High Density Manufacturing Cell (HDMC) Structure or The Like

Abstract

A high density manufacturing cell or carousel for optimizing floor space usage to reduce equipment footprint and material travel path is disclosed. The carousel allows processing and transferring of products to be concurrently performed, minimising non-productive time. The manufacturing cell or carousel comprises:

(a) a plurality of rotary platforms having one end being attached to a rotatable shaft positioned in the middle of the cell and being rotatable about the central axis thereof;

(b) a plurality of vertical moving platforms being mounted substantially perpendicularly to an external cylindrical housing, wherein the cylindrical housing can be raised upwards and downwards;

(c) a vertical walking beam located next to the cylindrical housing of the manufacturing cell which is a vertical beam having at a number of arms one less than the number of rotary platforms, to pick up and place products for processing and transferring products between platforms of the carousel;

(d) A load gripper and a unload gripper mounted to independent robots, to load products into the carousel for processing and to unload processed products from the rotary platform and transferring to a conveyor positioned next to the walking beam.

Claims

1. A high density manufacturing cell or carousel for optimizing floor space usage to reduce equipment footprint and material travel path comprising (a) a plurality of rotary platforms having one end being attached to a rotatable shaft positioned in the middle of the cell and being rotatable about the central axis thereof; (b) a plurality of vertical moving platforms being mounted substantially perpendicularly to an external cylindrical housing, wherein the cylindrical housing can be moved vertically upwards and downwards; (c) a vertical walking beam located next to the cylindrical housing of the manufacturing cell which is a vertical beam having a number of arms of quantity one less than number of platforms, to lift up a new product for processing and to place down completed product from the cell for transferring of products between platforms; (d) an unload gripper and a load gripper positioned at the topmost and bottommost platform to load products into the carousel for processing and to unload processed products from the rotary platforms to a conveyor positioned next or beside the walking beam.

2. The high density manufacturing cell as set forth in claim 1, wherein a plurality of work stations are positioned above the vertical moving platform, for the processing of products transferred thereto.

3. The high density manufacturing cell as set forth in claim 1, wherein the vertical moving platform is provided with a plurality of product holders.

4. The high density manufacturing cell as set forth in claim 2, wherein the vertical moving platform lifts up in progress products above the rotary platform and towards the work station to be processed.

5. The high density manufacturing cell as set forth in claim 1, further comprising independent robots or actuators to forward the load gripper and unload gripper into the carousel and to retract the load gripper and unload gripper from the carousel.

6. The high density manufacturing cell as set forth in claim 1, further comprising a robot or actuator to raise or lower the load and unload grippers within the carousel.

7. The high density manufacturing cell as set forth in claim 1, wherein a plurality of rotating platforms are positioned to a central shaft, wherein the rotating of the shaft allows all the rotating platforms to rotate.

8. The high density manufacturing cell as set forth in claim 1, wherein the conveyor is used to delivery products to the cell for processing or to transfer processed products away from the cell.

9. A method of loading and unloading processed product using the high density manufacturing cell of claim 1 comprising the step of (i) moving the vertical moving platforms downwards while the unload gripper moves into the carousel to retrieve the processed part from the top most rotary platform; (ii) moving the vertical walking beam to position its grippers to the bottom tier of the rotary platform and enter the carousel to retrieve products from the bottom tier platforms; (iii) returning the unload gripper to the original position thereof after it places the processed products onto the conveyor; (iv) moving the vertical walking beam to position the grippers to the upper tier platform, and while the load gripper is holding on to a new unprocessed product from the conveyor, moving it into the carousel to place the product on the bottom most rotary platform; (v) moving the vertical moving platform into the carousel to place the partially processed products on to the top tier rotary platforms and moving the load gripper to the conveyor to pick a new product to prepare for the next loading operation; (vi) returning the vertical walking beam to the standby position; (vii) lowering the vertical moving platform to place all parts on to the rotary platform moving all products on the rotary platform by an angular index to transfer products to the next adjacent workstation, where the work stations are housed on an independent external cylindrical housing. (viii) moving the vertical moving platform upwards to lift the products towards the workstations for processing.

