System and method for storing and processing a variety of part shapes using robotic tending

Abstract

A system and method for using a robotic arm and a part gripping jaw to tend a CNC machine. A robotic arm picks up a part gripping jaw and used the jaw to grip a part, and moves the part into a vise in the CNC machine. The part gripping jaw has features which the vise engages, and secures the part in the part gripping jaw for processing in the CNC machine. The system and method includes a novel racking system, robotic end of arm tool, jaw grippers and vise system. The jaw grippers that hold the part are moved from the rack system, with the part to be processed, by the robot, to the vise where the vise uses the jaw grippers to secure the part for processing. After the part is processed, the robot removes the part from the vise with the jaw grippers and stores the part back into the rack system using the jaw grippers.

Claims

1. A part gripping device to retain a workpiece for processing it in a workstation located in a CNC machine and for repositioning it with a robotic tender, the workpiece defining longitudinal workpiece axis and including first and second workpiece sides, the first and second workpiece sides forming opposing ends of the workpiece and having corresponding first and second workpiece surface portions that are perpendicular to the longitudinal workpiece axis, the part gripping device comprising: a first side inducing a first mechanical coupling for an end of arm tool of the robotic tender configured to engage and release (i) in one instance, the part gripping device and (ii) in another instance, the workpiece with the part gripping device at a location away from the workstation located in the CNC machine; a second side, different from the first side, including a second mechanical coupling for an actuatable workstation fastener that is operatively coupled to the CNC machine and is configured to restrain the part gripping device at the workstation; and a third side, perpendicular to the first side and different from the second side, defining a part gripping surface by which to confront and engage the first workpiece side and thereby unobstructedly present the second workpiece side for processing the second workpiece side in the workstation located in the CNC machine.

2. The part gripping device of claim 1, in which the second side is opposite the third side.

3. The part gripping device of claim 1, in which the actuatable workstation fastener comprises a vise operatively coupled to the CNC machine, and the second mechanical coupling of the second side comprises a vise engagement profile mechanically couplable to a complementary surface profile of the vise.

4. The part gripping device of claim 3, in which the vise engagement profile includes ridges of a vise jaw, and, in response to actuation of the vise in a direction transverse relative to the longitudinal workpiece axis, the vise engagement profile restrains, in three axes, relative movement of the part gripping device with respect to the vise.

5. The part gripping device of claim 1, further comprising: a vise; and in which the first mechanical coupling comprises: a set of pins matable with a corresponding set of pin-receiver apertures of the EOAT for restraining relative movement between the part griping device and the EOAT when it is engaged with the part gripping device; and a vise actuation port through which the vise is actuatable from the robotic tender.

6. The part gripping device of claim 5, in which the set of pins form a zero point mounting system with the corresponding set of pin-receiver apertures of the EOAT.

7. The part gripping device of claim 5, further comprising a pallet on which the vise is mounted, the pallet including the first and second mechanical coupling and thereby defining, respectively, the first and second sides.

8. The part gripping device of claim 7, in which the second mechanical coupling comprises a set of pins matable with a corresponding set of pin-receiver apertures of a CNC table, and the actuatable workstation fastener comprises the corresponding set of pin-receiver apertures.

9. The part gripping device of claim 7, in which the vise actuation port comprises a first vise actuation port, and in which the pallet includes a second vise actuation port through which the vise is actuatable from the CNC machine, the second vise actuation port having an opening included in the second side.

10. The part gripping device of claim 5, in which the vise includes first and second vise jaws, the part gripping device further comprising: first and second part gripping jaws matable with, respectively, the first and second vise jaws; and a pallet defining the first and second sides and providing a mounting surface, opposite the second side, on which the vise is mounted to define the third side.

11. The part gripping device of claim 1, further comprising a vise actuation port having an opening included in the first side and positioned to engage a complementary port having an opening included in the EOAT of the robotic tender.

