Processing apparatus

Abstract

A replacement device of a processing apparatus includes a gripping device having a single first support member positionally fixed, a first gripping portion provided on the first support member to grip a holder not to rotate in a releasing direction when the processing member is removed from the holder, and a second gripping portion provided on the first support member apart from the first gripping portion to grip the holder not to rotate in a restricting direction when the processing member is attached to the holder, and a holding device having a single movable second support member, plural first holding portions provided on the second support member to respectively accommodate the processing member removed from the holder, and plural second holding portions provided on the second support member apart from the first holding portions to respectively accommodate the processing member that is to be attached to the holder.

Claims

1. A processing apparatus, comprising: a processing tool that includes a drive mechanism, a processing member that is vertically movable to a processing-target member and rotatable relative to the processing-target member by utilizing a driving force of the drive mechanism, and a holder that detachably holds the processing member through a restricting portion; a moving mechanism that includes an arm to which the processing tool is attached, and that can freely move the processing tool to the processing-target member by moving the arm; and a replacement device that can freely replace the processing member, wherein the replacement device comprises, a gripping device that includes a single first support member, the single first support member being immovably fixed relative to a floor, a first gripping portion that is immovably fixed relative to the floor and is provided on the first support member, and can freely grip the holder so as to prevent rotation of the holder in a loosening direction when the processing member is removed from the holder, and a second gripping portion that is immovably fixed relative to the floor and is provided on the first support member apart from the first gripping portion, and can freely grip the holder so as to prevent rotation of the holder in a fastening direction when the processing member is attached to the holder, the fastening direction being opposite to the loosening direction; and a holding device that includes a single movable second support member, a plurality of first holding portions that are provided on the second support member, and can freely and respectively accommodate the processing member removed from the holder, and a plurality of second holding portions that are provided on the second support member apart from the plurality of first holding portions, and can freely and respectively accommodate the processing member to be attached to the holder, wherein when the processing member is detached from the holder during replacement of the processing member, the second support member of the holding device is moved relative to the gripping device, thereby positioning the first support member of the gripping device to extend across both a corresponding one of the plurality of first holding portions and a corresponding one of the plurality of second holding portions, arranging the corresponding one of the plurality of first holding portions vertically below the first gripping portion, and arranging the corresponding one of the plurality of second holding portions vertically below the second gripping portion.

2. The processing apparatus according to claim 1, wherein the first gripping portion and the second gripping portion of the gripping device, and the processing-target member placed on a placement member are disposed within a movable range of the processing tool, the movable range of the processing tool being defined by movement of the arm by the moving mechanism.

3. The processing apparatus according to claim 1, wherein the processing apparatus is a friction stir welding apparatus, and the fastening direction is a rotation direction of the friction stir welding apparatus at a time of friction stir welding.

4. The processing apparatus according to claim 1, wherein the second support member of the holding device is rotatable about a center axis thereof and is disk-shaped, wherein the plurality of first holding portions are disposed on a first concentric circle to form a first circular line, the first concentric circle being disposed at a first radial distance from the center axis of the second support member, wherein the plurality of second holding portions are disposed on a second concentric circle to form a second circular line, the second concentric circle being disposed at a second radial distance from the center axis of the second support member, the first and second radial distances being different, and when the processing member is detached from the holder during replacement of the processing member, the second support member is rotated in a state where the first line is positioned vertically below the first gripping portion, and where the second line is positioned vertically below the second gripping portion, thereby feeding each of the plurality of first holding portions successively to be positioned vertically below the first gripping portion, and feeding each of the plurality of second holding portions successively to be positioned vertically below the second gripping portion.

5. The processing apparatus according to claim 4, wherein a straight line, connecting the first gripping portion and the second gripping portion, does not pass through a center axis of the second support member.

6. The processing apparatus according to claim 1, wherein each of the first gripping portion and the second gripping portion grips the holder according to an operation of a ratchet.

7. The processing apparatus according to claim 1, wherein the gripping device is elastically supported.

8. The processing apparatus according to claim 1, further comprising a pressing device that presses the processing member when the processing member is released from the holder, and that presses the processing member when the processing member is attached to the holder.