10. The method of loading and unloading processed product as set for in claim 9, wherein the process of product transferring and product processing is performed simultaneously.

11. The method of loading and unloading product as set forth claim 9, wherein unload gripper and load gripper are mounted and activated independently by an unloading robot and loading robot.

12. The method of loading and unloading processed product as set forth in claim 9, wherein when the vertical moving platform moves upward, all the products are transferred and lifted away from the rotary platforms and move towards the work station, except for the products along a transfer zone, remaining on the rotary platforms.

13. The method of loading and unloading product as set forth in claim 9, wherein the angular spacing between workstations are similar to the product holders of the rotary and vertically moving platform.

14. The method of loading and unloading as set forth in claim 13, wherein the work station is provided with station tools to perform a dedicated process.

15. The high density manufacturing cell as set forth in claim 1, wherein the vertical walking beam is provided with grippers to place products onto the rotary platform or pick product from the rotary platform within a transfer zone and transferring them across rotary platforms.

16. The method of loading and unloading product as set for in claim 15, wherein the step of gripping, picking and placing products from and onto the carousel includes the use of mechanical or magnetic grippers, and/or vacuum cups.

17. The high density manufacturing cell or carousel of claim 1, wherein the vertical moving platforms and rotary platforms are configured to be lifted and rotated independently or grouped to allow flexibility of processing products.

18. The high density manufacturing cell or carousel of claim 1, wherein the vertical walking beam includes the use of linear actuators installed with independently driven grippers to move products independently across platforms.

19. The high density manufacturing cell as set forth in claim 15, wherein one, two or more than two transfer zones can be configured to allow cells to be linked together.

20. The high density manufacturing cell as set forth in claim 1, wherein the cell is operated individually along a conveyor or a plurality of cells are linked together to form a chain or cluster of process cells.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention will now be described by way of example, with reference to the annexed drawings, in which:

[0031] FIG. 1 a illustrates a perspective view of a high density manufacturing cell without the workstations attached in accordance with the present invention;

[0032] FIG. 1b illustrates a perspective view of a high density manufacturing cell having mounted beside a conveyor in accordance with the present invention.

[0033] FIG. 2 is a perspective exploded view of a high density manufacturing cell showing a plurality of platforms in accordance with the present invention;

[0034] FIG. 3a illustrates the assembly of the rotary and vertical moving platforms in the high density manufacturing cell;

[0035] FIG. 3b is a perspective view showing the vertical moving platform moved down and products resting on the rotary platform being able to perform an angular indexing of the product in accordance with the present invention;

[0036] FIG. 3c is a perspective view showing vertical moving platform moved upwards and all products except those in the transfer zone being lifted away from the rotary platform in accordance with the present invention.

[0037] FIG. 4 is a section view showing the vertical walking beam lifting products from the rotary platform of the present invention.

[0038] FIGS. 4a to 4g illustrate the steps (in perspective views) of loading of product for processing and unloading of processed products of the high density manufacturing cell in accordance with the present invention.

[0039] FIGS. 5 to 14 illustrates in sections views of loading of product for processing and unloading of processed products of the high density manufacturing cell in accordance with the present invention.

[0040] FIG. 15 is a top view of the high density manufacturing cell illustrating a vertical zone on the rotating platform allocated as the transfer zone in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] Hereinafter, there are described preferred embodiments of the present invention.

