Pneumatic sweeping system

A method and system for removing loose impediments from a surface in a manufacturing setting. The surface may be where a widget is processed. As the widget is processed, loose impediments may fall onto the surface. The surface may be transported to a cleaning station where at least one nozzle directs a stream of fluid onto the surface to displace the loose impediments. A container may be provided adjacent to the surface to receive the loose impediments displaced from the surface. The at least one nozzle may continuously direct the stream of fluid onto to surface so long as the surface is present at the cleaning station. When the surface is no longer present at the cleaning station, the at least one nozzle may be deactivated.

TECHNICAL FIELD

The present disclosure relates to a method and apparatus for removing debris from a manufacturing assembly line and, specifically, a pneumatic sweeping system for removing and collecting debris from an assembly line station surface.

BACKGROUND

In industrial manufacturing plants, a common problem that arises is loose impediments falling onto the ground. Manufacturing plants must employ workers to constantly be looking out for debris on the plant floor. If the loose impediments are left unchecked, many of the vehicles operating in the plant, whether they are autonomously guided vehicles or push-carts, will become obstructed and may cause manufacturing to be shut down until these vehicles are repaired. This problem is exacerbated when a race-track type production line system is employed, since the whole production line is shut down and no products can be produced if a vehicle becomes obstructed.

The present disclosure addresses this problem. By removing and collecting the loose impediments from the surface of the work station, the likelihood of the vehicle becoming obstructed is lessened and, therefore, the likelihood of manufacturing being stopped is lessened.

SUMMARY

A system and method for removing loose impediments from a surface and collecting the loose impediments is disclosed.

In one example, a method of removing loose impediments from an upwardly facing surface moving along a production line and configured to support a product element is disclosed. The method may comprise sensing a condition indicating a presence of the upwardly facing surface at a cleaning station. The cleaning station may include a container that is located adjacent to the upwardly facing surface and defining an opening angled with respect to the upwardly facing surface. The method may also comprise activating at least one nozzle located at the cleaning station and positioned at a height above the upwardly facing surface. The at least one nozzle may direct a stream of fluid from the at least one nozzle onto and across the upwardly facing surface and displacing any loose impediments from the upwardly facing surface into the container via the fluid directed across the upwardly facing surface. The method may also comprise determining the condition is no longer being sensed. The method may also comprise deactivating the at least one nozzle.

In another example, a system for removing loose impediments from a work station is disclosed. The system may comprise a work station having an upwardly facing surface configured to support a product element. The work station may move along a production line including a cleaning station. The cleaning station may comprise at least one nozzle located at the cleaning station and positioned above the work station when the work station is adjacent to the cleaning station. The at least one nozzle may selectively direct fluid onto and across the upwardly facing surface. The cleaning station may also comprise at least one sensor positioned to detect a condition corresponding to a presence of the work station at the cleaning station. The cleaning station may also comprise a container positioned at the cleaning station, the container being located adjacent to the work station when the work station is located at the cleaning station. The container may define an opening extending at an angle with respect to the upwardly facing surface of the work station. The system may also comprise a controller operatively connected to the at least one sensor and the at least one nozzle. The controller may be configured to activate the at least one nozzle to disburse fluid onto and across the upwardly facing surface of the work station towards the container responsive to receiving data from the at least one sensor indicating the condition being detected. The fluid may carry any loose impediments positioned on the upwardly facing surface to the container. The fluid and loose impediments may be carried through the opening and into the container. The controller may configured to deactivate the at least one nozzle responsive to receiving data from the at least one sensor indicating the condition is no longer being detected.

DETAILED DESCRIPTION

The present disclosure describes a system and method for removing loose impediments off of a work station and collecting the loose impediments in a container positioned adjacent to the work station. The loose impediments are removed by directing fluid across the work station and into the container, the fluid carrying with it the loose impediments. The exemplary system and method will be described below with reference to the accompanying figures.

Referring toFIG. 1, a production line system100is shown. The production line system100may include an assembly line102, a transfer station104, and a cleaning station106including a pneumatic sweeping system107. Alternatively, the production line system100may include the assembly line102, and the cleaning station106. The production line system100may be a race-track guide-way type production line system100. It should be noted that the assembly line102, the transfer station104, and the cleaning station106are fixed positions on the production line system100.

