configuring the machine and the machine workspace and instantiating the “machine workflow” and updating the “machine world model” with a design of the component-carrier.

Claims

1. A method for assembling non-electric components onto a component-carrier, by which the assembling is split into two assembly operations a pick & place operation picking a non-electric component and placing the picked non-electric component onto the component-carrier and a connect operation connecting the placed non-electric component with the component-carrier by implementing a connection technology, the method comprising: a) executing by machine motion generation including a collision-free motion or path planning of a machine within a machine workspace, the non-electric component is assembled onto the component-carrier, a1) primary kinematic machine-movement-sequences to enable the pick & place operation and a2) secondary kinematic machine-movement-sequences to enable the connect operation, b) providing a hybrid, at least reactive and deliberative machine architecture based on a “machine world model” as a digital twin to formulate correct machine-behavioral sets being used during machine run-time as well as a “machine workflow” a piece of machine work to carry out the pick & place operation and the connect operation is passed in series of machine stages from initiation to completion, to enable or ensure the execution of the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences via the machine motion generation by b1) initializing the “machine world model” according to a configuration file configuring the machine and the machine workspace and b2) instantiating the “machine workflow” and updating the “machine world model” with a design of the component-carrier.

2. The method according to claim 1, wherein the execution of the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences is carried out such that c) those sequences of the primary kinematic machine-movement-sequences responsible for placing the picked non-electric component onto the component-carrier are executed with force feedback to place the picked non-electric component and/or d) those sequences of the secondary kinematic machine-movement-sequences responsible for connecting the placed non-electric component with the component-carrier, when due to an ill-fitting between the picked and placed non-electric component to be connected and the component-carrier the connection technology cannot be implemented, are executed with an expanding pendulum motion for a fitting-finding to implement the connection technology.

3. The method according to claim 1, wherein intentional contact between the non-electric component and the component-carrier is enabled by the machine motion generation or by the machine motion generation executing the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences.

4. The method according to claim 1, wherein the sequences of the primary kinematic machine-movement-sequences responsible for placing the picked non-electric component onto the component-carrier are executed with the force feedback, when at least one other non-electric component is already placed on the component-carrier and is adjacent to the picked non-electric component to be placed.

5. The method according to claim 1, wherein the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences are executed either on one robot, one gantry, one delta picker etc. or on two robots, two gantries, two delta pickers etc., wherein on one the primary kinematic machine-movement-sequences and on the other the secondary kinematic machine-movement-sequences are executed.

6. The method according to claim 1, wherein the component-carrier is a back panel of a switch cabinet.

7. The method according to claim 1, wherein the non-electric component is at least one of a DIN-rail and a wiring duct.

8. The method according to claim 1, wherein the connection technology is based on riveting or screwing.

9. An assembling unit for assembling non-electric components onto a component-carrier, by which the assembling is split into two assembly operations a pick & place operation picking a non-electric component and placing the picked non-electric component onto the component-carrier and a connect operation connecting the placed non-electric component with the component-carrier by implementing a connection technology, the assembling unit comprising: a machine and a machine control working together technically and functionally are designed such that a) the machine and the machine control form a hybrid, at least reactive and deliberative machine architecture with a “machine world model”-module of the machine control implementing a “machine world model” as a digital twin to formulate correct machine-behavioral sets being used during machine run-time and a “machine workflow”-module of the machine control implementing a “machine workflow”—a piece of machine work to carry out the pick & place operation and the connect operation is passed in series of machine stages from initiation to completion, b) the machine control includes further a “machine motion generation”-module and a “machine motion execution”-module, wherein the “machine motion generation”-module provides a collision-free motion or path planning of the machine within a machine workspace, the non-electric component is assembled onto the component-carrier, to the “machine motion execution”-module, which executes on the machine b1) primary kinematic machine-movement-sequences to enable the pick & place operation and b2) secondary kinematic machine-movement-sequences to enable the connect operation c) the “machine world model”-module, the “machine workflow”-module, the “machine motion generation”-module and the “machine motion execution”-module form within the machine control a functional unit such that, when a configuration file configuring the machine and the machine workspace is inputted into in the “machine world model”-module of the machine control thereby initializing the “machine world model” and a design of the component-carrier in form of design data is inputted into the “machine workflow”-module of the machine control thereby instantiating the “machine workflow” and is inputted into in the “machine world model”-module thereby updating the “machine world model”, the execution of the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences via the machine motion generation is enabled or ensured.