9. The processing apparatus according to claim 1, wherein the moving mechanism is an industrial robot.

10. The processing apparatus according to claim 1, wherein the first gripping portion comprises a first hole formed on the first support member and a first ratchet disposed within the first hole, and the second gripping portion comprises a second hole formed on the first support member and a second ratchet disposed within the second hole.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a side view of an overall configuration of a friction stir welding apparatus according to an embodiment of the present invention;

(2) FIG. 2 is a top view of a replacement device in the friction stir welding apparatus according to the embodiment;

(3) FIG. 3 is a schematic top view showing a range where the replacement device in the friction stir welding apparatus according to the embodiment is disposed;

(4) FIGS. 4A to 4C are process diagrams showing an operation of the replacement device in the friction stir welding apparatus according to the embodiment; and

(5) FIGS. 5A to 5C are process diagrams showing an operation of the replacement device in the friction stir welding apparatus according to the embodiment, and show steps subsequent to those shown in FIGS. 4A to 4C.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(6) A processing apparatus according to an embodiment of the present invention is explained in detail below with reference to the accompanying drawings while exemplifying a friction stir welding apparatus. In the drawings, an x-axis, a y-axis, and a z-axis constitute a three-axis orthogonal coordinate system. A plane defined by the x-axis and the y-axis is parallel to a horizontal plane. The direction of the z-axis is a vertical direction, and the positive direction of the z-axis is a vertically upward direction. The processing apparatus of the present invention is also applicable to processing apparatuses including a rotatable processing member that performs mechanical processing such as cutting, drilling, and grinding, in addition to the friction stir welding apparatus explained in the present embodiment.

(7) FIG. 1 is a side view of an overall configuration of the friction stir welding apparatus according to the present embodiment. FIG. 2 is a top view of a replacement device in the friction stir welding apparatus according to the present embodiment. FIG. 3 is a schematic top view showing a range where the replacement device in the friction stir welding apparatus according to the present embodiment is disposed.

(8) As shown in FIGS. 1 to 3, a friction stir welding apparatus 1 includes a replacement device 10 that is fixedly provided on a floor F, a welding tool 30 that can be freely arranged above and opposite to the replacement device 10, and a robot 50 that is fixedly provided on the floor F and holds the welding tool 30 by an attachment jig 52.

(9) Specifically, the replacement device 10 includes a gripping device 12 and a holding device 20. The gripping device 12 is disposed above the holding device 20.

(10) The gripping device 12 includes support legs 14 that are fixedly provided on the floor F, and a support plate 16 that is fixedly provided on the support legs 14. On the support plate 16, gripping holes 16a and 16b are provided, each of which passes through an upper surface and a lower surface of the support plate 16. A ratchet 16c is disposed for the gripping hole 16a, and a ratchet 16f is disposed for the gripping hole 16b. The support plate 16 is typically made of metal such as steel. However, the support plate 16 is not limited to having a plate shape, and can have other shapes, as long as the support plate 16 has necessary and sufficient strength and rigidity.

(11) Specifically, the ratchet 16c includes a rotary member 16d that is rotatable only in a clockwise direction on the x-y plane as viewed in the negative direction of the z-axis (hereinafter, clockwise direction), and that includes the gripping hole 16a as its inner peripheral hole, and a locking member 16e that can freely lock the rotary member 16d. That is, when the rotary member 16d is to rotate in the clockwise direction, the locking member 16e does not lock the rotary member 16d including the gripping hole 16a, and allows them to rotate. In contrast, when the rotary member 16d is to rotate in a counterclockwise direction on the x-y plane as viewed in the negative direction of the z-axis (hereinafter, counterclockwise direction), the locking member 16e locks the rotary member 16d including the gripping hole 16a, thereby prohibiting them from rotating.

(12) The ratchet 16f includes a rotary member 16g that is rotatable only in the counterclockwise direction, and that includes the gripping hole 16b as its inner peripheral hole, and a locking member 16h that can freely lock the rotary member 16g. That is, when the rotary member 16g is to rotate in the counterclockwise direction, the locking member 16h does not lock the rotary member 16g including the gripping hole 16b, and allows them to rotate. In contrast, when the rotary member 16g is to rotate in the clockwise direction, the locking member 16h locks the rotary member 16g including the gripping hole 16b, thereby prohibiting them from rotating.

