AUTONOMOUS MANUFACTURING SYSTEM COMPRISING A MANUFACTURING DEVICE AND MULTIPLE AUTONOMOUS SUPPLY DEVICES

Abstract

A mobile autonomous manufacturing system including an autonomously mobile main device (10) performing a manufacturing task, a first auxiliary device (11) adapted to autonomously supply energy to the main device (10), a second auxiliary device (12), adapted to autonomously supply manufacturing items to the main device (10). A method for operating such a mobile autonomous manufacturing system, in which the auxiliary devices (11,12) move autonomously to and from the main device (10) and synchronously with the main device (10) when supplying the main device (10).

Claims

1. A mobile autonomous manufacturing system comprising: an autonomously mobile main device including a receptacle for receiving onboard energy storage, and the main device is adapted to perform a predetermined manufacturing task requiring supply of manufacturing items, a first auxiliary device adapted to: store energy, operate in an autonomous mode to move autonomously and independently from the main device, connect with the main device to supply the main device with energy, and operate in a synchronous mode to move synchronously with the main device, and a second auxiliary device adapted to: store the manufacturing items, operate in an autonomous mode to move autonomously and independently from the main device, automatically supply the main device with the manufacturing items, and operate in a synchronous mode to move synchronously with the main device.

2. The system according to claim 1, further comprising a third auxiliary device adapted to: store energy, operate in an autonomous mode to move autonomously and independently from the main device, automatically connect with the main device to supply the main device with energy, and operate in a synchronous mode to move synchronously with the main device.

3. The system according to claim 2, wherein the main device is adapted to be supplied with energy simultaneously by the first auxiliary device and by the third auxiliary device.

4. The system according to claim 1, wherein the main device is adapted to host at least one of the first auxiliary device and the second auxiliary device in a receptacle of the main device.

5. The system according to claim 1, further comprising a fourth auxiliary device adapted to: store a second type of energy, different from a first type energy stored by the first auxiliary device, operate in an autonomous mode to move autonomously and independently from the main device, connect with the main device to supply the main device with the second type of energy, and operate in a synchronous mode to move synchronously with the main device.

6. The system according to claim 1, further comprising a fifth auxiliary device adapted to: store a second type of manufacturing items, different from the manufacturing items stored by the second auxiliary device, operate in an autonomous mode to move autonomously and independently from the main device, connect with the main device to supply the main device with the second type of manufacturing items, and operate in a synchronous mode to move synchronously with the main device.

7. The system according to claim 1, further comprising a telecommunication device adapted to send a request signal upon a detection, by the main device or any of the first and second auxiliary devices connected to the main device, of a low energy level in the first auxiliary device or of a low manufacturing item level in the second auxiliary device.

8. The system according to claim 7, wherein the system is adapted, upon reception of a request signal, to generate instructions for another auxiliary device to be dispatched to the main device.

9. The system according to claim 1 further comprising: at least one energy loading station comprising a loading device adapted to load the first auxiliary device with energy, and at least one manufacturing item loading station adapted to load the second auxiliary device with the manufacturing items.

10. A method for operating a mobile autonomous manufacturing system, the method comprising: operating a main device to move autonomously to perform a predetermined manufacturing task using at least one type of manufacturing item, supplying energy to the main device by a first auxiliary device, wherein the first auxiliary device automatically: stores energy onboard the first auxiliary device, operates in an autonomous mode in which the first auxiliary device moves autonomously and independently with respect to the main device, connects to the main device to supply the main device with energy, and operates in a synchronous mode in which the first auxiliary device moves synchronously with the main device while the first auxiliary device supplies the main device with energy, and supplying manufacturing items to the main device by a second auxiliary device by: storing the manufacturing items onboard the second auxiliary device, automatically operating the second auxiliary device in an autonomous mode in which the second auxiliary device moves autonomously and independently with respect to the main device, automatically connecting the second auxiliary device to the main device, and automatically operating in a synchronous mode during which the second auxiliary device moves synchronously with the main device while the second auxiliary device supplies the main device with the manufacturing items.