10. The assembling unit according to claim 9, wherein the machine and the machine control with the “machine world model”-module, the “machine workflow”-module, the “machine motion generation”-module and the “machine motion execution”-module forming the functional unit are designed and carried out the execution of the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences such that d) those sequences of the primary kinematic machine-movement-sequences responsible for placing the picked non-electric component onto the component-carrier are executed with force feedback to place the picked non-electric component, e) those sequences of the secondary kinematic machine-movement-sequences responsible for connecting the placed non-electric component with the component-carrier, when due to an ill-fitting between the picked and placed non-electric component to be connected and the component-carrier the connection technology cannot be implemented, are executed with an expanding pendulum motion for a fitting-finding to implement the connection technology.

11. The assembling unit according to claim 9, wherein, the machine and the machine control with the “machine world model”-module, the “machine workflow”-module, the “machine motion generation”-module and the “machine motion execution”-module forming the functional unit are designed such that intentional contact between the non-electric component and the component-carrier is enabled, in particular due to either the machine motion generation by the “machine motion generation”-module or the machine motion generation executing the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences by the “machine motion generation”-module and the “machine motion execution”-module.

12. The assembling unit according to claim 9, wherein the machine and the machine control with the “machine world model”-module, the “machine workflow”-module, the “machine motion generation”-module and the “machine motion execution”-module forming the functional unit are designed such that the sequences of the primary kinematic machine-movement-sequences responsible for placing the picked non-electric component onto the component-carrier are executed with the force feedback, when at least one other non-electric component is already placed on the component-carrier and is adjacent to the picked non-electric component to be placed.

13. The assembling unit according to claim 9, wherein the machine, on which the primary kinematic machine-movement-sequences and the secondary kinematic machine-movement-sequences are executed, is a single robot, a single gantry, a single delta picker etc. or includes two robots, two gantries, two delta pickers etc., wherein on one the primary kinematic machine-movement-sequences and on the other the secondary kinematic machine-movement-sequences are executed.

14. The assembling unit according to claim 9, wherein the component-carrier is a back panel of a switch cabinet.

15. The assembling unit according to claim 9, wherein the non-electric component is at least one of a DIN-rail and a wiring duct.

16. The assembling unit according to claim 9, wherein the connection technology is based on riveting or screwing.

Description

BRIEF DESCRIPTION

[0038] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:

[0039] FIG. 1 shows an assembled back panel of a switch panel or control panel;

[0040] FIG. 2 shows—as a demonstration setup—an assembly unit for automated assembling a non-electric component onto a component-carrier within a workspace;

[0041] FIG. 3 shows the structure and design of the assembly unit according to the FIG. 2;

[0042] FIG. 4 shows a placement of a picked non-electric component onto a component-carrier with force feedback by the assembly unit depicted in the FIG. 3;

[0043] FIG. 5 shows a placement of a picked non-electric component onto a component-carrier with force feedback by the assembly unit depicted in the FIG. 3;

[0044] FIG. 6 shows an “μl-fitting”-scenario between a non-electric component, placed onto a component-carrier, and the component-carrier being connected by a connection technology; and

[0045] FIG. 7 shows applying an expanding pendulum motion for overcoming an ill-fitting by fitting-finding to implement the connection technology according to FIG. 6.

DETAILED DESCRIPTION

[0046] FIG. 1 shows an assembled back panel BP of a switch panel or control panel SC. On this back panel BP there are assembled wiring ducts WD and DIN-rails DR. Generally speaking, these assembled objects are non-electric components CP being assembled onto a component-carrier CPC.

[0047] FIG. 2 shows—as a demonstration setup—an assembly unit ABU for automated assembling a non-electric component CP onto a component-carrier CP within a workspace of the assembly unit ABU. The assembly unit ABU includes for the cited purpose a machine MA, which comprises according to the FIG. 2 two robot arms RB attached to a worktable WT, and a machine control MAC being connected with the machine MA and thereby with regard to the automated assembly of the non-electric component CP onto the component-carrier CP working technically and functionally together with the machine MA. For this reason the workspace is a machine workspace MAWS.

[0048] According to the depicted demonstration setup of the assembly unit ABU operating in the machine workspace MAWS to assemble—with regard to the FIG. 1—in an automated manner the DIN-rail DR and/or the wiring duct WD as the non-electric component CP onto the back panel BP as the component-carrier CPC the back panel BP is arranged on a table surface of the worktable WT and in a working distance of the two robot arms RB.

