Device and method for automated assembly of interlocking segments

Abstract

A device and method for automated computer controlled manufacture of assemblies composed of discrete linked product segments includes reciprocating product segment grippers having surface features engageable with the product segments, at least one robotic manipulating device whereby the product segments may be engage the product segment grippers. A fastener-insertion device is included to engage a fastener linking the product segments together, a segment container containing interchangeable product segments. The device also includes a machine vision device for verifying the identity of the selected product segment. A computer operated control mechanism with associated hardware and software operates and controls the reciprocating product segment grippers, the robotic manipulator arms, the machine vision device, and the fastener-insertion device.

Claims

1. An apparatus for automated manufacture of product assemblies comprised of discrete product segments, comprising: a) plurality of product segments; b) reciprocating product segment grippers having surface features engageable with said product segments; c) at least one robotic manipulating device whereby said product segments may be manipulated to engage said product segment grippers; and d) at least one fastener-insertion device whereby a fastener may be utilized to engage one or more of said product segments thereby linking said product segments together.

2. The apparatus as recited in claim 1, further comprising a control mechanism employing electronic hardware or software for controlling said robotic manipulating device and said reciprocating product segment grippers.

3. The apparatus as recited in claim 2, further comprising a machine vision device whereby said at least one robotic manipulating device is guided in selection and location of said product segments.

4. The apparatus as recited in claim 3, further comprising a retractable vertical restraining surface overlying product segment grippers.

5. The apparatus as recited in claim 4, wherein said reciprocating product segment grippers include a first segment gripper adapted for independent movement in a vertical direction and a longitudinal direction with respect to said table and a second segment gripper adapted for independent movement in a vertical direction.

6. The apparatus as recited in claim 5, wherein said at least one robotic manipulating device is a computer controlled robotic manipulator device.

7. The apparatus as recited in claim 6, wherein said control mechanism includes electronic hardware or software for receiving inputs describing the product component segments and for communicating with and controlling said fastener-insertion device, said machine vision device, and said retractable vertical restraining surface.

8. The apparatus as recited in claim 7, wherein said first segment gripper and said second segment gripper include a plurality of stanchions, each said stanchion having a stud for engaging said product segments.

9. The apparatus as recited in claim 8, further comprising an assembly table adjacent said reciprocating product segment grippers.

10. The apparatus as recited in claim 9, further comprising a supply of product component segments.

11. The apparatus as recited in claim 10, further comprising at least one container for storing said product segments prior to use.

12. The apparatus as recited in claim 11, wherein said fastener is a rod.

13. The apparatus as recited in claim 12 wherein said product segments and fastener are components of a link-style conveyor belt.

14. A method for automated manufacture of assemblies comprised of discrete product segments comprising the steps of: a) determining a desired product; b) determining the type and number of a plurality of discrete product segments required to assemble said desired product; c) determining appropriate surface geometry of said required plurality of discrete product segments; d) storing said required plurality of said discrete product segments in a segment container; e) providing an apparatus for automated manufacture of product assemblies comprising a gripper module having a forward end and a rearward end and first and second reciprocating product segment grippers having surface features engageable with said product segments; at least one robotic manipulator arms capable of manipulating said discrete product segments; providing a machine vision device whereby the surface geometry of said discrete product segments may be verified; a fastener-insertion device whereby fasteners may be connected to said discrete product segments, and a computer control mechanism for controlling said gripper module, said robotic manipulator arms; said machine vision device, and said fastener-insertion device; f) providing a plurality of fasteners and a plurality of said discrete product segments; g) selecting a desired discrete product segment from said segment container with said robotic manipulator arm; h) verifying said appropriate surface geometry of said selected desired discrete product segment with said machine vision device; i) manipulating said robotic manipulator arms and sequentially engaging a first row of said selected desired discrete product segments with said surface features of said first and second reciprocating product segment grippers toward said forward end of said gripper module; j) manipulating said robotic manipulator arms and sequentially creating a second row of said selected desired discrete product segments rearward of said first row of said selected desired discrete product segments by engaging a first second row selected desired discrete product segment with selected desired discrete product segments of said first row of said selected desired discrete product segments with said robotic manipulator arms; k) linking said first second row selected desired discrete product segment with said desired discrete product segments of said first row of said selected desired discrete product segments with a fastener inserted by said fastener-insertion device. l) engaging a second second row selected desired discrete product segment with selected desired discrete product segments of said first row of said selected desired discrete product segments with said robotic manipulator arms; m) linking said second second row selected desired discrete product segment with said desired discrete product segments of said first row of said selected desired discrete product segments with a fastener inserted by said fastener-insertion device; n) disengaging said first row of said selected desired discrete product segments from said surface features of said second reciprocating product segment gripper and moving said first reciprocating product segment gripper and thereby said first and said second rows of desired discrete product segments toward said forward end of said gripper module; (o) engaging said second row of said selected desired discrete product segments from said surface features of said second reciprocating product segment gripper; p) disengaging said first reciprocating product segment gripper from said first row of said selected desired discrete product segments; and q) moving said first reciprocating product segment gripper rearward and engaging said surface features of said first reciprocating product segment gripper with said second row of said selected desired discrete product segments.