11. The method according to claim 10, further comprising: monitoring a level of energy stored in the first auxiliary device, in response to detecting the level of energy below a predetermined threshold, automatically dispatching a request signal, in response to reception of the request signal, automatically dispatching a third auxiliary device with a level of energy stored on the third auxiliary device which is above a predetermined threshold level of energy, in response to being dispatched, the third auxiliary device moves automatically in an autonomous mode autonomously and independently to the main device, automatically connecting the third auxiliary device to the main device, while connected to the main device, operating the third auxiliary device automatically in a synchronous mode during which the third auxiliary device moves synchronously with the main device while the third auxiliary device supplies the main device with energy.

12. The method according to claim 11, wherein the steps of automatically connecting the third auxiliary device and operating the third auxiliary device in the synchronous mode are performed while the first auxiliary device is connected to and supplying energy to the main device.

13. The method according to claim 11, further comprising: automatically disconnecting the first auxiliary device from the main device after the third auxiliary device performs the connection to the main device and the supplying of the main device with energy, after the disconnecting step, operating the first auxiliary device in the autonomous mode to move the first auxiliary device autonomously and independently to a loading station, and loading the first auxiliary device with energy at the loading station.

14. The method according to claim 10, further comprising: monitoring the manufacturing items being supplied by the second auxiliary device to the main device, in response to detecting a remaining amount manufacturing items stored in the second auxiliary device being below a threshold, automatically dispatching a request signal, in response to receiving the request signal, automatically dispatching a sixth auxiliary device with a supply of the manufacturing items, and automatically operating the sixth auxiliary device in an autonomous mode to move the sixth auxiliary device autonomously and independently to the main device, automatically connecting the sixth auxiliary device to the main device, and automatically moving the sixth auxiliary device in a synchronous mode to move synchronously with the main device while the sixth auxiliary device supplies the main device with the manufacturing items.

15. The method according to claim 14, further comprising automatically issuing a replacing signal by the main device as the sixth auxiliary device approaches the main device; and in response to the replacing signal, automatically disconnecting the second auxiliary device from the main device.

16. A method comprising: dispatching a first auxiliary robotic device from an energy supply station; causing the first auxiliary robotic device to move automatically to a main robotic device; automatically connecting the first auxiliary robotic device to the main robotic device; automatically dispatching a second auxiliary robotic device with manufacturing items from at least one manufacturing item supply station; causing the second auxiliary robotic device to move automatically to the main robotic device, automatically connecting the second auxiliary robotic device to the main robotic device; and automatically moving an assembly of the main robotic device, the first auxiliary robotic device and the second auxiliary robotic device to perform a manufacturing task to install the manufacturing items stored on the second auxiliary robotic device while the assembly is powered by energy from the first auxiliary robotic device.

17. The method of claim 16, further comprising: monitoring a level of energy in the assembly; in response to detecting the level of energy below a threshold, automatically dispatching a third auxiliary robotic device with a supply of energy; automatically moving the third auxiliary device towards the main device, automatically disconnecting the first auxiliary robotic device from the assembly as the third auxiliary robotic device approaches the main robotic device; automatically connecting the third auxiliary robotic device to the main device and replacing in the assembly the first auxiliary robotic device with the third auxiliary robotic device, and thereafter repeating the step of automatically moving the assembly and performing the manufacturing task.

18. The method of claim 16, further comprising: automatically monitoring the manufacturing items stored in the assembly, in response to detecting that an amount of the manufacturing item being below a threshold, automatically dispatching a fourth auxiliary robotic device from the at least one manufacturing item supply station, wherein the forth auxiliary robotic device has a supply of the manufacturing items, automatically moving the fourth auxiliary robotic device towards the main device, automatically disconnecting the second auxiliary robotic device from the assembly as the third auxiliary robotic device approaches the main robotic device; connecting the fourth auxiliary robotic device to the main device to replace the second auxiliary robotic device in the assembly, and thereafter repeating the step of automatically moving the assembly and performing the manufacturing task.

Description

SUMMARY OF DRAWINGS

[0089] The invention also extends to other possible combinations of features described in the above description and in the following description relative to the figures. In particular, the invention extends to manufacturing systems and devices comprising features described in relation to the method for operating such system. The invention also extends to methods of the invention comprising features described in relation to the system.

[0090] Some specific exemplary embodiments and aspects of the invention are described in the following description in reference to the accompanying figures.