[0049] The same is the case with the DIN-rail DR and/or the wiring duct WD to be placed and connected on the back panel BP. Indeed, they are arranged also on the table surface of the worktable WT, but in an operating neighborhood of the back panel BP and in a picking distance of one of the two robot arms RB which is responsible for picking the DIN-rail DR and/or the wiring duct WD to be placed and connected on to the back panel BP.

[0050] The FIG. 2 shows further—according to the depicted demonstration setup—that one DIN-rail DR and one wiring duct WD are already placed and connected on the back panel BP. How the DIN-rail DR and the wiring duct WD were mounted on the back panel BP thereby using the depicted the assembly unit ABU including the machine MA in the form of the two robot arms RB and the machine control MAC will be described next according to the FIGS. 3 to 7.

[0051] FIG. 3 shows structure and design of the assembly unit ABU including the machine MA and the machine control MAC for assembling—as depicted in the FIG. 2—the non-electric component CP, e.g. the DIN-rail DR and/or the wiring duct WD onto the component-carrier CPC, e.g. the back panel BP of the switch cabinet or control cabinet SC.

[0052] So the machine MA, which can be designed preferably either as already mentioned as a single robot RB, a single gantry, a single delta picker etc. or alternatively as already mentioned as two robots RB, e.g. the two robot arms according to the FIG. 2, two gantries, two delta pickers etc.

[0053] Regardless from the cited design of the machine MA it is essential for the assembly purpose that the machine MA is able to carry out two assembly operations AO, so (i) a pick & place operation PPOP picking the non-electric component CP, DR, WD and placing the picked non-electric component CP, DR, WD onto the component-carrier CPC, BP, SC and (ii) a connect operation COP connecting the placed non-electric component CP, DR, WD with the component-carrier CPC, BP, SC by implementing a connection technology.

[0054] This means that in the case of a single robot both operations, the pick & place operation PPOP and the connect operation COP, the single robot must be able to carry out both operations, whereas in the case of two robots or two robot arms as depicted in the FIG. 2 one robot carries out the pick & place operation PPOP and the other the connect operation COP.

[0055] And further which connection technology for carrying out the connection operation COP is carried out will be described later on in the context of describing FIGS. 6 and 7.

[0056] The machine MA and the machine control MAC of the assembly unit ABU, which work together technically and functionally, form a hybrid, at least reactive and deliberative machine architecture. Such a machine architecture is described for example https://en.wikipedia.org/wiki/Robotic_paradigm according to the version from Aug. 29, 2020 and in https://de.wikipedia.org/wiki/Autonomer_mobiler_Roboter according to the version from Oct. 12, 2020.

[0057] According to this machine architecture (i) a “machine world model”-module MAWM-M, being part of the machine control MAC, implements a “machine world model” as a digital twin to formulate correct behavioral sets of the machine MA, so-called machine-behavioral sets, being used during a run-time of the machine MA and (ii) a “machine workflow”-module MAWF-M, being also part of the machine control MAC, implements a workflow of the machine MA, a so-called “machine workflow”, by which a piece of machine work to carry out the pick & place operation PPOP and the connect operation COP is passed in series of machine stages from initiation to completion.

[0058] The machine control MAC includes further a “machine motion generation”-module MAMG-M and a “machine motion execution”-module MAME-M. The “machine motion generation”-module MAMG-M thereby provides pry a collision-free motion or path planning of the machine MA within the machine workspace MAWS, where according to the FIG. 2 the non-electric component CP, DR, WD is assembled onto the component-carrier CP, BP, SC, to the “machine motion execution”-module MAME-M. Based on this provision the “machine motion execution”-module MAME-M executes exe on the machine MA primary kinematic machine-movement-sequences MAMS.sub.k1 to enable the pick & place operation PPOP and secondary kinematic machine-movement-sequences MAMS.sub.k2 to enable the connect operation COP.

[0059] Within the machine control MAC of the assembly unit ABE the “machine world model”-module MAWM-M, the “machine workflow”-module MAWF-M, the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M form a functional unit FTU. Forming this functional unit FTU the “machine world model”-module MAWM-M is updated upd by the “machine workflow”-module MAWF-M and the “machine motion generation”-module MAMG-M is updated upd and initialized ilz on one hand by the “machine world model”-module MAWM-M and is requested on the other by the “machine workflow”-module MAWF-M.