The production line system100further includes one or more work stations108. The work stations108continuously traverse the assembly line102, the transfer station104, and the cleaning station106. The work stations108may be sections of a conveyor belt (not shown), discrete pallets, or any substantially planar surface capable of supporting an in-process production element, or a widget110, being assembled. The work stations108may be serially arranged. Each work station108may have a support surface,114as shown inFIG. 2, which is substantially horizontal and is where the widget110is supported as it is processed and assembled. The surface114may be made up of a material that is ergonomic to stand and walk on. The material may be but not limited to a soft rubber, a flexible plastic, a soft wood, or any other material that workers may stand on for long periods of time without soreness in their legs. An exemplary material that may be used is an Ergomat® mat on the work station108. When using pallets as the work station108, the pallets may be moved through the assembly line102via friction or traction drive wheels112rotating in opposite directions and shifting the pallets forward along a guideway113.

As the work stations108traverse the assembly line102, the widget110is progressively assembled. The widget110may be assembled by autonomous robots (not shown), or by workers115. At each step of the assembly process, loose impediments116may fall onto the surface of the work station108. Loose impediments116may be, but not limited to, fasteners, breakaway tape, plastic, metal shavings, or the like employed as part of or resulting from the assembly process and which at the end of the assembly process are not consumed or affixed to the complete widget. As the widget110is assembled, more loose impediments116will inevitably fall onto the work station108.

At the final step of assembly of the widget110, several loose impediments116have fallen onto the work station108. Once the widget110is completely assembled, the widget110may be transferred to a different location. The work stations108may be moved to the transfer station104via a mobile mechanism, such as an autonomous guided vehicle118(referred to herein as AGV). Alternatively, the work stations108may be moved to the transfer station104via a conveyor belt (not shown), a friction drive (not shown), or the like.

The AGV118may continuously traverse the production line system100. The AGV118may carry the work station108with a fully assembled widget120to the transfer station104, where the fully assembled widget120will be removed and taken to a different location in the assembly plant. The AGV118may then carry the work station108to the cleaning station106. The AGV118may then carry the work station108that has been cleaned back to a starting point on the assembly line102via a guide-track125where the work station108will receive a new widget110to be assembled. The AGV118may then proceed to the end of the assembly line102, pick up the next work station108that has a fully assembled widget120and repeat the same process.

When the work stations108are transported to the transfer station104, a transfer means may remove the fully assembled widget120from the work station108and place it at a different location in the production line system100as illustrated in phantom. The transfer means may be a pick-and-place mechanism122, a worker, an autonomous robot, or any other means of moving a part from one location to another known in the art.

Once the fully assembled widget120is removed from the surface114of the work station108at the transfer station104, the work station108, which still has many loose impediments116on its surface114, may be moved to the cleaning station106. At the cleaning station106, the loose impediments116are blown off the work station108into a container124positioned adjacent to the work station108. Once all the loose impediments116are blown off the surface114of the work station108into the container124, the work station108may be transported back to the beginning of the assembly line102.

Alternatively, it should be appreciated that it may be desirable to clean both the work station108and the fully assembled widget120. The work stations108may be transported directly from the assembly line102to the cleaning station106. In this alternative embodiment, the surface of the work station108may be cleaned with the fully assembled widget120still positioned on the surface. This may be useful when not only the surface of the work station108is to be cleaned, but the fully assembled widget120itself has loose impediments116on its' surface that need to be removed.

It should be appreciated that, although the assembly line102, the transfer station104, and the cleaning station106are depicted on a straight away stretch defined by guideway113, they may be positioned anywhere throughout the production line system100. However, it is preferred that the assembly line102, the transfer station104, and the cleaning station106be positioned serially on a straight away stretch to lower the possibility of loose impediments116falling off of the surface of the work station108as the work station108changes direction at a corner127of the race-track guide-way125.

Referring now toFIG. 2, the cleaning station106is shown in greater detail. The cleaning station106may include a sensing means126, a controller128, a reservoir130, a support frame131having attached thereto at least one nozzle132, and the container124.

The sensing means126is constantly searching for a condition to be present indicative of the work station108being present at the cleaning station106. The condition may be the sensing means detecting a first point and a second point on the work station108. The first point on the work station108may correspond to a leading edge117of the work station108and the second point on the work station108may correspond to a trailing edge119of the work station108.