[0091] FIGS. 1 to 6 are schematic representations of a specific embodiment of a system according to the invention.

[0092] FIG. 7 is a schematic representation of steps of a method according to the invention.

[0093] FIGS. 8A and 8B represent exemplary embodiments of auxiliary devices of a system according to the invention.

[0094] FIG. 9 represents a system according to the invention with a main device connected to two auxiliary devices.

DETAILED DESCRIPTION

[0095] FIGS. 1 to 6 schematically represent a manufacturing plant comprising an autonomously mobile main device 10, and multiple auxiliary devices (11, 12, 13, 14, 16, 18). The manufacturing plant also comprises two manufacturing areas (30, 31). Moreover, the manufacturing plant comprises multiple loading stations (19, 15, 17).

[0096] The main device 10 is adapted to move autonomously at least between the first manufacturing station 30 and the second manufacturing station 31. The auxiliary devices (11, 12, 13, 14, 16, 18) are adapted to move autonomously at least between the main device 10 and their respective loading stations (19, 15, 17).

[0097] In this embodiment, the auxiliary devices embark on board the main device when in the synchronous mode.

[0098] In FIG. 1, the main device is represented at a first location with respect to the first manufacturing station 30.

[0099] A first auxiliary device 11 is adapted to store electrical energy. In FIG. 1, the first auxiliary device 11 is in a synchronous mode with the main device 10, supplying electrical energy to the main device 10. The first auxiliary device 11 is in a first receptacle 21 of the main device.

[0100] A second auxiliary device 12 is adapted to store manufacturing items. In FIG. 1, the second auxiliary device 12 is also in a synchronous mode with the main device 10, supplying the main device with manufacturing items. The second auxiliary device 12 is in a second receptacle 22 of the main device.

[0101] A third auxiliary device 13 is at an energy loading station 19, being loaded with electrical energy, the third auxiliary device 13 being identical to the first auxiliary device 11 and as such being adapted to store electrical energy. The main device 10 comprises an empty receptacle 23 adapted to host the third auxiliary device 13.

[0102] A fourth auxiliary device 14 is adapted to store energy in the form of compressed air. In FIG. 1, the fourth auxiliary device 14 is also in a synchronous mode with the main device 10, supplying the main device with compressed air. The fourth auxiliary device 14 is in a fourth receptacle 24 of the main device.

[0103] The system also comprises a fifth auxiliary device 18, identical to the fourth auxiliary device 14. In FIG. 1, the fifth auxiliary device 18 is at a loading station 17, being reloaded with compressed air.

[0104] Furthermore, the system comprises a sixth auxiliary device 16, identical to the second auxiliary device 12. In FIG. 1, the sixth auxiliary device 16 is at a loading station 15, being reloaded with manufacturing items. As mentioned before, the reloading of the auxiliary devices may be achieved manually or automatically.

[0105] FIG. 2 represents the same devices in a situation where the main device has carried on various manufacturing tasks and the energy level of the first auxiliary device 11 is low. Upon detection of this low level-below a predefined thresholdof energy of the first auxiliary device 11, the main device sends a request signal 33 towards the loading station 19 for electrical energy transporting auxiliary devices.

[0106] Upon receiving the request signal, the loading station 19 elaborates and transmits instructions to the auxiliary device 13 being recharged. Although in this embodiment only one auxiliary device is represented at the loading stations, each loading station may be adapted to accommodate a plurality of auxiliary devices of the same type. The instructions have for consequence for the auxiliary device 13 to be dispatched towards the main device, as long as the energy level of the auxiliary device 13 is above a predetermined threshold.

[0107] FIG. 3 represents a situation in which the third auxiliary device 13 moved autonomously towards the main device 10, docked to it in the corresponding receptacle 23 and is connected to the main device 10 to supply the main device with electricity. The main device 10 is then electrically connected to both the first auxiliary device 11 and the third auxiliary device 13.

[0108] In FIG. 4, the first auxiliary device 11 has disconnected undockedfrom the main device 10 such that the receptacle 21 remains available. The first auxiliary device 11 is moving autonomously towards its loading station 19. The main device 10 continues to carry its manufacturing tasks.

[0109] The docking of the third auxiliary device 13 and the undocking of the first auxiliary device 11 do not impede the main device 10 to carry on with its manufacturing tasks.

