DELIVERY APPARATUS FOR MOVING WORKPIECES

A method and apparatus for delivering workpieces to and from a machine table. This invention also relates to an apparatus for receiving at the machine table workpieces which are delivered to and retrieved by the delivery system. Carts move with respect to a surface, such as a floor surface. The carts move and deliver pallets to a loading station that uses a loading arm to deliver pallets with workpieces to and from a machine table.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention relates to a system and method for delivering and retrieving workpieces to and from a machine table, such as a CNC machine or a 5-axis machine table, and to a system and method for receiving the workpieces at the machine table.

Discussion of Related Art

Delivery systems are known for moving workpieces from a staging or supply area or location to a machine table, such as a CNC machine or a 5-axis machine. Many conventional delivery systems have a loading arm or similar element that rotates to pick up pallets holding workpieces. Other conventional delivery systems rotate the loading arm with respect to a table to pick up workpieces.

Cayley, Sr. et al., U.S. Pat. No. 9,950,867, and Cayley, Sr. et al., U.S. Pat. No. 10,486,278, teach known methods and apparatuses for delivering and retrieving workpieces to and from a machine table.

Many conventional delivery systems have a relatively large or substantial footprint and thus requires a significant amount of manufacturing floor space, which is relatively expensive. There is an apparent need for a delivery system that has a loading arm that moves, preferably but not necessarily in a linear direction to pick up workpieces from a mobile cart.

SUMMARY OF THE INVENTION

The delivery system of this invention provides access to workpieces or other materials to be modified without a requirement for a loading arm to rotate or pivot to pick up workpieces. The delivery system of this invention uses a train formed by one or more carts which can be moved into a position in which a programmable and/or displaceable loading arm moves, preferably within two dimensions, to pick up, move, deliver and/or retrieve pallets to and from a machine table of a CNC machine or another suitable machine. Each pallet has an attached workpiece and each pallet is releasably attached to one of the carts. The delivery system of this invention also uses movers to move the carts and/or the train to a loading station for the loading arm, for example, without rotating or pivoting to pick up the pallets with loaded workpieces and to move the workpieces to a machine table, which results in significant manufacturing and use cost reductions.

The loading arm of this invention accesses and delivers pallets, with attached workpieces, to the machine table. A receiver of this invention can be mounted at an existing machine table, such as a CNC machine or a 5-axis machine table, or can be mounted at a new machine table. The receiver can be located at the machine table and can accept pallets with attached workpieces, and the pallets can be delivered to the machine table, by the delivery system of this invention. The machine table can then machine or otherwise work the workpieces locked with respect to the receiver. Then, the loading arm can return the machined or worked workpieces on the pallet for the delivery system to retrieve, move and store the worked workpieces at a storage facility.

DETAILED DESCRIPTION OF THE INVENTION

Cayley, Sr. et al., U.S. Pat. No. 9,950,867, and Cayley, Sr. et al., U.S. Pat. No. 10,486,278, the entire disclosures of which are incorporated into this specification by reference thereto, describe methods and apparatuses for delivering and retrieving workpieces to and from a machine table, and some elements, systems and/or process steps of those U.S. patents can be used in combination with, in addition to and/or in place of some of the elements of this invention as described in this specification and/or as shown in the drawings of this invention.

FIG. 1shows a perspective view of a system and/or an apparatus, according to some embodiments of this invention, which can be part of a delivery system, for example, to use pallets20to deliver workpieces12to machine table10.FIG. 1shows train22comprising or including 4 carts23each having 2 pallets20connected, attached and/or otherwise detachably secured directly to and/or indirectly with respect to cart23. In other embodiments of this invention, train22can have more or less than 4 carts23, and top43of cart23can have more or less than 2 mounted pallets20, depending upon the total number of workpieces12desired.