15. The method as recited in claim 14, wherein said step of specifying desired discrete product segments is provided to electronic hardware or software integrated into said computer control mechanism.

16. The method as recited in claim 15, wherein said step of determining the type and number of a plurality of discrete product segments required for assembling said desired product is provided by electronic hardware or software integrated into said computer control mechanism.

17. The method as recited in claim 16, wherein the step of verifying said appropriate surface geometry of said selected desired discrete product segment with said machine vision device is controlled by electronic hardware or software integrated into said computer control mechanism.

18. The method as recited in claim 17, wherein said step of engaging said selected desired discrete product segment with said surface features of said reciprocating product segment grippers with said robotic manipulator arms is controlled by electronic hardware or software integrated into said computer control mechanism.

19. The method as recited in claim 18, wherein said steps 6(j) through 6(q) are repeated as desired.

Description

DESCRIPTION OP THE DRAWINGS

[0011] FIG. 1 is a schematic side view of the automated assembly device of the invention described herein.

[0012] FIG. 2 is a schematic end view of the automated assembly device of the invention described herein.

[0013] FIG. 3 is an isometric top view of the traction gripper module of the automated assembly device of the invention described herein.

[0014] FIG. 4 is a detail partial isometric top view of the arrangement of the guide plate and stanchions of the traction gripper module of the automated assembly device of the invention described herein.

[0015] FIG. 5 is a partial side cross-section view of the traction gripper module of the automated assembly device of the invention described herein cut along Section-A of FIG. 3.

[0016] FIGS. 6a, 6b, and 6c show an embodiment of a product segment configured as conveyor link segment for use with of the automated assembly device of the invention described herein.

[0017] FIG. 7 is a schematic top view of a plurality of exemplar interchangeable product segments interlocked with an interlock rod by the automated assembly device described herein.

[0018] FIGS. 8a and 8b show partial detailed views on an embodiment of the robotic manipulator arm with opposing gripping fingers of the automated assembly device of the invention described herein.

[0019] FIG. 9 is a diagram illustrating the method steps for assembly of a finished product with the automated assembly device described herein.

DESCRIPTION OF EMBODIMENT

[0020] FIGS. 1 and 2 show schematic views of live automated assembly device (10) for assembly of interchangeable component parts or product segments (140) of a product such as a link-style conveyor belt that are to be interlocked together to produce a desired product. The device (10) is comprised of an assembly table (110), one or more robotic manipulator arms (130) having gripping fingers (131) for selecting, manipulating, and placing a desired product segment (140) selected from a source of desired product segments (140) such as from segment containers (115) or from product segments (140) delivered by a conveyor or other similar mechanism, at least one machine vision device (150) for verifying the identity of the selected product segment (140); at least one traction gripper module (120) at least one fastener-insertion device (160) whereby fasteners referred to generically as interlocks (145) obtained from an interlock container (148) are engaged with the selected product segments (140); and a computer control mechanism (180) for operating and the controlling the traction gripper module (120); the robotic manipulator arms (130), the machine vision device (150), and the fastener-insertion device (160).