12. The part gripping device of claim 1, further comprising a vise actuation port having an opening included in the second side and positioned to engage a complementary port having an opening included in a CNC table of the CNC machine.

13. The part gripping device of claim 1, further comprising a set of vise actuation ports including a first vise actuation port having an opening in the first side and a second vise actuation port having an opening in the second side.

14. The part gripping device of claim 13, in which the second side is opposite the third side.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view showing the system of tending a CNC machine using a robotic arm.

(2) FIG. 2 is a perspective view of the top surface of a part gripping jaw.

(3) FIG. 3 is a perspective view of the bottom side of a part gripping jaw.

(4) FIG. 4 is a perspective view of an End of Arm Tool.

(5) FIG. 5A is a perspective view of a vise for use in a CNC machine.

(6) FIG. 5B is a side view of a vise for use in a CNC machine.

(7) FIG. 6 is a top view of an End of Arm Tool adjacent to a part gripping jaw.

(8) FIG. 7 is a view of the step in which the End of Arm Tool engages the part gripping jaw.

(9) FIG. 8 is a top view of the End of Arm Tool activating the part gripping jaws to grip a part.

(10) FIG. 9 is a side view of an End of Arm Tool attached to a robot arm gripping a part on a rack.

(11) FIG. 10 is a view of the robot arm moving the End of Arm Tool into a CNC machine to place the part gripping jaw in a vise.

(12) FIG. 11 is a side view of the vise securing the part gripping jaw.

(13) FIG. 12 is a side view of the EOAT removed from the CNC machine.

(14) FIG. 13 is a side view of the part being processed by a tool in the CNC machine.

(15) FIG. 14 is a view of the EOAT using a second part gripping jaw to grip a part and move it to a second vise.

(16) FIG. 15 is a view of the step in which the End of Arm Tool activates the part gripping jaws and secures the part in place.

(17) FIG. 16 is a view of a vise that is configured to be engageable and movable by a robot arm and EOAT and configured to be engageable with a CNC table.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

(18) Reference throughout this specification to an embodiment, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases in an embodiment, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

(19) Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of the embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

(20) The present invention provides for a method and system of Improved Robotic Tending System (IRTS), adaptable to process a wide variety of parts, with no robotic programming required and with substantially reduced engineering costs associated with each part adapted to the system. The IRTS can typically be configured to tend a wide variety parts by a CNC Machine programmer, leveraging the CNC Machine programmer's existing skills and without any special robotic skills or training.

(21) Some preferred embodiments of the present invention are shown in FIGS. 1-21. As can be seen in FIG. 1, the major components of the disclosed technology include a robotic arm 12, an end of arm tool (EOAT) 14, part gripping jaws 16, a rack 20 and a CNC machine 32 with a vise 34. For clarity, robot guarding and access doors around the robot are not shown and only the CNC machine 32, table 54 and vise 34 are shown. Shown in FIG. 1 is the rack 20 and disclosed on the rack 20 are two different approaches to the method of operating the robotic CNC system which is disclosed. One method of operating the system is one in which each position in the rack 20 is occupied by an individual part 18. The positions are designated as position-for-pickup 30, and the robot arm 12 is programmed to be able to locate and engage any part 18 that is in one of the designated position-for-pickup 30. An alternative method of operation of the system and method is for a part gripping jaw 16 to be placed in every position-for-pickup 30, with a part 18 positioned on every part gripping jaw 16. In the first mode of operation, a single pair of part gripping jaws 16 would be utilized by the system to move parts 18 from the position-for-pickup 30 into engagement with the vise 34 in the CNC machine 32. In the second mode of operation, the end of arm tool 14 would engage a separate part gripping jaw 16 at each position-for-pickup 30, with the part 18 in the jaws being secured by the end of arm tool 14.