FIG. 1shows cart23comprising body24and rollers26connected, attached and/or otherwise secured with respect to body24. In other embodiments of this invention, cart23can have slides, tracks, rails and/or any other suitable element and/or system that allows cart23to move with respect to loading arm37, such as shown inFIGS. 1-3. In some embodiments of this invention, a mover, such as a moving apparatus or system, moves or transfers train22and/or cart23in a downline direction or an upline direction, so that an active pallet20is positioned at or near loading arm37of loading station45. The mover can be an apparatus, a system, elements and/or any other parts or methods that allow or result in moving cart23with respect to loading arm37, such as in the downline direction or the upline direction. In some embodiments of this invention, loading arm37moves and/or otherwise operates to engage with an active pallet20, and after the active pallet20is delivered to machine table10and is moved back to cart23, the mover moves train22and/or cart23to engage and/or otherwise work on the next inline pallet20or another suitable active pallet20.

In some embodiments of this invention, for example as shown inFIGS. 1-3, cart23has 4 rollers26attached, secured and/or otherwise fixed in position with respect to body24of cart23. In other embodiments of this invention, more or less than 4 rollers26can be used to move cart23, such as with respect to loading arm37of loading station45. In addition to or in place of rollers26, any other suitable slide, track, rail and/or other structural element and/or system can be used to allow cart23to move with respect to loading arm37.

According to some embodiments of this invention, such as shown inFIGS. 1-4, top43can be secured, attached and/or otherwise fixed in position with respect to body24, for example, in a permanently fixed position or in a removably fixed position. In some embodiments of this invention, top43comprises one or more struts44and/or other suitable structural elements, each that allows pallet20to be positioned on and supported by each strut44. In some embodiments of this invention, strut44and/or pallet20comprise locating pins41, such as shown inFIG. 3, that allow each pallet20to be positioned and/or located in a defined position that temporarily holds, secures and/or otherwise fixes the position of pallet20with respect to top43and/or cart23.

The elements, the apparatuses and/or the systems of this invention can have any suitable layout, size, shape and/or dimensions that are suitable for any particular use and/or desired result of this invention. In some embodiments of this invention, machine table10, such as shown inFIG. 1, is a machine table, such as a CNC (computer numerical control) machine or a 5-axis machine table known to those skilled in the art of manufacturing. In some embodiments of this invention, pallet20is delivered onto a receiver secured, fixed and/or otherwise mounted onto a table surface of machine table10and persons skilled in the art of manufacturing know a suitable term to be a “work envelope” of the CNC machine or other machine to which pallet20is delivered and mated. Machine table10can be any other suitable device, apparatus and/or system that accepts, works, modifies and/or returns one or more workpieces12.

In some embodiments of this invention, a method for delivering and retrieving workpieces12, such as to and from machine table10, includes attaching, connecting and/or otherwise securing each workpiece12with respect to a corresponding one of pallets20, such as shown inFIG. 1. Any suitable apparatus or device can be used to secure workpiece12with respect to pallet20, which are known to those skilled in the art of manufacturing. In some embodiments of this invention, workpiece12is removably secured and/or attached with respect to pallet20, directly and/or indirectly.

In some embodiments of this invention, pallet20is detachably mounted or removably mounted, directly, indirectly and/or otherwise with respect to top43of cart23. According to some embodiments of this invention, each of a plurality of pallets20moves with respect to loading station45. In some embodiments, train22has multiple carts23and as shown inFIG. 1, forms a relatively straight line formation but in other embodiments of this invention train22has multiple carts23that forms a non-linear formation or configuration. Train22can be formed along a rail, a track, an elongated member and/or any other suitable device or apparatus that allows pallet20to move with respect to loading arm37of loading station45.

As shown inFIG. 1, moving one cart23contacts or engages with and moves at least one other cart23or adjacent cart23. In some embodiments of this invention, about 4-25 adjacent carts23are positioned in one train22and each cart23moves train22along or with respect to the corresponding loading arm37.

FIG. 1shows one workpiece12mounted or otherwise secured with respect to one pallet20. In other embodiments of this invention, it is possible to mount or otherwise secure two or more workpieces12with respect to one pallet20.