[0042] Referring to FIG. 1a, a high density manufacturing cell 100 designed for product handling and manufacturing processes to be performed simultaneously according to the present invention is disclosed. FIG. 1b is a perspective view showing the high density manufacturing cell 100 with a conveyor 40 mounted beside the cell 100 in accordance with the present invention. The high density manufacturing cell or carousel 100 comprises (a) a vertical walking beam 10 with a load gripper 12 (shown in FIG. 1b) and an unload gripper 14 (shown in FIG. 1b) positioned in the mid position of the carousel 100, (b) a plurality of vertical moving platforms 20a, 20b, 20c, 20d (shown in FIG. 2) attached at one edge thereof to an external cylindrical housing 22, each of the platforms 20a, 20b, 20c, 20d (FIG. 1a) being parallel to each other, and are equally spaced apart, (c) a plurality of rotating platforms 30a, 30b, 30c, 30d held together axially by a cylindrical shaft 32, positioned at the centre of the high density manufacturing cell 100, and (d) a conveyor 40 positioned beside the high density manufacturing cell 100. In a preferred embodiment, the high density manufacturing cell 100 is a carousel comprising of a plurality of vertically arranged platforms being attached to an external cylindrical housing 22, allowing these platforms to be moved vertically altogether, and a plurality of rotating platforms being attached to a central cylindrical shaft 32. In accordance with the present invention, the vertical moving platforms 20a, 20b, 20c, 20d have equally spaced vertical pitch between platforms 20 and equally spaced angular pitch between each unit holders thereof. The centre cylindrical shaft 32 is rotatable. When the cylindrical shaft 32 is rotated, the platforms 20 (20a, 20b, 20c, 20d) together with all the products are rotated. Along the vertical length of the carousel, the transferring of the products takes place along a single vertical row, also described as a transfer zone 34.

[0043] Positioned directly opposite of the transfer zone 34 is the vertical walking beam 10 which can move up and down vertically as well as into and out of the carousel 100, the load gripper 12 for picking up product or component to be processed from the conveyor 40 is shown in FIG. 1b and the unload gripper 14 for unloading a fully processed component out of the carousel and placing it onto the conveyor 40 is shown in FIG. 1b.

[0044] As shown in FIGS. 1a and 1b, the rotating platforms 30 (30a, 30b, 30c, 30d) are mounted to the external cylindrical housing 22, and the rotating platforms 30 has an equally spaced vertical pitch and equally spaced angular pitch between unit holders similar to the vertical moving platforms 20 (20a, 20b, 20c, 20d). A vertical zone on the rotating platform 30 is allocated as the transfer zone 34 (shown in FIG. 15), wherein processed products are moved out of the carousel 100, and the products would be moved between platforms, and new products would be loaded into the carousel 100.

[0045] FIG. 2 is a perspective exploded view of a high density manufacturing cell in accordance with the present invention. A longitudinal opening 24 is made to the external cylindrical housing 22 along the transfer zone 34 to allow the picking and the placing of products into the carousel 100. In the preferred embodiment, the vertical walking beam 10 in front of the transfer zone 34 is provided to pick product through a bottom-up motion and place product through a top-down motion, or any form of picking and/or loading products. The load gripper 12 is positioned at height of the bottommost rotary platform 30a and the unload gripper 14 is positioned at height of the topmost rotary platform 30d. The load gripper 12 and the unload gripper 14 place and pick product from a position directly above of the product. FIG. 3a shows a perspective schematic view of the vertical moving platforms 20 raised above the rotary platform 30, and the vertical walking beam 10 and the grippers 12, 14 are at home position in accordance with the present invention.

[0046] FIG. 3b is a perspective view showing the vertical moving platform 20 moved down and products resting on the rotary platform 30 being able to perform an angular indexing in accordance with the present invention. FIG. 3c is a perspective view showing the vertical moving platform 20 moved upwards and products except those in the transfer zone 34 being lifted away from the rotary platform 30 in accordance with the present invention.

[0047] FIG. 4 is a section view showing the vertical walking beam 10 lifting products from the rotary platform 30a-30d in accordance with the present invention. As shown in the figure, the unload gripper 14 removes a product from the carousel 100 and places the product onto the conveyor 40. The vertical walking beam 10 moves upwards to pick the products from the rotary platforms 30a-30d.