The sensing means126may be a position sensor detecting the leading edge117or the trailing edge119of the work station108, a weight sensor detecting whether there is an increase in weight indicative of the presence of a work station108, a camera, or any other means for detecting a position of the work station108in relation to the cleaning station106.

The at least one nozzle132may be in communication with the reservoir130storing pressurized fluid and supported within the cleaning station106by the support frame131. The pressurized fluid may be a liquid fluid or a gaseous fluid. There may also be a valve134between the reservoir130and the nozzle132. The valve134may be a control valve. The valve134may be opened or closed by the controller128based on the position of the work station108with respect to the cleaning station106. The valve134may also be operative to adjust a pressure at which fluid is directed onto the work station108. The controller128may adjust the pressure according to data it receives from the sensing means126.

Also, there may be an input receiving device123which signals to the controller128the type of loose impediments116located on the surface of the work station108, and the controller128may adjust the pressure accordingly. The input receiving device123may be an additional sensor (not shown) which detects the type of loose impediments on the surface and adjusts the pressure accordingly, or the input receiving device123may be used by a worker and information regarding the loose impediments may be manually put into the input receiving device123and the pressure adjusted accordingly. Also, the input receiving device123may receive data regarding a speed at which the work station108is traveling through the cleaning station106. The input receiving device123may adjust the pressure of the fluid as a function of the speed of the surface114of the work station108.

Although three nozzles132are shown inFIG. 2, it should be appreciated that as few as one nozzle132may be used. Alternatively, as many nozzles132may be used as necessary to move loose impediments116across the work station108. Nozzles132may be positioned to direct a stream129of fluid at an angle α, β, and γ, to the surface. Alternatively, nozzles132may be positioned to direct the stream129of fluid substantially parallel to the surface114. The nozzles132may have their respective position adjusted by an actuator (not shown) based on data received from the additional sensing means regarding the type of loose impediments116located on the surface114of the work station108.

The nozzles132may also include a plume adjuster137. The plume adjuster137may be used to adjust disbursement, X, Y, and Z, of the stream129of pressurized fluid onto the surface. The plume adjuster137may also be used to adjust the plume shape, defined by a plume leading edge133as shown inFIGS. 1 and 3, and a plume trailing edge135as shown inFIGS. 1 and 3. It should be noted that, although the plume shape can be adjusted, it is preferred that the plume leading edge133should remain substantially parallel to the leading edge of the work station108. Maintaining the plume leading edge133substantially parallel to the leading edge of the work station108ensures that the trajectory of the loose impediments116is substantially across the surface114of the work station108and into the container124.

The plume adjuster137may be adjusted mechanically by a worker. Alternatively, the plume adjuster137may be a control valve on the nozzle132that is automatically adjusted by the controller128based on the type of loose impediments116positioned on the surface114of the work station108. The plume adjuster137may be adjusted in the same manner as the control valve134regulating the pressure of the fluid communicated between the reservoir130and the nozzle132.

When the sensing means126senses the condition corresponding to the presence of the work station108at the cleaning station106, the controller128may open the valves134in order to communicate pressurized fluid from the reservoir130to the nozzle132, and, from the nozzle132, direct the pressurized fluid onto the surface of the work station108. As stated above, the condition may be detecting the leading edge of the work station108, detecting an increase in weight corresponding to a work station108being present at the cleaning station106, or any other means for determining the location of the work station108with respect to the cleaning station106.

As fluid is directed onto the work station108, the loose impediments116may be blown in a direction across the surface substantially parallel to the direction of the fluid being blown onto the surface. The loose impediments116may be blown into the container124positioned adjacent to the work station108. The work station108may be continuously moved in a direction substantially perpendicular to the direction in which the loose impediments116are blown to ensure all loose impediments116are blown off the surface of the work station108and into the container124.

It should be appreciated that the direction that in which the loose impediments116are blown should be at least perpendicular to the direction that the work station108is moving. This insures that the loose impediments116continuously move forward towards the container124and stay behind the fluid being blown onto the surface. If the loose impediments116cross in front of the fluid being blown onto the surface, the loose impediments116may remain on the surface as opposed to being blown into the container124.