[0021] As shown in FIG. 3, the traction gripper module (120), has a housing (121) positioned at the upper surface (112) at the end of the assembly table (110). The housing (121) of the gripping module (120) may be freestanding, on a stationary support, or be mounted to the table (110). Attached to the housing (121) is a guide plate (122) having a plurality of spaced apart guide fingers (123) forming a grip guide (124) between each of the guide fingers (123). A first product segment gripper (125) having a plurality of stanchions (126) each stanchion positioned in alternating grip guides (124). A second product segment gripper (127) also having a plurality of stanchions (128) each stanchion positioned in alternating grip guides (124) so that a stanchion (126) alternates with a stanchion (128). A pair of opposing studs (129) protrudes from the top of each stanchion (126) and stanchion (128). The guide plate (122), the alternated stanchions (126) and (128) with their opposing studs (129) of the traction gripper module (120) are shown in more detail in FIG. 4, a partial detail view of the arrangement of the guide plate (122) and stanchions (126) and stanchions (128) within the housing (121) of traction gripper module (120).

[0022] In the embodiment shown in FIGS. 3 and 4, the opposing studs (129) at each stanchion (126) are offset from the studs (129) on the adjacent stanchion (128) in order to facilitate placement of a desired product segment (140). The opposing studs (129) of each stanchion (126) and stanchion (128) may be placed in any suitable arrangement including in parallel rows depending upon the particular product segment (140) being utilized.

[0023] The traction module (120) may be further comprised of a retractable longitudinally and vertically positionable restraining surface (116) placed to overlay product segment gripper (125) and its corresponding stanchions (126) and product segment gripper (127) and its corresponding stanchions (128) dining assembly and interlocking of the product segments (140). The restraining surface (116) may be used to ensure that the selected product segments (140) do not buckle upwards or lose contact with stanchions (126) and stanchions (128) and their respective studs (129). The restraining surface (116) may also extend over the upper surface (112) of the assembly table (110). The restraining surface (116) may be adjustably moved to reciprocate longitudinally or vertically, upwards or downwards, as desired to accommodate selected product segments (140) of different height and/or a product-in-assembly (200) comprised of multiple layers of selected product segments (140). The movement of the restraining surface (116) to a desired position may be performed by at least one restraining surface actuator (117) operated and controlled by computer control mechanism (180). Actuator (117) may be any suitable mechanism for vertical movement and/or longitudinal movement including mechanically or electrically operated actuators, screw mechanisms, or hydraulically or pneumatically operated actuators.

[0024] As shown in FIG. 5, the first product segment gripper (125) is mounted on the housing (121) with a reciprocating mechanism (170a) to selectively move product segment gripper (125) and its corresponding stanchions (126) both vertically, upward and downward within its corresponding grip guide (124) independent of second product segment gripper (127), and a reciprocating mechanism (170b) to move product segment gripper (125) and its corresponding stanchions (126) longitudinally, within its corresponding grip guide (124) along the guide fingers (123). The second product segment gripper (127) is mounted on the housing (121) with a reciprocating mechanism (170c) to selectively move product segment gripper (127) and its corresponding stanchions (128) vertically, upward and downward within its corresponding grip guide (124) independent of first product segment gripper (125). The reciprocating mechanisms (170a), (170b) and (170c) may be any suitable actuator mechanism such as electrical, mechanical, hydraulic, or pneumatic linear actuators. Preferably pairs of reciprocating mechanisms (170a), (170b) and (170c) will be used in order to maintain alignment of the product segment grippers (125) and (127) within the housing (121) as they are reciprocated.

[0025] The computer control mechanism (180) will be use to operate the reciprocating mechanisms (170a), (170b) and (170c) and thereby manipulate product segment gripper (125) and its corresponding stanchions (126) to move vertically and longitudinally and manipulate product segment gripper (127) and its corresponding stanchions (126) to move vertically, upward and downward, as may be required or desired. Such manipulation allows adjustment for variation in the geometry of the selected product segments (140) due to manufacturing inconsistency or use of different materials.