(13) In the gripping device 12, it is preferable to dispose an elastic member 18 between the support legs 14 and the support plate 16. In such a case, the support plate 16 is elastically supported by the support legs 14. The elastic member 18 can be formed of a rubber member, or can be formed of a spring member and a damper member.

(14) The holding device 20 includes a shaft member 22 that is fixedly provided on the floor F, and a disk-shaped support plate 24 that is supported on the shaft member 22 to be rotatable about a center axis Z2 parallel to the z-axis by the driving of a motor or the like (not shown). On the support plate 24, a plurality of holding holes 24a and 24b are provided, each of which passes through an upper surface and a lower surface of the support plate 24. The support plate 24 is typically made of metal, such as steel. However, the support plate 24 is not limited to having a plate shape, and can have other shapes, as long as the support plate 24 has necessary and sufficient strength and rigidity.

(15) Specifically, the holding holes 24a are disposed in a circular line at equal spacing on the outer peripheral side of the support plate 24 on a circumference parallel to the outer periphery of the support plate 24. This circular line is arranged immediately vertically below the gripping hole 16a. When the support plate 24 is rotated about the center axis Z2, each of the holding holes 24a is fed to be successively positioned immediately vertically below the gripping hole 16a of the gripping device 12.

(16) Furthermore, the holding holes 24b are disposed in a circular line at equal spacing on the inner peripheral side of the support plate 24 on a circumference parallel to the outer periphery of the support plate 24. This circular line is arranged immediately vertically below the gripping hole 16b. When the support plate 24 is rotated about the center axis Z2, each of the holding holes 24b is fed to be successively positioned immediately vertically below the gripping hole 16b of the gripping device 12.

(17) The support plate 16 of the gripping device 12 is positioned to extend across and vertically above the circular line formed by the holding holes 24a and the circular line formed by the holding holes 24b.

(18) It is preferable to provide a straight line, connecting the center of the gripping hole 16a and the center of the griping hole 16b, to be displaced from the radial direction of the support plate 24 in order not to pass through the center axis Z2 of the support plate 24. The reason for this is as follows. In a case where the straight line, connecting the center of the gripping hole 16a and the center of the gripping hole 16b, passes through the center axis Z2 of the support plate 24, the gripping hole 16a and the gripping hole 16b are arranged in the radial direction of the support plate 24. Therefore, it is necessary to also arrange the holding hole 24a and the holding hole 24b in the radial direction of the support plate 24. However, when the straight line, connecting the center of the gripping hole 16a and the center of the gripping hole 16b, is provided to be displaced from the radial direction of the support plate 24 in order not to pass through the center axis Z2 of the support plate 24, it is not necessary to arrange the holding hole 24a and the holding hole 24b in the radial direction of the support plate 24. Therefore, the line formed by the holding holes 24a and the line formed by the holding holes 24b are provided close to each other in the radial direction of the support plate 24 by, for example, arranging one holding hole 24b between two holding holes 24a, and both the holding holes 24a and the holding holes 24b can be provided on an outer peripheral-end side of the support plate 24 in a concentrated manner. As a result, the number of the holding holes 24a to be disposed and the number of the holding holes 24b to be disposed can be respectively increased, and the number of probes 32 to be continuously replaced can be increased.

(19) From the viewpoint of the simplicity of making the configuration of the holding device 20 compact, the shape of the support plate 24 is preferably a disk shape. However, the shape of the support plate 24 is not limited to a disk shape, and can be a rectangular plate shape, for example. In a case where the support plate 24 has a rectangular plate shape, the holding holes 24a and the holding holes 24b are respectively disposed at equal spacing to form lines parallel to each other. In such a case, the support plate 24 is moved in a direction parallel to the horizontal plane by the driving of the motor or the like, and each of the holding holes 24a is fed to be successively positioned immediately vertically below the gripping hole 16a of the gripping device 12, and also each of the holding holes 24b is fed to be successively positioned immediately vertically below the gripping hole 16b of the gripping device 12.

