Abstract:
An assembling apparatus and method easily applicable to an existing production line and capable of improving assembling quality and reducing equipment cost. The assembling apparatus performs processing such as part assembling or the like to a processed part which is free-flow conveyed by a processed part conveyor. The processing is performed by a robot which is conveyed in the same direction as the processed part by a robot conveyor having its own motor. The processed part conveyor is provided with a removable pallet for supporting the processed part. The robot conveyor comprises a turntable which mounts and rotationally positions the robot thereon, a pallet support provided on the turntable so that the removed pallet from the processed part conveyor is supported thereon, and a connector for connecting with the processed part conveyor to synchronously convey the same.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to a method and apparatus for assembling and manufacturing in which processed processing of a conveyed processed part is performed by a processing device which is conveyed in the same direction as the processed part. 
   Conventionally, there has been known a part assembling method in which a carriage for supporting and conveying an assembled body (vehicle body) is synchronously conveyed together with a movable table on which an assembling robot or the like is mounted. During this synchronous conveying, parts are assembled into the assembled body by the robot or the like in a state where the assembled body is supported on the side of the movable table. Then, the assembled body is returned, when the assembling operation is finished, to the original carriage to be conveyed (for example, see Patent reference 1). 
   Patent reference 1: Japanese patent application publication No. 61-146690. 
   In the part assembling method disclosed in Patent reference 1, however, the delivery of the vehicle body is directly performed between the carriage and the movable table, so that the vehicle body can easily be externally scratched. Also, since the synchronization between the carriage and the movable table is performed with pulse signals generated by pulse generators mounted on motors for the carriage and the movable table, rather than by a mechanical connection, it is not possible to continue to convey the carriage and the movable table when the synchronization controller suffers a breakdown. Further, since the conveying method of the carriage is required to be limited to a speed adjustable self-propelled method, it is difficult to apply to the existing production line. 
   The present invention is made in view of such problems of the conventional art and aims to provide a method of assembling production and an apparatus therefor easily applicable to the existing production line and capable of improving the assembling quality and reducing the equipment cost. 
   SUMMARY OF THE INVENTION 
   To solve the above mentioned problems, the present invention according to a first aspect is directed to an assembling method of processing, such as part assembling or the like, to a processed part which is free-flow conveyed by a processed part conveying mean. The part processing is provided by a processing device which is conveyed in the same direction as the processed part using a processing device conveying means, which has its own driving source. The method comprises a conveying means connecting step for connecting the processed part conveying means with the processing device conveying means, a processed part holding step for transferring the processed part from the processed part conveying means to the processing device conveying means while being synchronously conveyed, so as to position and hold the processed part on the processing device conveying means, a processing step in which the processing device processes the processed part while being synchronously conveyed, a processed part returning step for transferring and returning the processed part from the processing device conveying means to the processed part conveying means while being synchronously conveyed, and a conveying means connection releasing step for releasing the connection between the processed part conveying means and the processing device conveying means. 
   The invention according to a second aspect is directed to an assembling apparatus for processing, such as part assembling or the like, to a processed part which is free-flow conveyed by a processed part conveying means. The processing is performed by a processing device which is conveyed in the same direction as the processed part by a processing device conveying means having its own driving source. The processed part conveying means is provided with a removable pallet supporting the processed part, and the processing device conveying means comprises a turntable having the processing device mounted thereon to rotationally position the processing device, a pallet supporting means provided on the turntable for removing the pallet from the processed part conveying means so as to support the same, and a connector means for connecting with the processed part conveying means so as to synchronously convey the same. 
   The invention according to a third aspect is directed to an assembling production apparatus of the second aspect, wherein a floating mechanism and a centering mechanism in relation to the conveying direction are provided on the driving source of the processing device conveying means. 
   In the invention according to the first aspect, the processed part is transferred from the processed part conveying means to the processing device conveying means to be positioned and held thereon, so that the relative positional relationship between the processing device and the processed part is fixed so as to improve accuracy of the assembling and processing by the processing device. 