[0026] The product segment grippers (125) and (127) may be detachably mounted to the respective reciprocating mechanisms (170a), (170b) and (170c) such as by a snap lit or by threaded bolts or screws in the manner of replaceable cartridges so that they may be replaced with product segment grippers (125) and (127) having a different configuration for the studs (129) depending upon the product-in-assembly being manufactured. Similarly, stanchions (126) and (128) may have sockets where the respective product segment grippers (125) and (127) may be detachably mounted or detachably mounted by other suitable attachment and detachable mechanisms such as threaded bolts or screw in order to install stanchions with a different configuration of studs (129) as may be required. Configuring the product segment grippers (125) and (127) as attachable and detachable cartridges will allow these components to be readily-repaired or replaced to accommodate different product designs or requirements with minimal downtime.

[0027] In instances where the product-in-assembly (200) is link-style conveyor belt, the selected product segments (140) will typically be a conveyor link segment (141) an embodiment of which is shown in in FIGS. 6a through 6c and the interlock (145) will be an interlock rod (147) such as that as shown in FIG. 7. Conveyor link segment (141) will have a link top surface (142), a link bottom surface (144), and link knuckles (143) each having with a bore (146). Conveyor link segment (141) will also have a sprocket indentations or recesses (149) for engaging the cogs or teeth of a sprocket-wheel of a conveyor. The arrangement of the studs (129) of the product segment grippers (125) and (127) will be configured so that the studs (129) will engage with the sprocket recesses (149) of the conveyor link (141). As shown in FIG. 7, during operation of the device (10) are interweaved with the link knuckles (143) of adjacent conveyor link segments (141) aligned so that fastener-insertion device (160) may engage interlock rod (147) with the aligned link knuckles (143) in order to link or connect the conveyor link segments (141) together. Such interlock rods (147) will typically be flexible rods having a length that matches (or slightly exceeds) the width of the product-in-assembly (200). Fastener-insertion device (160) is configured to insert and engage the interlock rods (147) with the link knuckle (143) of adjacent selected conveyor link segments (141) incremental steps or through the link knuckles (143) of an entire row of adjacent selected conveyor link segments (141).

[0028] The interlock rods (147) are configured for automated insertion through the link knuckles (143) of the selected conveyor link segments (141) by fastener-insertion devices (160). The fastener-insertion device (160) will typically be located in a fixed position, relative to the assembly table (110) to facilitate insertion of the interlock rods (147). Fastener-insertion devices (160) are well-known in the art. The interlock rods (147) comprising the interlocks (145) may thus be inserted either through the link knuckles (143) of an entire row of adjacent conveyor link segments (141) at once, or incrementally in a staggered or cascade fashion as the product-in-assembly (200) is moved along the length of the assembly table (110).

[0029] The robotic manipulator arms (130) will be used for selecting, manipulating, orienting, and placing for selecting, manipulating, and placing a desired product segment (140), such as a link segment (141), for engagement with the stanchion studs (129) of a desired stanchion (126) or (128) of product segment grippers (125) and (127), respectively. Gripping fingers (131) on the robotic manipulator arms (130) will engage and hold a desired product segment (140), such as a conveyor link segment (141) selected from the segment containers (115) where the product segments (140) are stored. The robotic manipulator arms (130) may be affixed to the sides of the assembly table (110) or they may be standalone devices. The robotic manipulator arms (130) and gripping fingers (131) will be operated and controlled by computer control mechanism (180).

[0030] FIGS. 8a and 8b show partial detailed views on an embodiment robotic manipulator arm (130) having a plurality of opposing gripping fingers (131). In the embodiment shown, gripping fingers (131) engaged between the link knuckles (143) of a conveyor link segment (141).

[0031] The segment containers (115) for the source of product segments may consist of bags, boxes or other similar containers. A conveyor or any other suitable delivery mechanism or device may also be utilized for the source of product segments (140). The source of product segments (140) such as the segment containers (115) will typically be positioned closely proximate to the robotic manipulator arms (130) to maximize their access to the product segments (140).