[0110] In FIG. 5, the main device 10 sends a request signal 34 towards the loading station 15 at which auxiliary devices for transporting manufacturing items may be loaded. The main device 10 also sends a request signal 35 towards the loading station 17 at which auxiliary devices with compressed air may be loaded.

[0111] In a method according to the invention, the thresholds at which request signals are sent are predetermined such that the main device 10 may carry on its manufacturing tasks until a fully loaded auxiliary device arrives in the vicinity of the main device 10.

[0112] In FIG. 6, the auxiliary device 16 that was being loaded at station 15 has moved in an autonomous mode towards the main device and docked to the main device 10 while the auxiliary device 12 that was previously supplying the main device 10 with manufacturing items is undocked and moving autonomously towards the loading station 15.

[0113] The auxiliary device 18, which was being loaded at the compressed air loading station 17, is moving in autonomous mode in the vicinity of the main device 10. The auxiliary device 14 supplying compressed air to the main device is in synchronous mode with the main device and remains in synchronous mode with the main device as long as its compressed air level has not reached a lower threshold. Once this lower threshold is reached, the auxiliary device 14 in synchronous mode with the main device disconnects from the main device and lets the receptacle 24 available for the replacing auxiliary device 18. The auxiliary device 18 in the vicinity of the main device replaces the auxiliary device 14 as soon as the auxiliary device 14 supplying compressed air to the main device has undocked from the main device.

[0114] In FIG. 6, the main device 10 also sends a new request signal 33 for electricity supply towards the loading station 19 at which the first auxiliary device 11 is being loaded.

[0115] FIG. 7, represents a method according to the invention with a timeline going from the top to the bottom of the figure. The line beginning at box 30 represents the process led by a main device of a system according to the invention. The line beginning at box 31 represents the process led by the first auxiliary device. The line beginning at box 33 represents the process led by the third auxiliary device. The line beginning at box 32 represents the process led by the second auxiliary device. The line beginning at box 36 represents the process led by a fifth auxiliary device, the fifth auxiliary device being identical to the second auxiliary device.

[0116] The bracket represents devices that are in synchronous mode with the main device.

[0117] In this process many steps are led in parallel. Represented on the top of FIG. 7, the following steps are led in parallel:

[0118] Step 30 of autonomous manufacturing led by the main device,

[0119] Step 31 of supplying the main device with electrical power by a first auxiliary device in synchronous mode with the main device,

[0120] Step 32 of supplying the main device with manufacturing items by a second auxiliary device in synchronous mode with the main device,

[0121] Step 33 of loading the electrical batteries of a third auxiliary device at a loading station, and

[0122] Step 36 of loading the fifth auxiliary device with manufacturing items at a loading station.

[0123] Step 40 represents the detection by the first auxiliary device of a low battery level. As a consequence, the main device emits a request signal 50 for an energy supply.

[0124] Upon reception of the request signal 50 at an energy loading station, in step 60, the third auxiliary device is dispatched towards the main device. Thereafter the third auxiliary device travels in an autonomous mode towards the main device. Once the third auxiliary device reaches the main device, it docks at step 61 with the main device to supply the main device with electric power. At this stage the third auxiliary device and the first auxiliary device are simultaneously docked and electrically connected to the main device.

[0125] At step 62, the first auxiliary device undocks and disconnects from the main device. The first auxiliary device then moves in an autonomous mode towards the energy loading station. In step 63, the first auxiliary device reaches and docks to the energy loading station to load its electrical batteries.

[0126] At step 41, a low level of manufacturing items-below a first thresholdin the second auxiliary device is detected. As a consequence, the main device emits a request signal 51 for manufacturing items. Upon reception of the request signal 51 by the manufacturing items loading station, in step 64, the fifth auxiliary device is dispatched towards the main device. Once the fifth auxiliary device is in the vicinity of the main device, it remains in the vicinity of the main device without docking to the main device.

[0127] At step 42, a second threshold of manufacturing items-below the first thresholdin the second auxiliary device is reached. The second threshold may correspond to a situation in which no manufacturing item remains in the second auxiliary device. As a consequence, in step 34, the main device interrupts its manufacturing tasks and emits a replacing signal 52.