(22) This system and method can be modified for a number of different scenarios, with the robot arm 12 being selected for the requirements of the particular job, particularly for the weight of the part 18. The parts 18 used as an example in the depicted system can be a cylindrical disc of aluminum weighing about 1 pound. For a part 18 of this general size a robot arm 12 such as an ABB IRB 140 with capability of lifting 14 pounds, would be suitable for this particular set up. For the system and method depicted, a CNC machine 32 of various styles and models can be utilized with one example being a CNC machine 32 made by Haas, model DT 1. Located inside the CNC machine is a table 54, vise 34 which engages either the part 18 or the part gripping jaws 16, depending on the particular set up, and optionally, second vise 56.

(23) FIG. 2 shows a closer view of a part gripping jaw 16 of the disclosed technology. Each part gripping jaw 16 has a left jaw 22 and a right jaw 24, with a top surface 36 and a bottom surface 38. The part gripping profiles 26 are machined into the top surface 36 of the part gripping jaws 16, so that moving the left jaw 22 and the right jaw 24 together can grip the outside profile of the part 18 or moving the two jaws apart can grip the inside profile of a part 18. These particular part gripping jaws 16 have internal channels 40, which are configured to interact with a certain type of EOAT 14, which has forks which fit into the internal channels 40 of this particular style of part gripping jaws 16. Other mechanisms for engaging the part gripping jaws 16 to the end of arm tool 14 are also possible, including well known mechanisms for securing and releasing objects using hydraulics or pneumatics or other methods. One such system is the Zero Point System by Jergens Workholding. The disclosed part gripping jaws 16 can be about 6 inches by 8 inches, and 1 inch thick, preferably made of aluminum, and weigh about 2 pounds.

(24) FIG. 3 shows the bottom surface 38 of a part gripping jaw 16, with the left jaw 22 and the right jaw 24 shown. Shown are vise engagement profiles 58, which in this case are gear-like, and made to engage similar gear-like profiles in the vise. Shown in FIG. 3 are projections 60 which have angled surfaces 62 which are engaged by the jaws of the vise 34.

(25) FIG. 4 shows an End of Arm Tool (EOAT) 14 which is configured with four forks 28 which are sized to engage the part gripping jaws 16 by insertion into internal channels 40. In this particular embodiment, the forks 28 of the EOAT 14 would be approximately 5 inches long and inches in diameter. The forks 28 on the End of Arm Tool 14 include a tip 42 which is slightly tapered, and which allows the forks 28 to self-center when entering the internal channels 40 of the part gripping jaws 16. The EOAT forks 28 can be moved to squeeze the part gripping jaws 16, by means of electronic activation of a mechanical, pneumatic, hydraulic or other means of movement.

(26) FIG. 5 shows a vise 34 which may be used with the system and methods of the disclosed technology. Shown in FIG. 5 is a vise 34 which mounts into the CNC machine 32 or on the table 54 in the CNC machine 32. It has a top surface of vise 44 on which are located jaw engagement profiles 46 for engaging the vise engagement profiles 58 of the part gripping jaw 16, with the jaw engagement profile 46 configured for securing and immobilizing the part gripping jaws 16, so that the part 18 is held securely in place in three axes while it is being processed by various implements in the CNC machine 32. Ridges 48 are configured to engage corresponding valleys in the bottom side of the part gripping jaws 16. The ridges 48 and valleys provide a very solid connection between the two pieces, and make the two pieces with their attached part 18 react more like one solid unit of metal, against the force of the various machining tools in the CNC machine 32. The ridges 48 on the vise 34 secure the part gripping jaw 16 from movement in the Y direction as shown.

(27) Vise jaws 50 are also shown, which secure the part gripping jaws 16 with its attached part 18 and prevents them from moving in an X and Z direction as shown. Angled surfaces 62 on the bottom surface of the part gripping jaws interact with the jaws 50 of the vise 34, so that the two sets of angled surfaces 62 interact. The jaws 50 of the vise 34 move together to engage against the corresponding projections 60 on the underside of the part gripping jaws 16, and lock it and the attached part securely in place against forces exerted by the processing tools of the CNC machine 32.