   In the invention according to the second aspect, the processing device conveying means has the pallet supporting means for removing the pallet from the processed part conveying means so as to support the same and the connector means connected with the processed part conveying means to synchronously convey the same. This allows the relative positional relationship between the processing device and the processed part to be fixed so as to improve accuracy of the processing by the processing device. 
   In the invention according to the third aspect, since the floating mechanism and the centering mechanism in relation to the conveying direction are provided on the driving source of the processing device conveying means, the driving source and peripheral parts are prevented from suffering damages even if the load is imposed thereon, when a power supply source is suddenly turned off and inertial conveying force is caused on the processing device conveying means and the processed part conveying means. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic plan view of an assembling production apparatus according to the present invention; 
       FIG. 2  is a schematic side view of the assembling production apparatus according to the present invention; 
       FIG. 3  is a plan view of a pallet support means; 
       FIG. 4  is a front view of the pallet support means; 
       FIG. 5  is a plan view of a connector means; 
       FIG. 6  is a side view of the connector means, wherein (a) shows a connected state and (b) shows a connection released state; 
       FIG. 7  is a plan view showing a floating mechanism and a centering mechanism of a motor; 
       FIG. 8  is a side view showing the floating mechanism and the centering mechanism of the motor; and 
       FIG. 9  is a flow chart showing an operation of the assembling production apparatus of the present invention and a process of an assembling production method of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Embodiments of the present invention will be explained hereunder with reference to accompanying drawings. Herein,  FIG. 1  is a schematic plan view of an assembling production apparatus according to the present invention,  FIG. 2  is a schematic side view thereof,  FIG. 3  is a plan view of a pallet support means,  FIG. 4  is a front view thereof,  FIG. 5  is a plan view of a connector means,  FIG. 6  is a side view thereof,  FIG. 7  is a plan view of a floating mechanism and centering mechanism of a motor,  FIG. 8  is a side view thereof, and  FIG. 9  is a flow chart showing an operation of the assembling production apparatus of the present invention and a process of an assembling production method of the present invention. 
   As shown in  FIG. 1  and  FIG. 2 , the assembling production apparatus of the present invention comprises a processed part conveying means  2  for having a processed part  1  mounted thereon to free-flow convey the same, and a robot conveying means processing device conveying means)  4  for having mounted thereon a robot  3  which applies processing such as part assembling or the like to the processed part  1 , so as to travel in the same direction as the processed part conveying means. Then, in this embodiments the processed part  1  is a door. Also, arrows shown in  FIG. 1  show the conveying direction of a pallet conveying carriage  6  and a robot conveying carriage  14 . 
   The processed part conveying means  2  has a pallet  5  which supports the processed part  1 , removably mounted on a pair of pallet bearing members  7  uprightly extending on front and rear sides of the pallet conveying carriage  6 . In the drawing, the processed part (door)  1  and the pallet  5  are shown in a phantom line. The pallet conveying carriage  6  has a plurality of rollers  8  provided on the lower side thereof and on right and left ends with respect to the direction of conveyance thereof. A guide rail  9  is fixedly provided along the lower center portion and in the direction of conveyance of the pallet conveying carriage. The processed part conveying means  2  free-flow carries the processed part  1  supported on the pallet  5  in such a state that the rollers  8  roll on rails  11  laid on a floor  10  in the direction of conveyance and the guide rail  9  moves while being held on both sides thereof by free-flow conveying rollers  12  arranged in the direction of conveyance. 
   The robot conveying means  4  comprises a robot conveying carriage  14 , a turntable  15  arranged on the robot conveying carriage  14  and mounting the robot  3  thereon to rotationally perform positioning of the robot, a pallet support means  16  provided on the turntable  15  to remove the pallet  5  from the processed part conveying means  2  so as to support the same, and a connector means  17  for synchronously conveying the processed part conveying means  2  in a mechanically connected state. A motor  18  serves as a driving source of the robot conveying means  4 . The motor  18  is provided with a floating mechanism  19  and a centering mechanism  20  in relation to the direction of conveyance. 