FIGS. 1-5each shows pallet20being an active pallet20when positioned at loading station45. In some embodiments of this invention, loading arm37moves along a travel path to pick up or lift pallet20away from top43, such as at loading station45, and delivers pallet20with the mounted or secured workpiece12from loading station45to machine table10. According to some embodiments of this invention, loading arm37moves along a linear travel path to pick up or lift pallet20, sometimes in a fashion in which loading arm37does not move from side-to-side, such as along a width of loading arm37. The linear travel path, particularly of loading arm37can reduce costs, because there is no need or requirement to move loading arm37in a direction perpendicular to or in a direction at any other angle or even in a rotatable manner. As shown inFIGS. 2-5, lifter36raises and/or lowers pallet20with respect to top43of cart23and/or any other suitable element and/or part of cart23. Any suitable hydraulic, electrical, magnetic and/or other lifting device can be used to accomplish raising and/or lowering pallet20with respect to top43of cart23and/or any other suitable element and/or part of cart23. As shown inFIGS. 1-4, supports, such as struts44and/or any other suitable support structure, can be positioned to engage and lift and/or raise pallet20with respect to top43of cart23and/or any other suitable element and/or part of cart23.

Costs of building and operating loading arm37can be reduced, for example, by limiting movement of loading arm37in only two dimensions. In some embodiments according to this invention, loading arm37moves or operates in only two dimensions by loading arm37moving between loading station45and machine table10, only in a planar air space or void having a length, a width and a depth forming boundaries of the planar air space. In some embodiments of this invention, such as shown inFIGS. 1-4, loading arm37moves forward and backward, such as along longitudinal axis38of loading arm37. In some embodiments of this invention, loading arm37is movably mounted with respect to a shaft, for example, a rotating screw shaft and/or any other suitable moving shaft or other device. In some embodiments of this invention, the planar space is defined by a length equal to the longitudinal movement of loading arm37with respect to loading station45, such as along longitudinal axis38, a depth equal to the lifting and lowering movement of lifter36such as in a vertical direction, and a width equal to a width dimension of loading arm37.

In some embodiments, machine table10receives or otherwise accepts pallet20or an active pallet20and then moves and/or performs work on workpiece12, and then machine table10returns pallet20or active pallet20with the attached and already worked or modified workpiece12. In some embodiments of this invention, such as shown inFIGS. 1-5, a delivery system moves an active pallet20from loading station45to machine table10, preferably but not necessarily along a linear travel path which may or may not be generally parallel to longitudinal axis38. The delivery system of this invention, in some embodiments, positions active pallet20and then loading arm37moves to lift and/or otherwise remove active pallet20of pallets20so that active pallet20moves away from cart23, which cart23remains movably attached and/or fixedly mounted with respect to loading station45, and delivers and receives active pallet20.

According to some embodiments of this invention, cart23remains movably attached or otherwise connected to train22, so that active pallet20can be picked up and easily moved away from top43and/or any other part or element of cart23and towards machine table10, particularly when loading arm37or another suitable displacement device lifts or otherwise picks up and moves active pallet20away from loading station45. In some embodiments of this invention, each cart23is able to move with respect to loading arm37and/or loading station45and not get out of line or derail from train22.

FIG. 1shows one embodiment of cart23movably and/or controllably mounted with respect to loading arm37and/or loading station45. As shown inFIG. 1, rollers26are secured or otherwise removably attached to each cart23. As shown inFIG. 1, roller26contacts a surface, such as a floor surface, to allow each cart23and thus train22to move or be guided in motion with respect to loading arm37and/or loading station45, particularly without each cart23being moved, detached, derailed and/or otherwise removed from train22. Each roller26can be used to significantly reduce frictional forces caused by or resulting from cart23moving with respect to loading arm37and/or loading station45. Each roller26can be used to reduce forces necessary to move cart23. Many other different mechanical, electrical and/or magnetic devices can be used to accomplish the same result of moving each cart23.

In some embodiments according to this invention, a moving device or a mover engages and moves at least one cart23with respect to loading arm37and movement of cart23engages and moves, directly or indirectly, other carts23of train22into or at a position located at or near loading station45, so that loading arm37can reach and act on active pallet20and move it to machine table10. In some embodiments of this invention, displacement or other movement of cart23causes movement of another cart23that then moves an adjacent cart23, which moves another adjacent cart23of train22, and so on, so that loading arm37can access and move multiple or several different workpieces12to machine table10.