(20) In the drawings, each of the holding holes 24a and 24b is shown in a mode of a through hole. However, each of them can be a recessed bottomed hole with its lower end closed. By providing a flange (not shown) on the probe 32, and setting the flange to be locked by an upper-end peripheral portion of each of the holding holes 24a and 24b, the probe 32 can be reliably held even when each of the holding holes 24a and 24b is a through hole.

(21) Preferably, the replacement device 10 further includes a pressing device 26. The pressing device 26 is fixed relative to the floor F by, for example, fixedly providing the pressing device 26 between the support legs 14 of the gripping device 12, and includes pressing members 26a and 26b, each of which is advanceable and retractable. The pressing device 26 does not necessarily include both the pressing members 26a and 26b, and can include either one of them.

(22) The welding tool 30 that is a processing tool is typically a cylindrical member made of metal, such as iron and extending in the vertical direction. The welding tool 30 includes the probe 32 that is rotatable about a center axis Z1 parallel to the z-axis and is vertically movable, and that serves as a processing member, a holder 34 that holds the probe 32, and a drive mechanism 33 that vertically moves the probe 32 held by the holder 34, and that rotates the probe 32 about the center axis Z1.

(23) The probe 32 is attached to the holder 34 through a restricting portion 32a that is coupled with a driving force of the drive mechanism 38. At the time of a normal operation of the friction stir welding apparatus 1 that performs friction stir welding, the probe 32 is vertically movable and rotatable with the holder 34 and the restricting portion 32a. In contrast, at the time of replacing the probe 32, the probe 32 is rotatable relative to the holder 34 through the restricting portion 32a.

(24) That is, at the time of the normal operation of the friction stir welding apparatus 1 that performs friction stir welding, the holder 34 and the restricting portion 32a do not rotate relative to each other, and a driving force of the drive mechanism 38 is transmitted to the probe 32 through the restricting portion 32a. The probe 32 rotates in the clockwise direction at the time of friction stir welding. In contrast, at the time of replacing the probe 32, the holder 34 and the restricting portion 32a rotate relative to each other. Therefore, according to the direction of their relative rotations, the probe 32 is fastened to/loosened from the restricting portion 32a, and is attached to/detached from the holder 34. The restricting portion 32a typically has a chuck structure such as a collet chuck structure. The drive mechanism 38 has a motor, a shaft, and the like (all not shown) incorporated in its casing 38a.

(25) The diameter of the gripping hole 16a of the gripping device 12 is set to provide a predetermined fastening margin relative to the diameter of the holder 34. When the holder 34 is inserted into the gripping hole 16a, the holder 34 is gripped by the gripping hole 16a without slipping through.

(26) Therefore, when the holder 34 with the probe 32 attached is inserted into the gripping hole 16a, and is to rotate in the clockwise direction, and accordingly the rotary member 16d is to rotate in the clockwise direction, the locking member 16e does not lock the rotary member 16d. Consequently, the gripping hole 16a that is the inner peripheral hole of the rotary member 16d is not locked, and is allowed to rotate, and thus the holder 34 is rotatable in the clockwise direction with the probe 32 and the restricting portion 32a. In contrast, when the holder 34 with the probe 32 attached is to rotate in the counterclockwise direction, and accordingly the rotary member 16d is to rotate in the counterclockwise direction, the locking member 16e locks the rotary member 16d. Consequently, the gripping hole 16a that is the inner peripheral hole of the rotary member 16d is locked, and is prohibited from rotating, and thus the holder 34 cannot rotate in the counterclockwise direction with the probe 32 and the restricting portion 32a. As a result, relative rotations are generated between the holder 34, and the probe 32 and the restricting portion 32a, and the probe 32 weakens the restricted state between the probe 32 and the restricting portion 32a, while rotating in the counterclockwise direction with the restricting portion 32a.