[0060] Furthermore the functional unit FTU enables or ensures the execution of the primary kinematic machine-movement-sequences MAMS.sub.k1 and the secondary kinematic machine-movement-sequences MAMS.sub.k2 via the machine motion generation in such a way that (a) a configuration file CFGF configuring the machine MA and the machine workspace MAWS is inputted ipt into in the “machine world model”-module MAWM-M and thereby initializing ilz the “machine world model” and

(b) a design of the component-carrier CPC, BP, SC in form of design data DD is inputted ipt
(b1) into the “machine workflow”-module MAWF-M thereby instantiating itt the “machine workflow” and
(b2) into in the “machine world model”-module MAWM-M thereby updating upd the “machine world model”.

[0061] The configuration file CFGF configuring the machine MA and the machine workspace MAWS as well as the design of the component-carrier CPC, BP, SC in form of the design data DD are taken from a data repository DRP by PUSH- or PULL-based data transfer.

[0062] FIG. 4 shows the placement of a picked non-electric component CP, CP.sub.A, CP.sub.B onto the component-carrier CPC, BP, SC with a force feedback FFB by the assembly unit ABU, depicted in the FIG. 3, including the machine MA and the machine control MAC with the “machine world model”-module MAWM-M, the “machine workflow”-module MAWF-M, the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M forming the functional unit FTU and thereby executing the primary kinematic machine-movement-sequences MAMS.sub.k1 and the secondary kinematic machine-movement-sequences MAMS.sub.k2.

[0063] To place the picked non-electric component CP, CP.sub.A, CP.sub.B, e.g. the DIN-rail DR and/or the wiring duct WD, onto the component-carrier CPC, BP, SC, e.g. the back panel BP of the switch cabinet or control cabinet SC, the following placing algorithm by the functional unit FTU executing the primary kinematic machine-movement-sequences MAMS.sub.k1 is used.

[0064] If according to a scenario “A” placing a picked non-electric component CP.sub.A there are no other, non-electric components already placed and connected on the component-carrier CPC, BP, SC, which are adjacent to the picked non-electric component CP.sub.A, the picked non-electric component CP.sub.A is placed in an orthogonal movement straight down onto the component-carrier CPC, BP, SC until a given force is applied. This force however is not the already mentioned force feedback FFB. This force feedback come into use with regard to a scenario “B” also depicted in the FIG. 4. But also in the scenario “A” the following is applied.

[0065] So, the assembly unit ABU including the machine MA and the machine control MAC with the “machine world model”-module MAWM-M, the “machine workflow”-module MAWF-M, the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M forming the functional unit FTU enable intentional contact between the picked non-electric component CPA and the component-carrier CPC, BP, SC. This intentional contact is released preferably due to either the machine motion generation by the “machine motion generation”-module MAMG-M or the machine motion generation executing the primary kinematic machine-movement-sequences MAMS.sub.k1 and the secondary kinematic machine-movement-sequences MAMS.sub.k2 by the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M.

[0066] However, if according to a scenario “B” placing a picked non-electric component CP.sub.B there are other, non-electric components CP.sub.OTH—a first other, non-electric components CP.sub.X and second other, non-electric components CP.sub.Y, —already placed and connected on the component-carrier CPC, BP, SC, which are adjacent to the picked non-electric component CP.sub.B, and if the other, non-electric components CP.sub.OTH, CP.sub.X, CP.sub.X constrain the placing motion, the picked non-electric component CP.sub.B is placed on a free location on the component-carrier CPC, BP, SC and then slit to the right location, against the first other, non-electric component CP.sub.X, until the force feedback FFB is applied.

[0067] Accordingly, the assembly unit ABU including the machine MA and the machine control MAC with the “machine world model”-module MAWM-M, the “machine workflow”-module MAWF-M, the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M forming the functional unit FTU execute the primary kinematic machine-movement-sequences MAMS.sub.k1 such that those sequences of the primary kinematic machine-movement-sequences MAMS.sub.k1 responsible for placing the picked non-electric component CP, CP.sub.B onto the component-carrier CPC, BP, SC are executed with the force feedback FFB to place the picked non-electric component CP, CP.sub.B.

[0068] But also in the scenario “B” the intentional contact between the picked non-electric component CP.sub.B and the component-carrier CPC, BP, SC is applied in the same way as stated with respect to the scenario “A”.

[0069] FIG. 5 shows the placement of a picked non-electric component CP, CP.sub.C onto the component-carrier CPC, BP, SC with a force feedback FFB by the assembly unit ABU, depicted in the FIG. 3, including the machine MA and the machine control MAC with the “machine world model”-module MAWM-M, the “machine workflow”-module MAWF-M, the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M forming the functional unit FTU and thereby executing the primary kinematic machine-movement-sequences MAMS.sub.k1 and the secondary kinematic machine-movement-sequences MAMS.sub.k2.