FIG. 1shows about 4 different carts23being part of and/or mounted or positioned within train22. In other embodiments of this invention, it is possible for train22to comprise more or less than 4 carts23and still accomplish the result of moving pallet20and the corresponding workpiece12with respect to loading arm37and/or loading station45. It is possible to use any suitable number and/or positioning of the mover device or the mover moving carts23and train22, depending upon the number of carts23and/or the layout or configuration that train22follows.

In some embodiments of this invention, loading arm37and/or loading station45includes a lift or a lift station for raising, lowering and/or otherwise moving pallet20or active pallet20between loading station45and machine table10. In some embodiments of this invention, the lift or the lift station for raising and lowering or otherwise moving pallet20or active pallet20comprises any suitable arm, lift, lift device, elevator and/or any other suitable apparatus, device and/or method that raises, lowers and/or otherwise moves one or more pallets20or active pallets20from loading station45to machine table10.

In different embodiments according to this invention, including the embodiment shown inFIG. 1, multiple trains22of carts23can be used to set up or preload many different workpieces12that can be delivered to and from machine table10, which can significantly reduce the cost of manufacturing and using the delivery system according to this invention, particularly the movements of loading arm37or another similar device.

Loading arm37and/or other elements or components of the delivery system, according to some embodiments of this invention, are used to move, transfer, transport and/or otherwise locate or position pallet20or active pallet20, each which has a mounted workpiece12, preferably but not necessarily attached to pallet20, to machine table10. In some embodiments, machine table10can be an existing machine table or can be a new machine table. In some embodiments according to this invention, a receiver is installed at and/or used with any suitable existing machine table10or a new machine table10. The receiver according to this invention can receive workpieces12which are delivered to and retrieved by an actuator of the delivery system according to this invention. Any receiver having features according to this invention can be used with an existing machine table10or a new machine table10.

In some embodiments according to this invention, a method for receiving workpieces12at machine table10, which are delivered to and retrieved by the delivery system includes movably mounting loading arm37with respect to machine table10. In some embodiments of this invention, a sequence of movements, controlled or not controlled, of loading arm37can be used to move one active pallet20from cart23, unload the active pallet20at machine table10, and then return to restart the method or process by moving the next pallet20which moves and becomes active pallet20, and the method or process steps can repeat.

FIG. 1shows an initial step or method in which loading arm37approaches an active pallet20which is moved into position and is ready to be lifted away from cart23, and loading arm37begins the method cycle. As shown inFIG. 1, cart23is moved until active pallet20is in position for loading arm37to begin lifting active pallet20with mounted workpiece12away from top43of cart23.

FIG. 2shows a later or further step or method in which loading arm37detachably engages with and forms contact with active pallet20and lifts active pallet20away from top43of cart23. As shown inFIG. 2, cart23is held in position or stopped in place so that loading arm37can move and engage with active pallet20.

FIG. 3shows a yet later or further step or method in which loading arm37continues to move in a direction towards machine table10. Loading arm37delivers active pallet20with the corresponding workpiece12to machine table10and drops or unloads pallet20with workpiece12so that machine table10can perform work on workpiece12. After workpiece12is worked, processed and/or otherwise machined at machine table10, loading arm37removes or moves active pallet20with the worked or processed workpiece12and drops, sets and/or otherwise positions active pallet20on or at cart23. Loading arm37then returns to its initial position to restart the cycle or process with the next pallet20moved in a downstream direction by cart23until the next pallet20becomes active pallet20to restart the cycle or process.

In some embodiments according to this invention, the moving device or the mover that moves cart23can be any suitable system and/or apparatus that moves cart23and thus train22in a controlled fashion. In some embodiments of this invention, a computer, an electronic controller and/or associated software program is used with a computer hard drive to automatically control movement of cart23and/or train22, depending upon the particular number of pallets20and/or workpieces12loaded on each cart23.

While in the foregoing specification this invention has been described in relation to certain preferred embodiments, and many details are set forth for purpose of illustration, it will be apparent to those skilled in the art that this invention is susceptible to additional embodiments and that certain of the details described in this specification and in the claims can be varied considerably without departing from the basic principles of this invention.