Abstract:
A method of detecting failure to tighten screws against works includes steps of detecting every screw tightening operation against a work after start of a screw tightening step, counting the number of times of the screw tightening operations detected in the previous step, detecting the completion of the screw tightening step, and comparing a counted value at the time of the completion of the screw tightening step with a predetermined value, thereby informing of a result of comparison. A device for carrying out this method includes a current relay responsive to a large load current during the tightening operation of an electric screwdriver in a screw tightening step, a presettable counter for counting the number of operations of the current relay for the purpose of counting the number of screw tightening operations, setting knobs operated for setting a desirable number of screws to be tightened, photoelectric switches for detecting completion of the screw tightening step for the work, and an alarming device for comparing a counter value obtained by the presettable counter and the value set by the knobs when a screw tightening work completion signal is generated by any one of the photoelectric switches. The alarming device includes a buzzer energized when counted value does not reach the preset value set at the presettable counter.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a method of detecting failure to tighten screws against works and a device therefor, suitable for preventing occurrence of failure to tighten the screws in working step for tightening the screws against the works. 
     In an assembly line for electrical equipments, for example, various parts are mounted on an electrical equipment body as work by means of screws in a plurality of working steps. Generally, a worker in charge for each step tightens the previously allotted number of screws against each electrical equipment body sequentially conveyed along the assembly line with a tool such as an electric screwdriver or pneumatic screwdriver. 
     Whether or not the screws are correctly tightened against each work depends upon the degree of skillfulness and carefulness of the worker. Accordingly, it is inevitable that the failure to tighten the screws occurs at a certain rate. Particularly, various types of one electrical equipment have recently been produced in a small number in order that a diversity of consumers&#39; needs can be met. In such circumstances, the number of screws to be used differs from one type of the electrical equipment to another and positions where the screws are tightened are changed with design changes even in one type. Accordingly, contents of work in the screw tightening step are also changed at relatively short intervals. Consequently, the workers cannot sometimes cope with the changes in the work contents, which has caused frequent occurrence of failure to tighten the screws. Conventionally, the products are checked in a final inspection at the assembly line. However, the products are visually inspected, which inevitably causes oversight. 
     SUMMARY OF THE INVENTION 
     Therefore, an object of the present invention is to provide a method of detecting failure to tighten screws and a device therefor, wherein upon occurrence of failure to tighten screws against the works in a work step of tightening the screws against the works with a tool, the failure can be immediately informed. 
     In order to achieve the object, the invention provides a method of detecting failure to tighten screws against works, comprising a first step of detecting every screw tightening operation against a work with a screw tightening tool after start of a screw tightening step, a second step of counting the number of times of the screw tightening operations detected in the first step, a third step of detecting the completion of the screw tightening step, and a fourth step of comparing a counted value at the time of the completion of the screw tightening step with a predetermined value, thereby informing of a result of comparison. 
     The invention also provides a device for detecting failure to tighten screws against works, comprising means for confirming a period for which a work step for tightening a plurality of screws against a work with a screw tightening tool is executed, counting means for counting the number of times of screw tightening operations in the confirmed period, and means for comparing the result of the counting by the counting means with a predetermined value, thereby informing of a result of comparison. 
     The invention may also be practiced by a device for detecting failure to tighten screws against works, comprising first detection means for detecting every screw tightening operation against a work with a screw tightening tool after start of a screw tightening step, thereby generating status signals, counting means for sequentially receiving the status signals generated by the first detection means to thereby count the number of the status signals, second detection means for detecting completion of the screw tightening step, thereby generating a completion signal, comparison means for comparing a counted value obtained by the counting means at the time of generation of the completion signal by the second detection means with a predetermined value, and means for informing of the result of comparison by the comparison means. 
     In the case where N (natural number) screws are tightened against the work, &#34;N&#34; is selected as a set value corresponding to the number of screws. In the screw tightening step, the counting means automatically counts the number of operations of the tool for tightening the screws. When the counting result at the time of completion of the screw tightening step differs from the set value &#34;N,&#34; an alarming operation is performed. More specifically, the counting result does not reach the set value &#34;N&#34; owing to occurrence of failure to tighten any screws in the work step in which N screws need to be tightened. Consequently, the alarming operation is automatically performed. 
     The screw tightening tool may preferably include an electric tool and the first detection means may preferably comprise a current detector generating the status signal when the value of a load current supplied to the electric tool for tightening the screws exceeds a predetermined value. 
     Furthermore, the screw tightening tool may include a pneumatic tool having an operation member allowing and disallowing compressed air to flow thereto and the first detection means may comply a switch generating the status signal in response to an operation of the operation member of the pneumatic tool. 
