Abstract:
An apparatus for attaching a clamp to a hose assembly, preferably automatic or semi-automatic, incorporates precisely located mounting devices for receiving clamp tooling, cooperating hose guiding and positioning tooling which can support a unique hose assembly and locate a predetermined location on such hose assembly properly aligned with a clamp in the clamp tooling. An operator only needs to load a clamp and a hose assembly into tooling, then initiate an automatic cycle which scrubs a small area on the hose, places a predetermined quantity (e.g. drop) of adhesive on that area, then brings the clamp into position and presses the clamp, adhesive, and hose together holding that position for a period sufficient to allow the adhesive to set. The operator then removes the finished part (the hose with attached clamp) and loads another clamp and hose into the tooling. The cycle optionally may terminate at the point where the adhesive is to be applied, that function then is initiated by an operator, and the cycle completed under automatic control. Interchangeable tooling provides quick setup in changing from one job to another, involving different sizes and/or types of clamps, and different sizes and shape of hose assemblies which require attachment of a clamp thereto.

Description:
RELATED APPLICATION  
       [0001]    This application is related to U.S. Provisional Patent Application S. No. 60/178,509 filed Jan. 28, 2000. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    This invention relates to apparatus to be utilized by an operator in an automated process of adhering a clamp, normally a circular metal clamp, to a tubular hose. In a production facility it is necessary to be able to precisely locate the hose end, scrub/roughen (e.g. prepare) a spot on the end region of the hose to which a clamp will be secured, place a metered amount of quick-setting adhesive on that region, move a clamp into precise position spaced from the adhesive and then press the clamp into position while the adhesive sets. The apparatus for accomplishing these steps must be precise, simple to use (e.g. to load and unload the clamps and hose), and have capability to accommodate a substantial variety of hose pieces and clamps with simple change of type specific tooling.  
         SUMMARY OF THE INVENTION  
         [0003]    Such an apparatus, according to this invention, is preferably automatic or semi-automatic, in that an operator is required to load a clamp and a length of hose into the tooling, then initiate an automatic cycle which scrubs a small area on the hose, places a predetermine quantity (e.g. drop) of adhesive on that area, then brings the clamp into position and presses the clamp, adhesive, and hose together holding that position for a period sufficient to allow the adhesive to set. The operator then removes the finished part (the hose with attached clamp) and loads another clamp and hose into the tooling. The cycle optionally may terminate at the point where the adhesive is to be applied, that function then is initiated by an operator, and the cycle completed under automatic control.  
           [0004]    The apparatus incorporates precisely located mounting devices for receiving clamp tooling, cooperating hose guiding and positioning tooling which can support a unique hose assembly and locate a predetermined location on such hose assembly properly aligned with a clamp in the other tooling. Use of the interchangeable tooling provides for quick setup of the apparatus in changing from one job to another, involving different sizes and/or types of clamps, and different sizes and shape of hose assemblies which, require attachment of a clamp thereto. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0005]    [0005]FIG. 1 illustrates a typical hose &amp; clamp assembly which is combined using the apparatus of invention;  
         [0006]    [0006]FIG. 2 is a frontal perspective view of a preferred embodiment of the apparatus;  
         [0007]    [0007]FIG. 3 is a side view of the apparatus;  
         [0008]    [0008]FIG. 4A is an enlarged perspective view, taken from the right and rear as viewed in FIG. 1, and FIG. 4B is a partial side view, showing details of the supports for the tooling,  
         [0009]    [0009]FIG. 5 is an enlarged perspective view of the tooling for holding a clamp and an end of a hose assembly to index the same;  
         [0010]    [0010]FIG. 6 is a side view of a hose end position tool or mandrel which cooperates with tooling shown in FIG. 5;  
         [0011]    [0011]FIG. 7 is a side view of the scrubbing tool;  
         [0012]    [0012]FIG. 8 is a side view of the adhesive dispenser,  
         [0013]    [0013]FIG. 9 is a side view of one of the height adjusting mechanisms which cooperate with the scrubbing tool shown in FIG. 7 and with the adhesive dispenser shown in FIG. 8;  