(28) The disclosed technology includes a preferred embodiment in the form of a method which utilizes the above components to tend a CNC machine 32. FIG. 6 shows the step of providing a robotic arm 12 with an end of arm tool (EOAT) 14 configured for engagement with the left 22 and right 24 jaws of the part gripping jaw 16. The EOAT 14 is also capable of moving the left 22 and right 24 jaws together or apart in order to grip the part 18 to be processed in the part gripping profile 26. A preferred EOAT 14 may use prongs or forks 28 which fit into internal channels 40 in each of the jaws, such as two forks 28 on each side of the EOAT 14, one fork 28, or by the use of other structures which grip the left 22 and right 24 jaws and enable the EOAT 14 to move the left and right jaws 22 and 24 apart or together. A preferred embodiment of EOAT 14 utilizes four forks 28 which interfit with four internal channels 40 in the part gripping jaw 16.

(29) FIG. 7 shows the next step in the disclosed method, which is engaging the part gripping jaw 16 with the EOAT 14. FIG. 8 shows the step of moving the left and right jaws 22 and 24 together in this case, such as when external features of the part 18 are gripped. In the example shown in FIG. 8 the part 18 is a cylindrical disc. If internal features of the part are to be gripped, the jaws would be moved together. FIG. 9 shows the next step in the disclosed method, which is placing the part gripping jaw 16 in an inverted position over the part 18 in a position-for-pickup 30, which could be on a rack 20. FIG. 9 also shows the step of moving the left and right jaws 22 or 24 together or apart in order to grip the top section of the part 18. The jaws would be moved together to grip the outside surface of the part, and they would be moved apart to grip an inside surface of the part. Once the part 18 is gripped by the part gripping jaw 16, the next step is lifting the part 18 by movement of the robotic arm 12. The next step is inverting the part 18 and part gripping jaw 16 by the robot. The next step is moving the part 18 and part gripping jaw 16 to a position over the vise 34 in the CNC machine 32, which is shown in FIG. 10.

(30) FIG. 10 shows the part gripping jaw 16 in position over the vise 34 inside the CNC machine 32. The next step is engaging the vise 34 to secure the part 18 on the part gripping jaw 16 in the vise 34, as shown in FIG. 11. The part gripping jaw 16 is secured to the vise 34 activating the vise jaws 50, which is an action which can be programmed into the machinery. FIG. 12 shows and next step of the disclosed method, in which the EOAT 14 is disengaged from the part gripping jaws 16 and removed from the CNC machine, leaving the part 18 in the CNC machine 32 for processing by a processing tool 52. Further steps in the process can include engaging the part gripping jaw 16 with the EOAT 14, as shown in FIG. 7, disengaging the vise 34 from said part gripping jaw 16, as shown in FIG. 11, removing the part gripping jaw 16 from the CNC machine by use of the robotic arm 12, as shown in FIGS. 10 and 9, and placing the now processed part 18 in a finished part position 64 (shown in FIG. 1), which could be in a rack 20 like that shown in FIG. 1.

(31) The step of providing a part gripping jaw 16 can include providing the part gripping jaw 16 with a vise engagement profile 58 on the bottom side 38 of the part gripping jaw 16, as shown in FIG. 3, and providing the vise 34 with a jaw engagement profile 46, on the top surface 44 of the vise 34, as shown in FIGS. 5a and 5b.

(32) The step of engaging the part gripping jaw 16 with the vise 34 can include gripping projections 60 on the part gripping jaw 16, with vise jaws 50 on the top surface 44 of the vise 34, with as shown in FIGS. 3, 5a, 5b, and 11. This step can include engaging angled surfaces 62 on the projections 60, and on the vise jaws 50, as best shown in FIGS. 3 and 5b. The angled surfaces 62 on the projections 60 and on the vise jaws 50 are angled in opposite directions, so that engagement by the vise jaws 50 pulls the part gripping jaws 16 down onto the vise 34 in the Z direction, and also secures the part gripping jaw 16 from movement in the x direction. The projection can also be called a locating rail 60, and a single or multiple locating rails 60 can be utilized.