[0048] FIG. 4a is a perspective view showing the unload gripper 14 entering the carousel 100 to unload a completed processed product from a rotary platform 30a, and the vertical walking beam 10 moves to a lower position, aligned below the rotary platform 30b in accordance with the present invention. Referring to FIG. 6a, the fully processed product at the topmost level of the rotary platform 30a is first removed by the unload gripper 14. The unloading gripper 14 enters the carousel 100 and picks the product from the top most level of the transfer zone 34, while the vertical walking beam 10 moves downwards and aligns its grippers at a height below the resting positions of the remaining products below the topmost level.

[0049] As shown in FIG. 4b, the unload gripper 14 extracts a completed/processed product from the carousel 100, and the vertical walking beam 10 enters the carousel 100, positioning its grippers directly beneath the products.

[0050] FIG. 4c is a perspective view showing the vertical walking beam 10 picking products from the rotating platform 30 in accordance with the present invention. The vertical walking beam 10 moves upwards, transferring the products from the rotating platform 30 to the grippers of the vertical walking beam 10.

[0051] FIG. 4d is a perspective view showing the vertical walking beam 10 moving to the upper tier platforms with arms aligned to the top of the rotary platform 30 and the loading gripper 12 loading a new product onto the rotary platform 30 in accordance with the present invention. As shown in the figure, the vertical walking beam 10 moves out of the carousel 100 and moves upwards to the upper position and positions its grippers above the top tier rotating platforms.

[0052] FIG. 4e is a perspective view showing the vertical walking beam 10 moving the products into the carousel 100 in accordance with the present invention. As shown in FIG. 11, the vertical walking beam 10 moves into the carousel 100 and moves its gripper directly above the rotating platform 30.

[0053] FIG. 4f is a perspective view showing the vertical walking beam 10 lowering the products onto the rotary platforms 30 of the present invention. In FIG. 12, the vertical walking beam 10 lowers the products onto the rotating platform 30 and further lowers beneath the rotating platform 30. FIG. 6g is a perspective view showing the vertical walking beam 10 moving to its home position and the vertical moving platform 30 lowering to place products onto rotary platform 30 in accordance with the present invention.

[0054] As shown in FIG. 4g, the vertical walking beam 10 moves out of the carousel 100 and returns to its home position. All products in the transfer zone 34 of the carousel 100 are now in position and ready to be indexed to the first working station 28 at its respective level.

[0055] FIG. 5 is a section view showing the unload gripper 14 picking a completed/processed product from the top most rotary platform 30a and the vertical walking beam 10 positioning the gripper below the lower tier of the rotary platforms 30b-30d in accordance with the present invention. As shown, the unload gripper 14 enters the carousel 100 to pick up a completed/processed product from the top most rotary platform 30a.

[0056] FIG. 6 is a section view showing the unload gripper 14 moving a completed/processed product to a conveyor 40 (as shown in FIG. 1 b) and the vertical walking beam 10 moving into the carousel 100 of the present invention. As shown in the figure, the unload gripper 14 removes a completed/processed product from the top level of the rotary platform 30a and places the product onto the conveyor 40, as shown in FIG. 1 b. The vertical walking beam 10 positions its grippers directly beneath the bottom tier of the rotary platforms 30b-30d in accordance with the present invention.

[0057] FIG. 7 is a sectional view showing the vertical walking beam 10 moving the products out of the lower tier platforms out of the carousel 100, while the unload gripper 14 returns to its home position.

[0058] FIG. 8 is a section view showing the vertical walking beam 10 moving up to the upper tier of the carousel 100 and the load gripper 12 placing an unprocessed product into the carousel 100 in accordance with the present invention. The vertical walking beam 10 position its arms above the rotary platform 30a-30c. The load gripper 12 moves into the carousel 100 with the unprocessed product and places onto the bottom most level of the rotary platforms 30d.

[0059] FIG. 9 is a section view of the vertical walking beam 10 moving into the upper tier of the carousel while the load gripper 14 moving out of the carousel 100 to the conveyor 40 to prepare a new part and moves to the standby position in accordance with the present invention.