   The robot conveying carriage  14  has a plurality of guide members  21  arranged on the lower wall thereof and on right and left ends in the direction of conveyance. These guide members  21  are slidably engaged with rails  23  laid on both ends of a base  22 . Further, the motor  18  which projects a rotational spindle  18   a  from the lower wall thereof is uprightly fixed on the robot conveying carriage  14  through the intermediary of the floating mechanism  19  and the centering mechanism  20 , The rotational spindle  18   a  of the motor  18  has a pinion gear  24  mounted on the tip end thereof. The pinion gear  24  is in engagement with a rack  25  provided on the side wall of the base  22  in the direction of conveyance. 
   The turntable  15  is rotatably placed on the robot conveying carriage  14  so as to be fixed in a predetermined rotational position. The fixation in the predetermined position of the turntable  15  by being turned from the original position thereof is performed by pulling and inserting a lock pin  30  out of and into a fixing hole  30   a . Further, on the turntable  15  there is provided a robot mounting stand  31  for mounting the robot  3  thereon. As shown in  FIG. 3  and  FIG. 4 , the pallet support means  16  comprises a cylinder  35  fixed on the turntable  15 , a pallet support body  36  mounted on a rod  35   a  of the cylinder  35  so as to removably support the pallet  5 , a pair of rails  37  laid on the lower wall of the pallet support body  36  so as to extend parallel to the rod  35   a , and a plurality of guide members  38  slidably engaged with each of the rails  37 . The guide members  38  are fixed on the turntable  15 . The forward movement of the cylinder  35  allows the pallet  38  to be supported by the pallet support body  36  while the backward movement thereof allows the pallet support body  36  to move away from the processed part conveying means  2 . 
   The pallet support body  36  comprises a lifting table  40 , a pair of clamp claws  41  mounted on the lifting table  40  to clamp and fix lower portions  5   a  of the pallet  5 , two kinds of cylinders  42 ,  43  mounted on the lifting table  40  so as to operate each of the clamp claws  41 , a pair of cylinders  44  having the lifting table  40  moved upward and downward, a base plate  45  fixedly mounting the cylinders  44  and having the pair of rails  37  extended on the lower wall thereof, and pallet seating members  46  fixedly mounted on the lifting table so as to receive the pallet  5  on the lower side. A reference numeral  47  denotes a table for mounting the clamp claw  41 . 
   The cylinder  42  mounted on the lifting table  40  is the one for having the clamp claw  41  moved forward to and backward from the lower portion  5   a  of the pallet  5  by sliding the table  47  on which the clamp claw  41  is mounted. The cylinder  43  mounted on the table  47  is the one for pressing the clamp claw  41  against the lower portion  5   a  of the pallet  5  and releasing the same from the lower portion  5   a  of the pallet  5 . Then, the object that the pair of clamp claws  41  clamps is a plate member  5   b  provided on the lower portion  5   a  of the pallet  5 . The plate member  5   b  is fixedly secured to the back wall of the pallet  5 . The pair of clamp claws  41  enters a cutout formed on the center portion of the plate member  5   b  so as to clamp the edge of the cutout. 
   The sliding movement of the clamp claw  41  by the cylinder  42  is smoothly performed by a slide guide  48   a  fixedly provided on the table  47  and a slide rail  48   b  fixedly provided on the lifting table  40 . Further, the upward and downward movement of the lifting table  40  by the cylinder  44  is smoothly performed by a slide rail  49   a  fixedly provided on the lifting table  40  and a slide guide  49   b  fixedly provided on the base plate  45 . Herein, when the rod  35   a  of the cylinder  35  is in an advanced state, the pallet support body  36  and the pallet bearing members  7  uprightly provided on the front and rear of the pallet conveying carriage  6  are constructed not to interfere with each other. 