(33) The step of providing a vise engagement profile 58 and a jaw engagement profile 46 can include the type of profile shown in the figures, which are gear-like ridges 48 and corresponding valleys. In another embodiment, the step of providing a vise engagement profile 58 and jaw engagement profile 46 is provided by a hydraulically or pneumatically securing device. One such commercially available device is the Zero Point System by Jergens Workholding Solutions. (http://www.jergensinc.com/site/showcase_zps/index.html).

(34) The method described above can be augmented by adding after the step of disengaging the EOAT 14 from the vise 34, the step of engaging a second part gripping jaw 66, which would appear as shown in FIG. 7. The second part gripping jaw 66 would typically have a part gripping profile shaped to fit the form of the part 18 after a first operation of processing. The next step would be moving the second part gripping jaw 66 into engagement with the part 18 held in the part gripping jaw 16 in the vise 34, as shown in FIG. 14. The second part gripping jaw 66 is then secured on the part 18, and the vise 34 releases the part 18 by releasing the part gripping jaw 16.

(35) The next step is also shown in FIG. 14, which is moving the second part gripping jaw 66 into position with a second vise 56. After securing the second part gripping jaw 66 to the second vise 56, the EOAT 14 is removed and the part 18 is further processed in the CNC machine as shown in FIG. 13.

(36) Another preferred embodiment is a variation of the methods above, in which after processing in the CNC machine 32, the next step is engaging the part gripping jaw 16 with the EOAT 14, disengaging the vise 34 to release the part gripping jaw 16, moving the part gripping jaw 16 and part 18 from the CNC machine 32, placing the part 18 in a finished part position 64, which can be on a rack 20 as shown in FIG. 1, and disengaging the part gripping jaw 16 from the part 18.

(37) An alternative preferred embodiment is shown in the FIGS. 1 through 14. This method is similar to the previously described method, but includes the step of placing multiple parts 18 on multiple part gripping jaws 16, so that when the EOAT 14 engages a part gripping jaw 16, the part gripping jaw 16 is in a position-for-pickup 30 in a rack 20, with the part already in the part gripping jaws 16, as shown in FIG. 1. After engagement of the first part gripping jaw 16, the steps proceed as in the procedure discussed above. When processing of the part 18 has been completed through one or more processing cycles, it can be placed in a finished part position 64 as shown in FIG. 1.

(38) The robotic arm will typically follow a sequence of commands to process each part in a job. In a preferred embodiment, the representative part requires two operations in the CNC Machine and the CNC Machine is configured with a first operation vise and a second operation vise. To begin the cycle, the operator loads the part racking system with the part's first operation jaw grippers and then secures each part to be processed in the job into the first operation jaw grippers in a first jaw rack. The operator secures the part's second operation jaws in a well-known location in a second jaw rack. The basic steps to process each part follow:

(39) Robotic arm moves and positions the EOAT to a set of first operation jaws holding a part in the racking system

(40) Robotic arm actuates the EOAT to secure the first operation jaws and the part

(41) Robotic arm lifts and pulls the EOAT, jaws and part away from the racking system

(42) Robotic arm moves the first operation jaws and part into the CNC Machine and positioned over the first vise

(43) First vise actuates securing the first operation jaws onto the vise and the part in the jaws

(44) Robotic arm de-actuates the EOAT to release the first operation jaws

(45) Robotic arm retracts away from the first vise and out of the CNC Machine

(46) CNC Machine processes the part for the first operation

(47) Robotic arm moves and positions the EOAT to a second set of jaws in the racking system; the second set of jaws are configured to secure the part after the CNC Machine first operation process

(48) Robotic arm actuates the EOAT to secure the second set of jaws in the EOAT

(49) Robotic arm lifts and pulls the EOAT and jaws away from the racking system

(50) Robotic arm inverts the second set of jaws

(51) Robotic arm moves and positions the EOAT so that the second set of jaws are in position over the part in the first vise