         [0014]    [0014]FIG. 10 is a front view of the height adjusting mechanism;  
         [0015]    [0015]FIG. 11 is a side view of the adhesive supply container,  
         [0016]    [0016]FIG. 12 is a top view of the adhesive supply container showing its removable top;  
         [0017]    [0017]FIG. 13 is a schematic diagram of the pneumatic control system for the apparatus;  
         [0018]    [0018]FIG. 14 comprises two electrical schematic diagrams, with notation, detailing the microprocessor control for the apparatus; and  
         [0019]    FIGS.  15 - 19  are the ladder logistics diagrams comprising the connections and instructions for the microprocessor control and the various switches, solenoids and position sensing switch contacts which make up the control system. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0020]    Referring to FIG. 1, a length of shaped tubing, specifically a shaped flexible rubber hose  10 , is fitted with metal clamp(s)  12  at predetermined spacings from one or more of its opposite ends  14 . The invention is applicable to hose or tubing of various sizes 4 , shapes and materials (hereinafter identified as a hose assembly), may include branches so an assembly has more than two ends, and the clamps may be metallic or other equivalent material and may be fitted to one or more ends of the hose assembly. The clamps  10  illustrated are of a well known pre-tensioned type which are latched in an open position prior to attachment to the hose. The clamps are usually released in later assembly operations when the ends of the tubing and clamp assembly are placed on ferrules or other connectors, so as to clamp the hose in that end position. Again, other types of clamps can be fitted to hose assemblies with the apparatus of this invention.  
         [0021]    The tubing or hose can have various inner and outer diameters, and various bends or curves which are unique to the intended installation of the completed hose assembly with attached clam. It is important that the clamps be properly spaced at a predetermined distance from the end of the hose to which it is attached, and that the clamp be in proper circular orientation with respect to the shape of the hoses or tubes making up the assembly. This assures that the clamp will be positioned over a ferrule or connector, and at a predetermined angular orientation, when it is installed in its intended environment to allow convenient release or operation of the clamp mechanism. Thus, it will be apparent that each hose and clamp assembly has a unique set of parameters for the alignment of clamp and hose before the clamp is adhered to the hose end.  
         [0022]    The overall apparatus for carrying out the automated operation of locating or indexing and preparing the hose end for adhesive application, and for locating a clamp in a properly aligned orientation and position, is illustrated in FIGS. 2 &amp; 3. A table  20  has a top  22  and a lower shelf  24 . The table is preferably of a somewhat wedge shape in plan view, with the forward end  25  of top  22  located at an operator&#39;s station S.  
         [0023]    Supported in the middle of table top  20  is a tool holder  30  which is adapted to receive various tooling which locates and supports a ring-like clamp to be attached, and also defines the receptor and indexer for a hose end. Typical such tooling is shown in FIGS.  4 - 6 . Forward of the tool holder is a hose locating tool  26  (FIG. 2) which is a part of the interchangeable tooling, and comprising an index base  27  secured to top  22 , an upward extending stand  28 , and a hose receptor  29 . Parts  28  and  29  are of unique shape and dimension according to the size, shape, and predetermined positioning of the hose in the apparatus.  
         [0024]    [0024]FIG. 5 shows the opposing sections  32 A and  32 B of a clamp receiver and carrier  34  which is supported on a movable plate  35  (FIGS. 4A &amp; B), and defines through the middle of carrier  34  a central cylindrical opening  36  having a counterbored opening  37  for receiving the periphery of a clamp such as shown in FIG. 1, and having upper and lower gaps  38  to embrace the clamp. Plate  35  is part of the tooling support and actuation shown in FIGS. 4A &amp; 4B as viewed from the back and side of table  20 .  
         [0025]    [0025]FIG. 6 illustrates the mandrel  40  and its surrounding stop ring  42  which mounts upon, and extends forward from, the rear vertical post  45  projecting upward from the base plate  46  of the tooling support structure, which base plate is secured to table top  22 . The nose  43  of mandrel  40  receives the open end of a hose and stop ring  42  defines an index point for positioning the hose end along its length, that is, along the Z axis of the hose end, by pushing the hose end against the stop ring.  