   The connector means  17 , as shown in  FIG. 5  and  FIG. 7 , is provided to connect the pallet conveying carriage  6  of the processed part conveying means  2  with the robot conveying carriage  14  of the robot conveying means  4  and comprises a cylinder  51  provided through an attachment member  50  on the edge of the robot conveying carriage  14 , a lock claw  54  mounted rotatably around a pivot  53  on a lock claw mounting member  52  which is attached to a rod  51   a  of the cylinder  51 , a spring  55  arranged between the lock claw  54  and the lock claw mounting member  52  so as to be contracted in the locking direction of the lock claw  54 , and an engaging member  56  provided on the pallet conveying carriage  6  to be engaged with a recessed engaging portion  54   a  formed on the lock claw  54 . A reference numeral  57  denotes a guide member of the cylinder  51 . 
   In the case where the rod  51   a  of the cylinder  51  is in an advanced state (the state ready for connection) and the robot conveying carriage  14  is in a stopped state or is behind the pallet conveying carriage  6 , the engaging member  56 , when the pallet conveying carriage  6  aligns with the robot conveying carriage  14 , comes into contact with a slant portion  54   b  of the lock claw  54  and then presses the lock claw  54  downward in opposition to the contracting force of the spring  55 , as seen in  FIG. 6(   a ). Next, when the lock claw  54  rotates around the pivot  53  so as to allow the engaging member  56  to come into engagement with the recessed engaging portion  54   a , the lock claw  54  returns to the original position under the contracting force of the spring  55 . Then, the pallet conveying carriage  6  is connected with the robot conveying carriage  14 . 
   In the case where the connection between the pallet conveying carriage  6  and the robot conveying carriage  14  is released, the rod  51   a  of the cylinder  51  is moved backward. As seen in  FIG. 6(   b ), when the rod  51   a  of the cylinder  51   a  is moved to the backward position, the lock claw  54 , the lock claw mounting member  52  mounting the lock claw  54  thereon, etc. move downward to have the engaging member  56  disengaged from the recessed engaging portion  54   a , so that the engaging member  56  is released from the locked state. Then, the pallet conveying carriage  6  is free-flow conveyed. Arrows in  FIG. 5  and  FIG. 6  show the direction of conveyance with respect to the pallet conveying carriage  6  and the robot conveying carriage  14 . 
   As shown in  FIG. 7  and  FIG. 8 , the floating mechanism  19  and the centering mechanism  20  of the motor  18  comprise a plate  60  for fixing the motor  18  thereon, four guide members  61  fixedly provided on four corners of the upper wall of the plate  60 , four rails  62  laid on the lower wall of the robot conveying carriage  14  to be slidably engaged with the guide members  61 , and a couple of cylinders  63 ,  64  in series connected with each other by connecting each end opposed to the rods  63   a ,  64   a.    
   Further, the rod  63   a  of the cylinder  63  is connected through a bracket  65  with the robot conveying carriage  14  while the rod  64   a  of the cylinder  64  is connected through a bracket  66  with the plate  60  on which the motor  18  is fixed. Moreover, the rod  63   a  of the cylinder  63  is in a forwardly moved position in its normal condition while the rod  64   a  of the cylinder  64  is in a backwardly moved position in its normal condition, Air under predetermined pressure is supplied to the cylinders  63 ,  64 . 
   Furthermore, on the robot conveying means  4  there is provided a lock mechanism  65  for locking the floating mechanism  19  and the centering mechanism  20  at the time of high speed traveling. 
   The lock mechanism  65  comprises a rotational roller  67  provided on a rod  66   a  of a cylinder  66  which is fixedly attached to the robot conveying carriage  14 , and a cam member  69  mounted on the end of the plate  60  through a bracket  68 . When the roller  67  comes into engagement with the cam member  69  in the advanced position of the rod  66   a  of the cylinder  66 , the floating mechanism  19  and the centering mechanism  20  are brought to the non-functional locked state. Herein, arrows in  FIG. 7  and  FIG. 8  show the conveying direction of the robot conveying carriage  14 . 