(52) Robotic arm actuates the EOAT to secure the part in the second set of jaws

(53) First vise de-actuates releasing the part

(54) Robotic arm moves the second operation jaws and part away from the first vise, inverts the second operation jaws and part and precisely positions them over the second vise

(55) Second vise actuates securing the second operation jaws onto the vise and the part in the second operation jaws

(56) Robotic arm de-actuates the EOAT to release the second operation jaws

(57) Robotic arm positions in front of the first vise and actuates the EOAT to secure the first operation jaws

(58) Robotic arm retracts away from the first vise and out of the CNC Machine

(59) CNC Machine processes the part for the second operation

(60) Robotic arm positions the first operations jaws back into the racking system, de-actuates the EOAT to release the jaws on the rack and then retreats from the racking system

(61) Robotic arm moves and positions the EOAT to the second operation jaws in the second vise

(62) Robotic arm actuates the EOAT to secure the second operation jaws and the part

(63) Robotic arm signals the second vise to release

(64) Robotic arm moves the second operation jaws and part away from the second vise, retracts out of the CNC Machine, inverts the part and precisely positions the part over the first operation jaws in the racking system, gently places the part onto first operation jaws and de-actuates the EOAT to release the completed part into the first operation jaws

(65) Robotic arm retracts from the racking system, positions the second operation jaws to an available position in the racking system and de-actuates the EOAT to release the second operation jaws into the rack

(66) The entire cycle is repeated until all parts are processed

(67) A second preferred alternative embodiment is shown in FIGS. 15 and 16. In this embodiment, an EOAT 14 and CNC table 54 are configured to engage and release a vise 34 that is mounted atop a pallet 67. Both the EOAT 14 and the CNC table 54 are configured to actuate or de-actuate the vise 34 when engaged. To engage and release the vise from the EOAT 14 and CNC table 54, the ZPS system by Jergens Workholding is used. The ZPS system includes a pin 68 and a receiver 70. When the receiver 70 is actuated with pneumatic or hydraulic pressure, the pin 68 will slide into the receiver 70. When the pressure is released, a spring cam mechanism within the receiver 70 pulls the pin 68 securely into the receiver 70.

(68) The EOAT 14 and the CNC table 54 are each configured with a ZPS receiver plate 72 containing two ZPS receivers 70. Between each ZPS on the receiver plate is at least one vise actuation port 74. The vise actuation port 74 allows the EOAT 14 or CNC table 54 to actuate and de-actuate the vise 34 when engaged. The vise 34 is securely mounted to a plate having ZPS pins 68 for engaging the EOAT 14 and ZPS pins 68 for engaging the CNC table 54. Between each ZPS pin 68 is a vise actuation port 74 configured to engage with the vise actuation port 74 on the EOAT or CNC table receiver plate. The vise may be configured with jaws 76 for part pickup 18.

(69) In this configuration the robot arm 12 positions the EOAT 14 into engagement with the vise 34 and actuates the ZPS receivers 70 to secure the vise 34. The robot arm 12 then positions the vise 34 over a part 18 in a pickup location 30. The EOAT 14 actuates the vise 34 via the vise actuation port 74 to secure the part 18 in the vise 34. The robot arm 12 the moves the vise 34 into engagement with the CNC table 54 ZPS receivers 70 and actuates to the CNC table 54 ZPS receivers 70 to secure the vise 34. The robot arm 12 then de-actuates the EOAT 14 ZPS receivers 70 to release the vise 34. The robot arm 12 moves away and the CNC machine 32 processes the part.

(70) This second preferred alternative embodiment utilizes a robot EOAT to transfer a vise that can engage and release a part between a part pickup location and a CNC machine. One skilled in the art can readily see that this system can be used in place of the part gripping jaws and vise to perform the same methods previously described.

(71) The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.