         [0026]    A horizontal positioning mechanism is supported on post  45 , and includes a pair of guided slide rods  48  and a pneumatic cylinder  52 . The rod  50  of cylinder  52  and the slide rods all extend forward to, and terminate in, the rear of a horizontally movable block  56 . Together these parts are the major parts of a reciprocating mechanism  54  carrying the main support plate  57  which extends upward above (and free from) base plate  46 . Block  56  is fastened to the back of a horizontally movable plate  57  of the clamping mechanism  60  which carries movable plate  35 . A bracket  58  at the top of plate  35  provides the attachment and support for the sections  32 A,  32 B of the clamp receiver with openings  36 ,  37  surrounding mandrel  40 .  
         [0027]    The clamping mechanism  60  comprises the front plate  35 , which is attached to a vertically acting pneumatic cylinder  65  having its rod ends  66  connected between upper and lower brackets  62  projecting forward from plate  57 . The body of cylinder  65  is attached to front plate  35 . Actuation of cylinder  65  causes limited vertical motion of plate  35  and the attached sections  32 A,  32 B of the clamp receiver  32 , between an upper position clear of the end of a hose on mandrel  40  (before a spot of adhesive is applied to the hose end), and a lower clamping position wherein the clamp is pressed against the glue spot on the hose end.  
         [0028]    In this function, the sections  32 A,  32 B have a clamping action against the hose end, and the mandrel  40  functions as an anvil supporting the inner portion of the hose end.  
         [0029]    Air under pressure is supplied to the pneumatic cylinder  52  through ports connections  52 A,  52 B to pressurize and/or vent the opposite chambers of the cylinder and produce the forward/rearward motion of the tooling. Similarly, air under pressure is supplied to the appropriate chambers of cylinder  65  to produce the up/down action of the tooling.  
         [0030]    Referring to FIG. 7, the scrubbing tool is shown as a conventional in-line rotary pneumatic driver  70  having a collet  72  on its drive shaft  73  to hold the scrubbing tool  75 . This tool comprises a base  76  and a frustoconical wheel array of fibers  77 . In an actual embodiment, the fibers are formed of carbon impregnated silicone strands.  
         [0031]    [0031]FIG. 8 shows the adhesive dispenser, in the form of a cylindrical body  80  with a cuplike part  82  at its bottom connected to an adhesive supply tube  84  extending from a source of adhesive under pressure (later described). A solenoid operated valve  85  controls flow from tube  84  into part  82 , which in turn is fitted with a tapered nozzle  87  (preferably replaceable) from which a controlled quantity of adhesive is dispensed onto the end of a hose supported on mandrel  40 .  
         [0032]    The scrubbing tool and the adhesive dispenser are supported on a horizontally extending slide way  90  (FIGS. 2 &amp; 3) above and extending transversely to mandrel  40 . A pair of separate but similar support brackets  91  and  92  are mounted upon a slide way  94  (FIG. 3), spaced apart a predetermined distance such that one or the other can be located over the center of the clamp tooling, or at a center location where each is located on opposite sides of that center.  
         [0033]    The support brackets  91 ,  92  each include a vertically extending back plate  95  and an arm  96  extending rearward and downward of plate  95  and having a horizontally extending slide  97  at its bottom, spaced rearwardly of plate  95 . The lower portion of plate  95  and the bottom of slide  97  are mounted to slide way  90 . Upper and lower blocks  100  and  101  extend forward from plate  95  and carry between them spaced apart vertically arranged rods  102  which form a guide for an L-shaped carrier bracket  105  which has a receiving/mounting aperture  106  in its horizontal section  107  that embraces and holds the dispenser body  80  (on one bracket) and the body  70  of the scrubber driver (in the other bracket).  
         [0034]    The vertical section  108  of the carrier bracket has spaced apart crossbars  110  which have appropriate holes for receiving rods  102  and forming a vertically adjustable restraint for bracket  105 . A threaded rod  112  with an adjustment knob  113  extends through block  100  and is seated in block  101 , and has a treaded connection to internal threads in one or both of cross-bars  110 . Rotation of knob  113  will cause raising or lowering of bracket  105  to set the operating level of the scrubbing tool  75  and the level of the adhesive dispensing nozzle  87 .  