[0032] During assembly of the product-in-assembly (200), the machine visions device (150) may be used to confirm appropriate selection, and guide appropriate placement of the selected product segment (140), such as a link segment (141), to be engaged with the stanchion studs (129) of a desired stanchion (126) or (128) by the robotic manipulator arms (130) prior to insertion of the interlock (145) such as interlock rod (147). The machine vision device (150) may be any suitable machine vision device, such as a device employing one, two or three dimension digital sensors, specialized optics to acquire images, and computer hardware and software to process, analyze, and measure the image characteristics in order to determine the geometry characteristics of a selected product segment (140) and to confirm appropriate selection, and guide appropriate placement of a selected product segment (140). The machine vision device (150) will also be operated and controlled by computer control mechanism (180).

[0033] The assembly device (10) may be used to create, manipulate and advance the product-in-assembly (200) from the traction gripper module (120) onto the table (110) or to a storage bin so that additional selected product segments (140) may be linked to the product-in-assembly (200). For a product such as a link-style conveyor belt this is accomplished by raising and moving tire restraining surface (116) of the traction gripper module (120) longitudinally upstream or forward from the product segment grippers (125) and the product segment grippers (127). Then the robotic manipulator arms (130) are used to create a first row of link segments (141) by sequentially placing a desired plurality of link segments (141) onto the stanchions (126) of product segment grippers (125) and the stanchions (128) of the product segment grippers (127) to engage studs (129) with the recesses (149) of the link segments (141). The restraining surface (116) may then be lowered and moved longitudinally downstream or rearward over the row of link segments (141) just created.

[0034] A second row of link segments (141) is then created by using the robotic manipulator arms (130) to manipulate, interweave and aligned the link knuckles (143) of a second row first link segment (141) with link knuckles (143) of a first selected link segment or segments (141) on the first row of link segments (141) and then employing the fastener-insertion device (160) to insert an interlock rod (147) through the aligned second row first link segment (141) and the first selected link segment or segments (141) on the first row of link segments (141). Then, by use of the robotic manipulator arms (130), a second row second link segment (141) is selected and its link knuckles (143) are interweaved and aligned with the link knuckles (143) of a second selected link segment or segments (141) on the first row of link segments (141) and those of the second row first link segment (141). Then employing the fastener-insertion device (160), the previously inserted interlock rod (147) is inserted further through the aligned second row second link segment (141) and the second selected link segment or segments (141) on the first row of link segments (141). This process is then repeated for a second row third link segment (141) and thereafter for additional link segments (141) if desired. This second row of interweaved link segments (141) link segments (141) is not constrained by the restraining surface (116).

[0035] The assembly device (10) is then indexed by lowering product segment grippers (127) to disengage its studs (129) from the recesses (149) of the link segments (141). The product segment grippers (125) are then moved longitudinally upstream to move the connected link segments (141) a distance of one link segment pitch. The product segment grippers (127) are then raised to engage its studs (129) with the recesses (149) of the second row of link segments (141). Product segment grippers (125) are then lowered to disengage its studs (129) from the recesses (149) of the connected link segments (141), then moved longitudinally downstream one link segment pitch and then raised to engage its studs (129) with the recesses (149) of the second row of link segments (141). This indexing process is then completed. The sequence of adding link segments (141) is the repeated as desired for creation of a link-style conveyor belt.

[0036] The internal logic circuitry and/or external hardware and software necessary to appropriately program, transmit, and control the function of the computer control mechanism (180), the robotic manipulator arms (130), the machine vision devices (150), fastener-insertion device (160), and die lateral gripping surfaces (114) of the device (10) are known in the art. The device (10) will be programmatically capable of coordinating the selection, placement and manipulation of selected product segments (140) in order to produce any desired product either by direct programming of logic circuitry built into the device (10) or by interlacing with an external PLC (programmable logic controller) or standalone personal computer (PC) equipped with appropriate software.