     The second detection means may preferably be disposed on the assembly line along which works against which the screws are tightened are conveyed and generate the completion signal when the work passes a predetermined position on the line. 
     Preferably, the second detection means may also comprise a support on which the work against which the screws are tightened is placed and a switching element mounted on the support for responding to the placement of the work on the support. 
     Preferably, the second detection means may further comprise a holding member for holding a tool for tightening the screws at a standby position and a switching element mounted on the holding member for responding to the detachment of the tool from the holding member. 
     Other objects of the present invention will become obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the accompanying drawings: 
     FIG. 1 is an electrical circuit diagram employed in a first embodiment of the invention; 
     FIG. 2 a perspective view of a detecting device in accordance with the first embodiment; 
     FIGS. 3(a) to 3(l) are time charts for explaining the operation of the detecting device; 
     FIG. 4 is a view similar to FIG. 1 showing a second embodiment of the invention; 
     FIG. 5 is a longitudinal section of the major part of the detecting device in accordance with the second embodiment; 
     FIG. 6 is a perspective view of the major part of a third embodiment of the invention; 
     FIG. 7 is a perspective view of the major part of a fourth embodiment of the invention; and 
     FIG. 8 is a perspective view of the detecting device in accordance with a sixth embodiment of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A first embodiment of the present invention will now be described with reference to FIGS. 1 to 3(a)-3(l) of the accompanying drawings. Referring to FIG. 2, an assembly line 1 for electrical equipments such as microwave ovens is provided with a belt conveyor 2 driven at a predetermined speed. Works such as electrical equipment bodies 3 are sequentially conveyed by belt conveyor 2. For the purpose of confirming a period of a screw tightening work by detecting the completion of a screw tightening step, a displacement detecting device is provided at one of sides of belt conveyor 2 for detecting the displacement of electrical equipment body 3. The displacement detecting device comprises first and second reflection type photoelectric switches 4 and 5 disposed with a predetermined distance therebetween in the direction in which electrical equipment bodies 3 are sequentially conveyed on belt conveyor 2. The distance between photoelectric switches 4 and 5 is determined to be shorter than the dimension of electrical equipment body 3 in the direction in which it is conveyed on belt conveyor 2. Each of photoelectric switches 4 and 5 is of the built-in contact type. Photoelectric switch 4 disposed at the upper side has a normally closed sensor contact 4a (see FIG. 1) which is opened when electrical equipment body 3 being conveyed on the belt conveyor 2 is detected. Photoelectric switch 5 has a normally open sensor contact 5a (see FIG. 1) which is closed when electrical equipment body 3 is detected. Cables 4b and 5b for drawing outputs from contacts 4a and 5a are connected to photoelectric switches 4 and 5 at one ends and to plugs 4c and 5c at the other ends, respectively. 
     A detecting device body 6 is provided in the vicinity of belt conveyor 2 of assembly line 1. Detecting device body 6 is provided, at one side thereof, with jacks 4d and 5d to which plugs 4c and 5c are coupled. A door 6a is provided for closing the front opening of detecting device body 6. A twin plug socket 7, reset button 8 and counter unit 9 as counting means are mounted on the outer side of door 6a and an alarming buzzer 10 is mounted on the inner side thereof. 
     A power supply plug 11a of an electric screwdriver 11 as a tool for tightening screws is inserted into one of the plug sockets of twin plug socket 7. Electric screwdriver 11 comprises a body portion 11b which is held by a worker so that the worker performs the screw tightening job with screwdriver 11. A switch knob 11c of a power supply switch (not shown) is mounted on the body portion 11b. Knob 11c is operated so that power supply switch is closed, thereby driving an electric motor (not shown) provided within body portion 11b. Since twin plug socket 7 is employed, two electric screw drivers having different tightening torques may be used together. Two reset switches 8a and 8b (see FIG. 1) are mounted on the inner side of door 6a of detecting device body 6. Reset switches 8a and 8b are combined with reset button 8 such that both switches are opened when reset button 8 is depressed. 
     Counter unit 9 comprises a presettable counter 12 and a power supply section (both shown in FIG. 1). Presettable counter 12 comprises setting knobs 12a and 12b for setting a two digit preset value Ns and a display 12c each digit of which is formed from seven segments each consisting of one light-emitting diode. Display 12c is externally operated to selectively display the digital preset value Ns or a digitized value Nr counted by counter 12. Detecting device body 6 is supplied with electrical power from a AC power source through a power supply plug 14. 