   Next, the operation of the assembling production apparatus of the present invention and an assembling production method of the present invention will be explained hereunder with reference to a flow chart shown in  FIG. 9 . 
   Firstly, in step SP 1  (conveying means connection step), when the robot conveying carriage  14  stands by in an original position, the pallet conveying carriage  6  mounting thereon the pallet  5  which supports the processed part  1  is free-flow conveyed so as to have the pallet conveying carriage  6  mechanically connected with the robot conveying carriage  14  by the connector means  17 . 
   Next, in step SP 2  (processed part holding step), when the pallet conveying carriage  6  is connected with the robot conveying carriage  14 , the robot conveying carriage  14  and the pallet conveying carriage  6  start to be synchronously conveyed by rotation of the pinion gear  24  engaged with the rack  25 , through driving operation of the motor  18 . At the same time that the synchronous conveyance starts, the rod  35   a  of the cylinder  35  of the pallet support means  16  goes forward to position the pallet support body  36  mounted on the rod  35   a  under the pallet  5  which is placed on the pallet bearing members  7  of the pallet conveying carriage  6 . 
   Then, the pair of cylinders  44  advances to move the pallet seating members  46  upward so that the pallet seating members  46  lift the pallet  5  up thereby to mount the pallet  5  on the pallet seating members  46 . After that, the pair of clamp claws  41  clamps the plate member  5   b  provided on the lower portion  5   b  of the pallet  5  by the operation of the cylinders  42 ,  43 . 
   Next, in step SP 3  (processing step), the robot  3  applies processing such as part assembling or the like to the processed part  1  supported on the positioned pallet  5  while synchronously conveying the robot conveying carriage  14  and the pallet conveying carriage  6 . At this time, since the robot  3  and the pallet  5  are positioned and fixed with reference to the same turntable  15 , the relative positional relationship between the robot and the processed part  1  is fixed thereby to maintain the predetermined processing accuracy 
   Then, in step SP 4  (processed part returning step), when the processing to the processed part  1  is completely applied by the robot  3 , the clamp of the plate member  5  by the pair of clamp claws  41  is released by the operation of the cylinders  42 ,  43  and, at the same time, the pair of cylinders  44  is backed to move the pallet seating member  46  downward so that the pallet  5  is placed on the pallet bearing members  7  instead of the pallet seating members  46 . 
   Next, in step SP 5  (conveying means connection releasing step), when the returning operation of the pallet  5  to the pallet conveying carriage  6  is completed, the rod  51   a  of the cylinder  51  of the connector means  17  moves backward to disengage the engagement between the engaging member  56  provided on the pallet conveying carriage  6  and the recessed engaging portion  54   a  of the lock claw  54 . Then, the pallet conveying carriage  6  is conveyed to the next stage by the free-flow conveying roller  12 . The robot conveying carriage  14  is returned to the original position by the operation of the motor  18  so that the processing (one cycle) to the processed part  1  is completed. The robot  3  stands by in the original position until the following pallet carriage  6  is conveyed. 
   On the other hand, on the motor  18  there are provided the floating mechanism  19  and the centering mechanism  20  in relation to the conveying direction. Therefore, the motor  18 , the pinion gear  24 , the rack  25  and peripheral parts can be prevented from suffering damages even if the load is imposed thereon, in the case where an electric power source for the motor  18  is suddenly turned off during operation and inertial conveying force is caused on the robot conveying carriage  14  and the pallet conveying carriage  6 . 
   INDUSTRIAL APPLICABILITY 
   According to the present invention, the processed part is transferred from the processed part conveying means to the processing device conveying means and held in position to fix the relative positional relationship between the processing device and the processed part, so that it is possible to provide the method of assembling production and the apparatus therefor that accuracy of the assembling processing by the processing device is improved.