[0037] FIG. 9 is a diagram of the method steps for assembly of product comprised of interlocked product segments (140) utilizing the automated assembly device (10) described herein. The method includes a multi-step process commencing with defining (Step 1), determination of the desired product such as a link-style belt conveyor or other product of a desired length and width, composed of appropriate pre-fabricated product segments (140) having appropriate surface geometry to permit manipulation by robotic manipulator arms (130) and traction gripper module (120).

[0038] Step 2 requires input of the desired output parameters defined in Step 1, the product length, width, thickness, and composition, into custom software on logic circuitry of the computer control mechanism (180) of the device (10) or on a general-purpose computer to interface with the computer control mechanism (180) of the device (10). For example, a link-style conveyor bell for use as a conveyor of heavy loads in a straight line might require particularly robust segments or multiple interlocking layers of segments to achieve a necessary carrying capacity. A link-style conveyor belt carrying light loads around comers might be constructed with segments permitting variable-radius geometry so that adjacent product segments (140) in sequential rows could separate at the outside of conveyor turns.

[0039] Given necessary parameters required by Step 2, and working from a pre-programmed library of available product segments (140) comprising a variety of lengths, widths, thicknesses, materials and surface geometries, the control software in Step 3 determines, first, the type and number of product segments (140) required to assemble the desired product-in-process (200); and, second, the necessary traction gripper module (120) components required. Such determinations may include the number and spacing of the guide fingers (123) required for the guide plate (122), the number, type, and location of the stanchions (126) for product segment gripper (125) and for the stanchions (128) of the product segment gripper (127), and a bill of materials describing type and number of required product segments (140) and interlocks (145) which are then communicated to the user either by the computer control mechanism (180) of the device (10) or, in other embodiments, the external PLC or general-purpose computer running appropriate software.

[0040] Step 4 involves user provisioning and assembly of the device (10) including assembly of the table (110), the traction gripper module (120), robotic manipulator arms (130), machine vision devices (150), container (115) and container (148), the restraining surface (116), appropriate product segments (140) and interlocks (145), as communicated in Step 3.

[0041] At Step 5, the computer control mechanism (180) of the device (10) or the general-purpose computer interfacing with the computer control mechanism (180) of the device (10) is initialized and runs (controlled by internal or external logic) a setup routine, (Step 5a), for performing the steps of: raising the restraining surface (116), (Step 5b); instructing robotic manipulator arms (130) to select and retrieve product segments (140), (Step 5c); employing the machine vision device (150) (or verifying the correctness of the selected product segments (140). (Step 5d); then employing the robotic manipulator arms (130) for placing the selected product segments (140) in appropriate traction gripper module (120) (depending on desired product), (Step 5e): automated lowering the restraining surface (116), (Step 5f); employing robotic manipulator arms (130) for selecting, retrieving, and placing appropriate additional product segments (140) on appropriate stanchions (126) and stanchions (128) of the traction gripper module (120) in a manner appropriate for the desired product, (Step 5g).

[0042] Step 6 consists of employing an assembly routine of the computer control mechanism (180) of the device (10) or the general-purpose computer interfacing with the computer control mechanism (180) of the device (10), repeated as necessary to produce the desired product including employing and using fastener-insertion device (160) for automated insertion of interlocks (145), such as interlock rods (147), to the product segments (140) (either through an entire row or in stepwise/cascaded fashion), (Step 6a); employing traction gripper module (120) for automated advancing of the product-in-assembly (200), (Step 6b); and the repeating of (Step 5g) through (Step 6b), as necessary, (Step 6c). Succeeding product segments (140) are loaded sequentially from the downstream end of assembly table (110) and traction gripper module (120).

[0043] Finally, once the desired product-in-assembly (200) is completed, Step 7 employs advancing and removing the completed product-in-assembly (200) from the assembly table (110) by repeated sequential movements of the appropriate stanchions (126) and stanchions (128) of the traction gripper module (120), and, if desired, into a holding bin placed downstream of assembly table (110) into which the product-in-assembly (200) folds as it advances. At the conclusion of Step 7, the automated assembly device (10) is ready to begin an entirely new assembly operation, either of the same product or of another.