The sensing means126may constantly be monitoring whether the condition remains present. So long as the condition remains present, the sensing means126may indicate to the controller128that the condition is still present and that the nozzles132should remain open. When the sensing means126senses the condition is no longer present indicative that the work station108is no longer present at the cleaning station106, the controller128may close the valves134in order to shut off the nozzles132.

Referring toFIG. 3, the container124is shown in greater detail through a perspective view. The container124may comprise a basin136, a first side138, and a second side140. The first side138and second side140may be substantially tangential to the surface of the work station108. The basin136is where all the loose impediments116are collected and has an opening142substantially planar to the work station108and aligned with the fluid directed across the work station108. The first side138of the container124is positioned directly adjacent to the work station108. The second side140is positioned opposite the basin136parallel to the first side138. The container124may also include a flow-inducing means and a sorting means. By flow-inducing means, it may be baffles, slots, or other passages positioned in various locations throughout the container124to ensure the fluid communicating across the surface of the work station108flows into the container124and carries loose impediments116with it. By sorting means, it may be devices positioned within the container124to separate some loose impediments116from others or to position some loose impediments116in different locations based on their size, weight, or metallic composition (e.g. magnetic).

The basin136of the container124may further comprise a drawer144for conveniently removing the loose impediments116blown off the surface114without having to move the container124as a whole. The drawer144may comprise a slotted filter146for allowing smaller loose impediments116, such as nuts, bolts, screws, and the like, to fall into the drawer144and the larger loose impediments116, such as breakaway tape, and larger pieces of plastic or metal shavings, to remain on top of the slotted filter146for easier separation and recycling. Also, the drawer144may comprise a basin flow baffle148. The basin flow baffle148allows the fluid directed across the surface and into the container124to pass through the lower half of the basin136and, thus, direct the loose impediments116downward into the basin136instead of swirling out of the basin136and out of the container124.

The first side138and the second side140may include edges150. The edges150may extend at an angle to encourage laminar fluid flow into the container124.

The second side140may also include a backboard152. The backboard152may include an electromagnet154. The electromagnet154may direct magnetic loose impediments116downward towards the front of the drawer144and make separation and recycling of parts easier. The electromagnet154may be connected to and activated by the controller128simultaneously with the nozzles132.

The backboard152may also include an extension156. The extension156may extend at an angle from the backboard152to encourage fluid flow into the container124. The extension156may also deflect loose impediments116blown into the extension156downward as opposed to back at the surface. The extension156may also include an extension flow baffle158. The extension flow baffle158may also induce the fluid directed across the surface of the work station108to flow through the extension156creating a venturi effect. The loose impediments116blown into the extension156would be separated from the fluid being directed across the surface and the loose impediments116would be directed downward into the container124.

Referring now toFIG. 4, a control method of controlling the nozzles132is depicted through a flow diagram400with reference to the structural components disclosed and described above.

In the flow diagram400, a continuous loop is shown. At logic step402, the sensing means126is waiting for a condition to be present. The condition is indicative of the work station108being present at the cleaning station106. At logic step404, the nozzles132are deactivated until the sensing means126determines at step402that the condition is present.

When, at logic step402, the sensing means126detects the condition, the sensing means126communicates with the controller128, and, at logic step406, the controller128activates the nozzles132. The controller128may activate the nozzles132by opening valves134that are connected between the reservoir130containing the fluid and the nozzles132. The valves134may be control valves and the controller128may adjust the valves134to raise or lower a pressure of the fluid directed onto the surface114of the work station108.

At logic step408, the nozzles132direct fluid across the surface114of the work station108. At logic step410, a container124is provided adjacent to the surface114of the work station108and the container124has an opening142that is aligned with the directed fluid across the surface114. At logic step412, the loose impediments116located on the surface114of the work station108are displaced from the surface114of the work station108and are received by the container124.

Logic steps406,408,410and412are continuously looped while the condition remains present at the cleaning station106. When it is detected that the condition is no longer present at the cleaning station106, the nozzles132are deactivated and the control method proceeds back to logic step402, where the sensing means126waits for the next work station108to become present.

The foregoing description relates to what are presently considered to be the most practical embodiments. It is to be understood, however, that the disclosure is not to be limited to these embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.