     Various control equipments such as a relay, current relay and timer are provided within alarming device body 6. The arrangement of a control circuit including these control equipments, counter unit 9 and so on will be described with reference to FIG. 1. A DC power (100 V, for example) is supplied through a pair of power supply lines 15 and 16 and plug 14. Plug socket 7 is connected to a current relay 17 as a current detector between power supply lines 15 and 16. Consequently, when plug 11a of electric screwdriver 11 is connected to plug socket 7, electric screwdriver 11 may be energized. Upon energization of electric screwdriver 11, a load current is caused to flow through current relay 17. Current relay 17 is provided for detecting a starting current as the load current flowing into the built-in motor of screwdriver 11. In the case where the motor of screwdriver 11 draws approximately 0.75 amps. at start-up, for example, current relay 17 is operated to close normally open relay switch 17a when a current of 0.5 amps. or more is drawn. 
     Counter unit 9 is connected between power supply lines 15 and 16. Counter 12 of the counter unit is adapted to count up one step every time a voltage signal is stepped down after the voltage signal is supplied to a clock terminal CK. Counter 12 is adapted to initialize the counted value when the voltage signal is supplied to a reset terminal R. Counter 12 has a normally open counter switch 12d and a normally closed counter switch 12e. When the counted value Nr reaches the preset value Ns, switch 12d is closed and switch 12e opened. 
     A first relay 18 is connected in series to a relay switch 17a of current relay 17 and a normally closed timer contact 19a of a timer 19 between power supply lines 15 and 16. First relay 18 has three normally open relay switches 18a, 18b and 18c. Relay switch 18a is connected in parallel with relay switch 17a of current relay 17. Relay switch 18b is connected between power supply line 15 and the clock terminal CK of counter 12. Timer 19 is connected in parallel with first relay 18. Timer 19 is adapted to open timer contact 19a thereof when energization thereof is continued for a predetermined period T (1.5 seconds, for example). Period T is set so as to be a little longer than a period necessary for tightening a screw with the screwdriver 11. 
     A second relay 20 is connected in series to sensor contacts 4a and 5a between power supply lines 15 and 16. Second relay 20 has three normally open relay switches 20a, 20b and 20c. Relay switch 12a is connected between power supply line 15 and the reset terminal R of counter 12. 
     A third relay 21 is connected in series to relay switch 18c of first relay 18, a normally closed relay switch 22a of a fourth relay 22 described later, and reset switch 8a between power supply lines 15 and 16. Relay 21 has three normally open relay switches 21a, 21b and 21c. Relay switch 21a is connected in parallel with relay switch 18c of first relay 18. 
     Fourth relay 22 has a normally closed relay switch 22b as well as relay switch 22a. Fourth relay switch 22 is connected in series to counter switch 12d of counter 12, relay switches 20b, 21b and 22b between power supply lines 15 and 16. 
     An alarm buzzer 10 is connected in series to counter switch 12e of counter 12, relay switches 20c and 21c and reset switch 8b between power supply lines 15 and 16, which series circuit constitutes an alarm circuit 23. 
     Operation of the above-described arrangement will now be described with reference to FIG. 4 as well as FIGS. 1 and 2. In the case where four screws are to be tightened against each work with electric screwdriver 11 in the screw tightening step, the preset value Ns of counter 12 is set at &#34;4.&#34; Display 12c may be switched so as to display the preset value Ns for confirmation thereof and need be switched again so as to display the counted value Nr after confirmation. 
     When first reflection-type photoelectric switch 4 detects electrical equipment body 3 conveyed on the belt conveyor 2, sensor contact 4a of the photoelectric switch is opened, thereby detecting start of the screw tightening step. Subsequently, when electric screwdriver 11 is driven so that a first screw is tightened against a predetermined position of electrical equipment 3 (at time t1 in FIG. 3), a large starting current of approximately 0.7 amps. flows into built-in motor of screwdriver 11, thereby determining that the screw tightening operation has been performed. Upon detection of the starting current, current relay 17 causes relay switch 17a to be closed. Consequently, first relay 18 is energized with the result that relay switches 18a, 18b and 18c are closed (at time t2). In response to closure of relay switch 18a, first relay 18 is maintained in the self-holding state and timer 19 is continuously energized in response to the self-holding state of relay 18. Timer contact 19a is opened after timer 19 is energized for the predetermined period T, thereby releasing relay 18 from the self-holding state (at time t3). Consequently, since relay contact 18b is opened and then closed, that is, since the voltage applied to clock terminal CK of counter 12 is stepped down, counter 12 counts up one step at time t3 when relay switch 18b is opened. As described above, third relay 21 is energized to thereby close relay switches 21a, 21b and 21c at time t2 when relay switch 18c is closed. Third relay 21 is maintained in the self-holding state owing to closure of relay switch 21a. 