[0060] FIG. 10 is a section view of the vertical walking beam 10 placing products onto the rotary platforms 30a-30d. The vertical walking beam 10 lowers and places the product onto the rotary platform 30a-30d.

[0061] FIG. 11 is a vertical walking beam 10 moving out of the carousel 100 and into the standby position in accordance with the present invention. As shown in the figure, the vertical walking beam 10 moves its grippers out of the carousel 100 and to its standby position. The transfer zone 34 now has a new parts at each level ready for processing.

[0062] FIG. 12 is a section view showing the vertical moving platform 20a-20d lowering the products onto the rotary platforms 30a-30d of the present invention. The vertical moving platform 20a-20d lowers the products on the rotary platform 30a-30d.

[0063] FIG. 13 is a section view showing the rotary platforms 30a-30d making an index in accordance with the present invention. The making of an index is to move all the products directly beneath the next adjacent work station 28.

[0064] FIG. 14 is a section view showing the vertical moving platform 20 lifting all the products except those on the transfer zone 34, towards their respective work station 28 in accordance with the present invention. As shown in the figure, the vertical moving platform 20 raises and lifts all the products to the next work station 28, while leaving all the products within the transfer zone 34 to be transferred.

[0065] In accordance with the preferred embodiment of the present invention, the work stations 28 are positioned directly above the vertical moving platforms 30, and are spaced evenly at a similar pitch as the product on the vertical moving platforms 20 and the rotary platforms 30.

[0066] The conveyor 40 is placed beside the carousel 100, at the end stroke of the load and unloading grippers 12, 14, opposite of the transfer zone 34. The transfer process of products is triggered after the vertical moving platforms 20a-20d are in the up position. As the units within the transfer zone 34 of the vertical moving platforms 20a-20d do not have features to pick up products, products on the transfer zone 34 remains on the rotating platform 30a-30d as the vertical moving platform 20a-20d move upwards.

[0067] In accordance with the present invention, upon completion of all the processing steps within the stations of the carousel 100, the vertical moving platforms 20a-20d are being lowered, and place all the processed products onto the rotary platforms 30a-30d. The vertical moving platforms 20a-20d will continue to lower below the rotary platforms 30a-30d to clear away from the rotary platforms 30a-30d. The rotary platforms 30a-30d are then rotated by an angular pitch. All products within the carousel 100 are now in a new position and ready for subsequent processing step to be performed. The vertical moving platforms 20a-20d will then move upwards, lifting all products, except for those in the transfer zone 34, away from the rotary platforms 30a-30d and continue moving, until the products are within the working envelope of their respective work stations 28. All work station 28 will begin their respective processes and the transferring of products begins concurrently at the transfer zone 34.

[0068] The rotary platforms 30a-30d are fixed to a rotating shaft 32. The rotary shaft 32 has a rotary mechanism (not shown) used to rotate the platforms 30a-30d with a desired motion profile. The type of rotating mechanism is selected depending on the size and weight of the rotating mass as well as the desired motion profile. The rotation of the shaft can be achieved with an indexing mechanism, gears and other means of indirect power transmission mechanisms or through direct methods of direct motor coupling. In the preferred embodiment of the present invention, the picking of products includes the use of mechanical or magnetic grippers, vacuum cups or other forms of part handling end effectors.

[0069] In the present invention, the vertical moving platforms and rotary platforms may be configured to be lifted and rotated independently or grouped to allow flexibility of processing products, and the vertical walking beam may include the use of linear actuators installed with independently driven grippers to move products independently across platforms. The number of transfer zones may be modified to have two or more to allow cells to be linked together and the cell can be operated individually along a conveyor or a plurality of cells may be linked together to form a cluster of manufacturing processes. Independent robots or actuators can be used to form and the load gripper and unload gripper into the carousel and to retract the load gripper and unload gripper from the carousel, and a robot or actuator is used to raise or lower the load and unload grippers within the carousel.

[0070] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

[0071] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.