(27) Furthermore, when the holder 34 with the probe 32 not attached is inserted into the gripping hole 16b, and is to rotate in the counterclockwise direction, and accordingly the rotary member 16g is to rotate in the counterclockwise direction, the locking member 16h does not lock the rotary member 16g. Consequently, the gripping hole 16b that is the inner peripheral hole of the rotary member 16g is not locked, and is allowed to rotate, and thus the holder 34 is rotatable in the counterclockwise direction. In contrast, when the holder 34 with the probe 32 not attached is to rotate in the clockwise direction, and accordingly the rotary member 16g is to rotate in the clockwise direction, the locking member 16h locks the rotary member 16g. Consequently, the gripping hole 16b that is the inner peripheral hole of the rotary member 16g is locked, and is prohibited from rotating, and thus the holder 34 cannot rotate in the clockwise direction. As a result, relative rotations are generated between the holder 34 and the restricting portion 32a, and the probe 32, to be accommodated in and connected to the restricting portion 32a, strengthens the restricted state between the probe 32 and the restricting portion 32a.

(28) At the time of replacing the probe 32, the support plate 24 of the holding device 20 is rotated about the center axis Z2, and therefore the support plate 16 of the gripping device 12 is positioned to extend across and vertically above a corresponding one of the holding holes 24a and a corresponding one of the holding holes 24b. As a result, the corresponding one of the holding holes 24a is positioned immediately vertically below the gripping hole 16a, and also the corresponding one of the gripping holes 24b is positioned immediately vertically below the gripping hole 16b.

(29) The robot 50 is a moving mechanism that can freely move the welding tool 30, and is typically an industrial robot. Specifically, the robot 50 includes the attachment jig 52 that attaches the welding tool 30 thereto, an arm 54 that is typically a multijoint manipulator and has the attachment jig 52 attached thereto, and a robot body 56 that has a drive mechanism that moves the arm 54, a computing processing device, a memory, and the like (all not shown) incorporated therein. The casing 38a of the drive mechanism 38 of the welding tool 30 is attached and fixed to the attachment jig 52.

(30) As shown in FIG. 3, the gripping holes 16a and 16b of the gripping device 12, and a processing-target member W placed on a placement table 40 are arranged within a movable range L defined by the movement of the arm 54 of the robot 50 and showing a limited range where the probe 32 and the holder 34 of the welding tool 30 can be positioned.

(31) Various corresponding constituent elements in the friction stir welding apparatus 1 receive a control signal transmitted from a controller C, and are appropriately controlled, and also operate to perform friction stir welding on the processing-target member W, while automatically replacing the probe 32 as necessary. The controller C has a computing processing device, a memory, and the like (all not shown) incorporated therein. In the memory, a control program for replacing the probe 32 and performing friction stir welding, data regarding a predetermined processing direction, and the like are stored.

(32) Next, in the friction stir welding apparatus 1 having the above configuration, a replacement operation for automatically replacing the probe 32 is explained below in detail also with reference to FIGS. 4 and 5.

(33) FIGS. 4A to 4C are process diagrams showing an operation of the replacement device in the friction stir welding apparatus according to the present embodiment. FIGS. 5A to 5C are also process diagrams showing an operation of the replacement device in the friction stir welding apparatus according to the present embodiment, and show steps subsequent to those shown in FIGS. 4A to 4C.

(34) First, when the probe 32 is worn down or smeared after repeating a friction-stir welding step a predetermined number of times, the arm 54 of the robot 50 is moved to position the probe 32 of the welding tool 30 and the holder 34 with the probe 32 attached vertically above the gripping hole 16a of the gripping device 12, as shown in FIG. 4A. At this time, the support plate 24 of the holding device 20 is rotated to position an empty holding hole 24a, in which nothing is held, vertically below the gripping hole 16a, and also to position the holding hole 24b, in which a new probe 32 is held, vertically below the gripping hole 16b.