     When the screw is tightened against electrical equipment body 3 by electric screwdriver 11, the load current flowing into the motor of screwdriver 11 varies as shown in FIG. 3(c). More specifically, upon start of drive of screwdriver 11, the relatively large starting current of approximately 0.7 amps. temporally flows into the motor of screwdriver 11. Thereafter, when the screw tightening is completed, a lock current of approximately 0.5 amps. is drawn. Accordingly, relay switch 17a of current relay 17 the operative current of which is set at 0.5 amps. could be closed when the lock current is drawn. As a result, counter 12 counts up at the occurrence of the lock current and there is the possibility that the counted value Nr does not correspond to the number of screws tightened against the work. However, first relay 18 is maintained in the self-holding state such that counter 12 counts up by one step, until the period T set in timer 19 elapses, the period T being set so as to be a little longer than the period necessary for tightening one screw with the screwdriver. Consequently, the counted value Nr corresponds to the number of screws tightened with screwdriver 11. 
     Relay 18 is thus operated by timer 19 every time the screw tightening operation is executed. Counter 12 counts up by one step every time relay 18 is operated. When the counted value Nr of counter 12 reaches the preset value Ns or &#34;4&#34; or when the necessary number of screws are tightened, counter switch 12d is closed and counter switch 12e is opened (at time t4). On the other hand, electrical equipment body 3 is further conveyed on belt conveyor 2 and detected by second photoelectric switch 5. Sensor contact 5a of photoelectric switch 5 is closed to thereby detect the completion of the screw tightening step. Since the distance between photoelectric switches 4 and 5 is set so as to be shorter than the dimension of electrical equipment body 3 in the direction in which it is conveyed on belt conveyor 2, sensor contact 4a of first photoelectric switch 4 is still opened. When electrical equipment 3 is further conveyed on belt conveyor 2, sensor contact 4a of first photoelectric switch 4 is closed at time t5 corresponding to the time of completion of the screw tightening step. Then, both of sensor contacts 4a and 5a are closed and second relay 20 is energized, thereby closing relay switches 20a and 20b. Counter 12 is initialized when relay switch 20a is closed. Relay switch 21b of third relay 21 which is still in the self-holding state is in the on-state and counter switch 12d is closed. Consequently, fourth relay 22 is energized when relay switch 20b is closed. Then, since relay switches 22a and 22b are opened, third relay 21 is released from the self-holding state and second relay 22 is deenergized, thereby restoring the initial state. Since counter switch 12e is opened, alarm buzzer 10 is not energized even when relay switch 20c is closed, that is, alarm buzzer 10 is not driven when necessary four screws are tightened against electrical equipment 3, with the result that electrical equipment 3 is successively conveyed on belt conveyor 2. 
     On the contrary, when all the screws are not tightened against electrical equipment 3 by the worker&#39;s mistake, counter switch 12d remains open and counter switch 12e remains closed. Accordingly, even when relay switch 20b is closed in response to energization of second relay 20 at the time of completion of the screw tightening step or when sensor contact 4a is re-closed, fourth relay 22 is not energized with the result that third relay 21 is maintained in the self-holding state. Consequently, when relay switch 20c of second relay 20 is closed, alarm buzzer 10 is energized through counter switch 12e, relay switches 20c and 21c and reset switch 8b, thereby informing of the occurrence of failure in the screw tightening. Upon alarming operation of buzzer 10, the worker can tighten one or more screws which have not tightened. Upon the alarming operation, reset button 8 is depressed to open reset switches 8a and 8b, whereby third relay 21 is released from the self-holding state and alarm buzzer 10 is deenergized, thereby restoring the initial state. 
     According to the above-described embodiment, when all the screws are not tightened in the work step of tightening necessary number of screws against the electrical equipment 3, alarm buzzer 10 is immediately driven in the work step to thereby inform the worker of the occurrence of a failure. Consequently, such occurrence of the failure to tighten the screws against the electrical equipment 3 may safely be coped with. Furthermore, since the automatic execution of the alarming operation necessitates only the setting of the necessary number of screws as the preset value Ns in counter 12, the screw tightening efficiency is not reduced. 