[0128] Upon receiving the replacing signal 52, the seventh auxiliary device undocks from the main device in step 65. The second auxiliary device leaves the synchronous mode and moves in autonomous mode towards the manufacturing items loading station. In step 67, the second auxiliary device reaches the manufacturing items loading station where it may be loaded automatically or manually.

[0129] After step 65, at step 66, the fifth auxiliary device docks to the main device to supply the main device with manufacturing items. The main device resumes, in step 35, its manufacturing tasks with the third auxiliary device and the fifth auxiliary device in the synchronous mode.

[0130] In FIG. 8A a first auxiliary device 11 according to the invention is represented, as well as a portion of a main device, in particular a portion of an interface panel 102 of the main device 10.

[0131] The auxiliary device 11 comprises mobility functions ensured at least in part by wheels and a processing unit adapted to control motors for actuating the wheel in order to be able to move autonomously between a loading station and the main device 10. The auxiliary device 11 comprises onboard electrochemical batteries to store electrical energy. Moreover, the auxiliary device 11 comprises an interface panel 112 which comprises a plug 113 adapted to connect to a corresponding socket 103 on an interface panel 102 of the main device 10. The auxiliary device 11 further comprises a camera 111 adapted to capture images and to deliver these images to the processing unit of the auxiliary device 11, such that a guiding method based for example on image recognition may be implemented for the auxiliary device 11 to move in autonomous mode. Moreover, the main device's interface panel 102 may comprise a target 101 in order to assist the guidance of the auxiliary device 11 in its approach with the main device. In particular the camera 111 of the auxiliary device 11 is adapted to capture images of the target 101 of the main device upon approaching the main device to dock to the main device.

[0132] In FIG. 8B, similarly, a second auxiliary device 12 is represented. This second auxiliary device 12 also comprises mobility functions ensured at least in part by wheels and a processing unit adapted to control motors for actuating the wheel in order to be able to move autonomously between a loading station and the main device 10. The auxiliary device 12 is adapted to store manufacturing items, such as rivets for example.

[0133] Moreover, the auxiliary device 12 comprises an interface panel 122 which comprises a plug or opening 123 adapted to connect to a corresponding socket or opening 108 on an interface panel 102 of the main device 10. The auxiliary device 12 further comprises a camera 121 adapted to capture images and to deliver these images to the processing unit of the auxiliary device 12, such that a guiding method based for example on image recognition may be implemented for the auxiliary device 12 to move in autonomous mode. Moreover, the main device's interface panel 102 may comprise a target 107 in order to assist the guidance of the auxiliary device 12 in its approach with the main device. In particular the camera 121 of the auxiliary device 12 is adapted to capture images of the target 107 of the main device upon approaching the main device to dock to the main device.

[0134] The main difference between the second auxiliary device 12 and the first auxiliary device 11 is that the interface panel 102 of the second auxiliary device 12 is connected to the auxiliary device 12 by a tube connection 124, such that the auxiliary device 12 may remain mobile with respect to the main device when connected to the main device.

[0135] Also, the second auxiliary device 12 comprises an opening 123 which is adapted to connect to the opening 108 of the main device in order to refill the main device with manufacturing items.

[0136] In FIG. 9, a main device 10 with the first auxiliary device 11 and the second auxiliary device 12 connected to it in synchronous mode is represented.

[0137] The first auxiliary device 11 is docked to the main device in a receptacle 21 of the main device so as to move with the main device in synchronous mode. The first auxiliary device 11 may deactivate its mobility functions such that it is displaced by the main device.

[0138] The second auxiliary device 12 is connected to the main device by its interface and tube connection 124. The second auxiliary device 12 is also in synchronous mode with the main device 10 but the second auxiliary device 12 uses its own mobility functions to move in synchronous mode with the main device.

[0139] The main device comprises at least one further receptacle 23 comprising an interface 104 with a socket 106 and a target 105 for receiving an additional auxiliary device, for example a second power storing and transporting auxiliary device.

[0140] The invention is not limited to the specific embodiments herein disclosed as examples. The invention also encompasses other embodiments not herein explicitly described, which may comprise various combinations of the features herein described.

[0141] It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. It is to be noted that the term or as used herein is to be interpreted to mean and/or, unless expressly stated otherwise.