[0070] To place the picked non-electric component CP, CP.sub.C, e.g. the DIN-rail DR and/or the wiring duct WD, onto the component-carrier CPC, BP, SC, e.g. the back panel BP of the switch cabinet or control cabinet SC, the following placing algorithm by the functional unit FTU executing the primary kinematic machine-movement-sequences MAMS.sub.k1 is used.

[0071] If according to a scenario “C” placing a picked non-electric component CP.sub.C there is a constraint of two other, non-electric components CP.sub.OTH—a first other, non-electric components CP.sub.X and second other, non-electric components CP.sub.Y, —already placed and connected on the component-carrier CPC, BP, SC, which are adjacent to the picked non-electric component CP.sub.C, and if the other, non-electric components CP.sub.OTH, CP.sub.X, CP.sub.X constrain the placing motion, the picked non-electric component CP.sub.C is placed first (“1” in the FIG. 1) down at an angle to the component-carrier CPC, BP, SC against the first other, non-electric component CP.sub.X, until the force feedback FFB is applied and then slit towards (“2” in the FIG. 1) the second other, non-electric component CP.sub.Y until the force feedback FFB is applied again and only then the picked non-electric component CP.sub.C is placed down flat on the component-carrier CPC, BP, SC.

[0072] Accordingly also here, the assembly unit ABU including the machine MA and the machine control MAC with the “machine world model”-module MAWM-M, the “machine workflow”-module MAWF-M, the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M forming the functional unit FTU execute the primary kinematic machine-movement-sequences MAMS.sub.k1 such that those sequences of the primary kinematic machine-movement-sequences MAMS.sub.k1 responsible for placing the picked non-electric component CP, CP.sub.C onto the component-carrier CPC, BP, SC are executed with the force feedback FFB to place the picked non-electric component CP, CP.sub.C.

[0073] But also again in the scenario “C” the intentional contact between the picked non-electric component CP.sub.C and the component-carrier CPC, BP, SC is applied in the same way as stated with respect to the scenario's “A” and “B”.

[0074] FIG. 6 depicts an “μl-fitting”-scenario between a non-electric component CP, placed onto a component-carrier CPC and the component-carrier CPC being connected by a connection technology CT. The connection technology CT being used is based on riveting rvt. Alternatively other connect technologies are possible, although they are not depicted, so for instance screwing.

[0075] Thus, to rivet the non-electric component CP onto the component-carrier CPC rivets (cf. FIG. 7) are placed through rivet-holes RH.sub.CP, preferably pre-drilled, in the non-electric component CP and through corresponding further rivet-holes RH.sub.CPC, also preferably pre-drilled, in the component-carrier CPC. The locations of these rivet-holes RH.sub.CP, RH.sub.CPC are specified in the design of the component-carrier CPC. Because of tolerances in the non-electric component CP, the component-carrier CPC and/or the placing of the non-electric component CP, the rivet-holes RH.sub.CP in the non-electric component CP and the rivet-holes RH.sub.CPC in the component-carrier CPC do not always line up as depicted. The result is an ill-fitting IFG.

[0076] FIG. 7 depicts an applied expanding pendulum motion EPM for overcoming the ill-fitting IFG shown in the FIG. 6 by fitting-finding to implement the connection technology CT.

[0077] To implement the connection technology CT and according to the FIG. 3 the assembly unit ABU including the machine MA and the machine control MAC with the “machine world model”-module MAWM-M, the “machine workflow”-module MAWF-M, the “machine motion generation”-module MAMG-M and the “machine motion execution”-module MAME-M forming the functional unit FTU execute the secondary kinematic machine-movement-sequences MAMS.sub.k2 such that those sequences of the secondary kinematic machine-movement-sequences MAMS.sub.k2 responsible for connecting the placed non-electric component CP with the component-carrier CPC, when due to the ill-fitting IFG between the picked and placed non-electric component CP to be connected and the component-carrier CPC the connection technology CT cannot be implemented, are executed with the expanding pendulum motion EPM for a fitting-finding to implement the connection technology CT.

[0078] Thus, if the machine MA of the assembly unit ABU, for example a “riveting robot arm” of the pair of robot arms RB according to the FIG. 2, is unable to insert a rivet RV at the specified location, motions are generated that move the rivet RV in an expanding pendulum motion until the rivet RV is placed via the rivet-hole RH.sub.CP through the non-electric component CP and via the rivet-hole RH.sub.CPC through the component-carrier CPC.

[0079] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

[0080] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.