     FIGS. 4 and 5 illustrate a second embodiment of the invention. Although the screws are tightened against the electrical equipments 3 conveyed on belt conveyor 2 in the foregoing embodiment, the invention may be applied to a screw tightening step in which jigs are employed. Referring to FIG. 5, an electrical equipment panel 24 as a work is placed on a holding jig 25. A plurality of boss portions 24a are formed in panel 24. A necessary number of screws 27 is engaged with boss portions 24a so that, for example, a printed wiring board 26 is secured. A normally closed limit switch 28 serving as means for generating a screw tightening completion signal is mounted on jig 25 for the purpose of confirming the period necessary for the screw tightening step. Limit switch 28 is opened when panel 24 is placed on jig 25. 
     Limit switch 28 is connected between power supply lines 4 and 5 through second relay 20 within alarming device body 6, as shown in FIG. 4. Provision of limit switch 28 eliminates first and second photoelectric switches 4 and 5 from alarming device body 6 in the foregoing embodiment. Connection of limit switch 28 is made by means of jack 4d of detecting device body 6 and jack 5d is short-circuited by, for example, a plug adapter (not shown). 
     The predetermined number of screws 27 is set at counter 12 as the preset value Ns. In the condition that panel 24 is placed on jig 25, limit switch 28 is opened and accordingly, second relay 20 is deenergized. During deenergization of second relay 20, counter 12 counts up by one step every time one screw is tightened with electric screwdriver 11. When the necessary number of screws are tightened, counter switch 12d is closed and counter switch 12e is opened. Thereafter, when panel 24 is removed from jig 25 and limit switch 28 is closed, fourth relay 22 is energized through counter switch 12d and relay switches 20b, 21b and 22b. Consequently, alarm buzzer 10 is not driven. On the other hand, in the case that the necessary number of screws are not tightened against electrical equipment 3 by the worker&#39;s mistake or that counter contact 12d is opened and counter switch 12e is closed, fourth relay 22 is not energized even when panel 24 is removed from jig 25 and limit switch 28 is closed. Consequently, alarm buzzer 10 is energized to thereby inform the worker of the occurrence of failure to tighten screws. 
     Although limit switch 28 is mounted on jig 25 for detecting completion of the screw tightening step, in the second embodiment, it may be mounted on a conventional reel disposed over the worker for holding electric screwdriver 11 at a standby position as shown in FIG. 6 as a third embodiment. Limit switch 28 is closed when a wire 29a suspending electric screwdriver 11 is taken up by reel 29 such that electric screwdriver 11 is lifted. Or, as illustrated in FIG. 7 as a fourth embodiment, limit switch 28 may be mounted on a stand 30 of electric screwdriver 11 disposed in the vicinity of the worker. Limit switch 28 is closed when electric screwdriver 11 is held on stand 30. 
     The system shown in FIGS. 1 and 2 may be further modified as a fifth embodiment. In order to tighten the screws against one work with a plurality of electric screwdrivers in a single screw tightening step, n number of electric screwdrivers 11 are provided. Between power supply lines 4 and 5 are connected two or more screw-tightening detecting circuits each including plug socket 7 and current relay 17 connected in the same manner as shown in FIG. 1 and two or more circuits each including relay 18, timer 19 and relay switches 17a, 18a and 19a connected in the same manner as shown in FIG. 1. Two or more relay switches 18b of relays 18 of circuits are connected in parallel with one another between power supply line 15 and clock terminal CK of counter unit 19. In the fifth embodiment, failure to tighten the screws may be detected and informed when a plurality of workers are engaged in the screw tightening work against one work. 
     Referring to FIG. 8 illustrating a sixth embodiment, a pneumatic screwdriver 32 is provided as a screw tightening tool so as to be driven by compressed air supplied through a hose 31 communicated to a compressed air source (not shown). Pneumatic screwdriver 32 has a lever 33 for closing and opening a valve which allows and disallows compressed air to flow to pneumatic screwdriver 32 and a first switch 34 connected in series to a lead wire 35. First switch 34 is interlocked with lever 33. When lever 33 is gripped by the worker for the screw tightening, the valve is opened, thereby driving pneumatic screwdriver and turning a first switch on by way of lever 33. A holder 36 is provided over assembly line 2 for holding pneumatic screwdriver 32 with completion of the screw tightening step. Holder 36 is provided with a second switch 37 responsive to the weight of pneumatic screwdriver 32. A circuit arrangement wherein first switch 34 is employed instead of switch 17a and second switch 37 instead of switches 4a and 5a in FIG. 1 performs the same operation of detecting failure to tighten screws as the device shown in FIG. 1. 
     The foregoing disclosure and drawings are merely illustrative of the principles of the present invention and are not to be interpreted in a limiting sense. The only limitation is to be determined from the scope of the appended claims.