(35) Next, as shown in FIG. 4B, the drive mechanism 38 of the welding tool 30 is driven to vertically lower the probe 32 and the holder 34 with the probe 32 attached. After the probe 32 passes through the gripping hole 16a, the holder 34 enters into the gripping hole 16a to be gripped by the gripping hole 16a. In this state, when a driving force for generating rotations in the counterclockwise direction is applied to the probe 32 from the drive mechanism 38 through the restricting portion 32a, the holder 34 is gripped by the gripping hole 16a, and is prohibited from rotating. Therefore, the restricting portion 32a weakens the restricted state of the probe 32 relative to the restricting portion 32a, while rotating in the counterclockwise direction. When such a restricted state is then weakened completely, a driving force from the drive mechanism 38 is not coupled to the probe 32. Thereafter, the probe 32 drops off the holder 34 vertically downward by its weight.

(36) At this time, when the pressing member 26a of the pressing device 26 is advanced toward the probe 32 to press the probe 32, the probe 32 easily comes off the holder 34.

(37) Next, as shown in FIG. 4C, the probe 32 drops vertically downward by its weight, and is caught by an empty holding hole 24a of the holding device 20, and held therein. Simultaneously, the drive mechanism 38 of the welding tool 30 is driven to remove the holder 34 with the probe 32 detached from the gripping hole 16a, and to raise the holder 34. At this time, when the restricting portion 32a is first rotated in the clockwise direction, and is then rotated in the counterclockwise direction to apply an impact force to the holder 34, the holder 34 is easily removed from the gripping hole 16a.

(38) Next, as shown in FIG. 5A, the arm 54 of the robot 50 is moved to position the holder 34 with the probe 32 detached vertically above the gripping hole 16b of the gripping device 12. At this time, the holding hole 24b in which a new probe 32 is held is positioned vertically below the gripping hole 16b.

(39) Next, as shown in FIG. 5B, the drive mechanism 38 of the welding tool 30 is driven to vertically lower the holder 34 with the probe 32 detached to enter the holder 34 into the gripping hole 16b to be gripped by the gripping hole 16b. Also, the probe 32 held in the holding hole 24b is accommodated inside of the holder 34, and is connected to the restricting portion 32a to enter a state where a driving force from the drive mechanism 38 is coupled to the probe 32. In this state, when a driving force for generating rotations in the clockwise direction is applied to the probe 32 through the restricting portion 32a, the holder 34 is gripped by the gripping hole 16b, and is prohibited from rotating. Therefore, the restricting portion 32a strengthens the restricted state of the probe 32 relative to the restricting portion 32a, while rotating in the clockwise direction. After such a restricted state is strengthened completely, a driving force from the drive mechanism 38 is shut off to completely attach the probe 32 to the holder 34 through the restricting portion 32a.

(40) At this time, when the pressing member 26b of the pressing device 26 is advanced toward the probe 32 to press the probe 32, the probe 32 is reliably connected to the restricting portion 32a easily.

(41) Next, as shown in FIG. 5C, the drive mechanism 38 of the welding tool 30 is driven to raise the holder 34 with the probe 32 attached, in order to be prepared for the next friction stir welding. At this time, when the restricting portion 32a is first rotated in the counterclockwise direction, and is then rotated in the clockwise direction to apply an impact force to the holder 34, the holder 34 is easily removed from the gripping hole 16b.

(42) Furthermore, when the probe 32 is worn down and smeared after repeating the friction-stir welding step a predetermined number of times, the support plate 24 of the holding device 20 is rotated to position an empty holding hole 24a, in which nothing is held, vertically below the gripping hole 16a, and also to position the holding hole 24b, in which a new probe 32 is held, vertically below the gripping hole 16b, in order to repeat the above step of replacing the probe 32.

(43) In the present invention, the shape, the arrangement, the number, and the like of the members are not limited to those in the embodiment explained above, and it is needless to mention that the constituent elements can be modified as appropriate without departing from the scope of the invention, such as appropriately replacing these elements by other ones having identical operational effects.

(44) As described above, the present invention can provide a processing apparatus including a replacement device that can freely and automatically replace a plurality of processing members continuously in a manner of high-precision alignment between constituent components with a simple configuration in which the number of components is reduced. Therefore, because of its general purposes and universal characteristics, applications of the present invention are expected in a wide range in the field of machine processing such as friction stir welding of a strength member of a movable body such as an automobile.