         [0035]    Supported on shelf  24  is an enclosed adhesive reservoir  120  (FIGS. 2, 3,  11  &amp;  12 ). This reservoir acts as the supply source for liquid adhesive, and comprises a closed body  122  including a removable cover  124  held in sealed relation to the body by several screw-type clamps  125 . A compressed air fitting  126  is fitted to cover  124  to allow pressurizing the reservoir interior, and cover  124  includes a depending intake tube (not shown) which is connected to the bottom of an adhesive outlet fitting  127  and has a ferrule at it exterior for attachment of an adhesive supply tube  128  which leads to the dispenser body  80 . In practice, it is preferred that the adhesive storage include an open top pot (not shown) set within reservoir body  122 , into which the intake tube descends. Normal operating pressure in reservoir  120  is in the order of 5 p.s.i.  
         [0036]    [0036]FIG. 13 illustrates schematically the pneumatics of the apparatus. The compressed air supply may be from any suitable source; in a manufacturing environment this often a “shop air” connection which supplies compressed air in sufficient volume at a pressure in the order of 90 p.s.i. The inlet air is routed through a filter and pressure regulator module, and then to the adhesive (glue) reservoir  120  and through a dump valve module to a) a further regulator which has its output connected through an oiler to the buffer motor  70  and to the various pneumatic cylinders (previously described) including the clamping head.  
         [0037]    The apparatus is semi-automated under the control of a digital microprocessor. In an actual embodiment, an Allen-Bradley Micrologix 1000 microprocessor is employed, as shown in FIG. 14. On the left side of FIG. 14 is a power supply control circuit, including manually operated Right &amp; Left optical switches (LOS &amp; ROS) which must be actuated simultaneously to initiate an operating cycle. The physical spaced apart location of these is shown in FIGS. 2 and 3. Normally (and in this case) these switches are operated by an operator placing right and left index fingers in the switch housings. The angularly mounted box  130 , to the left and behind slide way  90 , houses the manually operated switches marked control power ON, power OFF, and cycle reset CR The hand (palm) actuated switch ER is an emergency stop switch that, when actuated by the operator, causes all air pressure in the system to be dumped, immediately disabling and stopping the apparatus.  
         [0038]    [0038]FIG. 14 also illustrates (right side) the pin connections for the microprocessor, and the related notations identify the mechanical functions of the apparatus which are under this control. FIGS.  15 - 19  together illustrate sequential step-by-step control functions of the processor. The notations on these drawings provide a fill description of the control system in detail which is sufficient to fully describe the same in detail sufficient to allow one skilled in this art to reproduce the system.  
       Set Up of the Apparatus  
       [0039]    Each time a new part is to be assembled, tooling corresponding to the hose and clamp of the part must be affixed to the assembly apparatus. These include a mandrel, clamp receiver/carrier, and hose locating tool. In addition, the height of the scrubber and adhesive nozzle must be adjusted to new elevations dictated by the job specification. The timing of the opening of the solenoid glue dispenser valve  85  is set into the processor control to achieve the desired size of glue “spot” for the particular job. The apparatus is slowly moved through an initial cycle with a hose and a clamp in place, and the alignment of mandrel  40  and the clamp holders  32 A,  32 B are adjusted as necessary, then these parts are tightened into position. The height of glue nozzle is adjusted to assure the glue “spot” will be properly placed on the end of the hose, and the scrubber functions is visibly checked for accuracy of its alignment and action on the hose end where the “spot” is to be placed. The processor is adjusted for the desired time the clamping action is maintained, and for the response time of the emergency stop (air pressure dump) operation. Once these adjustments are complete, the operator may begin assembly operation.  
         [0040]    In a fully automatic mode, to run the desired quantity of a job order the operator has only to supply a hose and a clamp into the tooling (alignment is assured by the placement of the tooling), initiate the operating cycle using the two optical switches, and remove the hose-clamp assembly when the cycle is finished. The system is also capable of operating in a semi-automatic mode, wherein the operation of glue spot deposit is controlled by a foot treadle actuated switch TS (FIGS. 2 &amp; 3) which is then connected independently of the automatic cycle controller. In that case, the apparatus functions up to the point where the control is ready to actuate the glue spot valve, and then halts. When the operator actuates the treadle switch, the solenoid valve  80  opening is initiated, and the apparatus completes the cycle.  
         [0041]    The method described, and the forms of apparatus for effecting this method, constitute preferred embodiments of this invention, but the invention is not limited to this method and apparatus. Changes may be made in either without departing from the scope of the invention.