System and method for testing or calibrating a manufactured part in a wet environment

A system for testing or calibrating a part, the system including: a plurality of test stations, each test station including a container and a clamping mechanism, wherein the clamping mechanism includes: a clamp frame including: two clamp plates; a plurality of clamp bars configured to securely hold the clamp plates at a distance relative to each other; a seal manifold provided on one of the two clamp plates; and a clamping module, located opposite the seal manifold on another of the two clamp plates, wherein the clamping module includes: a plurality of pistons to hold the part against the seal manifold for the test operation; and at least one cleaning station comprising a spin mechanism for spinning the part to remove excess fluid; and a robotic system for moving individual parts to and from the plurality of test stations and to and from the at least one cleaning station.

FIELD

The present document relates to a system and method for testing and/or calibration in a pressurized and/or wet environment, particularly for parts that must be tested using fluids and pressure is needed on the part for the testing and/or calibration, or the like.

BACKGROUND

Existing systems for testing or calibrating use various techniques to allow for the testing or calibration depending on the nature of the parts. Two instances where testing and calibration become more complex include: (1) those where some element of the part to be tested needs to be placed under pressure during testing; and (2) those where the testing or calibration process makes use of a liquid and the liquid is ideally removed prior to moving the part to another processing operation. One example of where these two conditions apply is the testing and calibration of a transmission control apparatus. In this process, a part is submerged in oil and requires a predetermined amount of pressure to be placed on bolt locations where the part would be attached when in use.

Current systems and methods for testing and calibration can be complex and costly in order to meet these requirements. For example, when testing a transmission control apparatus, a large press is conventionally used to provide the necessary pressure to the transmission control apparatus. As another example, in some “wet” testing/calibration processes, the part may be air-dried following the testing. However, air drying can release mist which may require a complex mist collection mechanism to prevent spread of the mist into other areas. A mist can be particularly problematic when it is formed from an oil that was used in the process.

There is a need for an improved system and method for testing and/or calibration in a pressurized and/or wet environment.

SUMMARY

In a first aspect, the present disclosure provides a system for testing or calibrating a part, the system including: a plurality of test stations, each test station comprising a container and a clamping mechanism, wherein the container is configured to hold a fluid and the clamping mechanism is configured to receive the part in a vertical orientation and clamp the part horizontally with sufficient force to withstand a predetermined pressure to be placed on the part while submerged in the fluid, wherein the clamping mechanism includes: a clamp frame including: two clamp plates; a plurality of clamp bars configured to securely hold the clamp plates at a distance relative to each other; a seal manifold provided on one of the two clamp plates; and a clamping module, located opposite the seal manifold on another of the two clamp plates, wherein the clamping module includes: a plurality of pistons to hold the part against the seal manifold for the test operation; and at least one cleaning station comprising a spin mechanism for spinning the part to remove excess fluid; and a robotic system for moving individual parts to and from the plurality of test stations and to and from the at least one cleaning station.

In a particular case, the robotic system may include: a gantry located above the plurality of test stations; a robotic module comprising: at least one moving mechanism configured to move along the gantry; and a robot gripper attached to each moving mechanism and configured to grip and transport the part.

In another particular case, the robot gripper may be configured to maintain the vertical orientation of the part.

In still another particular case, the system may include a pallet for carrying the part and wherein the robot gripper includes a lock/release mechanism configured to interact with the pallet.

In yet another particular case, the robotic system may include: a floor mount; and a robotic arm attached to the floor mount, wherein the robotic arm moves the part to and from the plurality of test stations.

In a particular case, the spinning mechanism may maintain the part in a vertical orientation.

In another particular case, the system may include: a plurality of test panels, wherein each of the plurality of test panels engage with one of the plurality of test stations such that each of the engaged test panels and test stations can be slidably removed from the system.

In another aspect, there is provided a method for testing or calibrating a part, the method including: receiving the part from a conveyor; transporting the part to a test station while orienting the part in a vertical orientation; inserting the part in a clamping mechanism in the test station while maintaining the part in a vertical orientation; applying pressure to the part via the clamping mechanism, wherein the pressure is applied in a horizontal direction; testing the part, while maintaining the part in a vertical orientation and while under pressure; releasing the pressure and removing the part from the clamping mechanism; and returning the part to the conveyor.

In a particular case, the test station includes a fluid and the part is tested in a fluid, the method further comprising cleaning the part at a cleaning station by spinning the part to remove excess fluid.

In still yet another aspect, there is provided a system for testing or calibrating parts under pressure, the system including: a plurality of test stations, each test station comprising: a clamping mechanism configured to receive the part in a vertical orientation and clamp the part horizontally with sufficient force to withstand a predetermined pressure to be placed on the part; and a robotic system for moving individual parts to and from the plurality of test stations.

In a particular case, the clamping mechanism may include: a clamp frame including: two clamp plates; a plurality of clamp bars configured to securely hold the clamp plates at a distance relative to each other; a seal manifold provided on one of the two clamp plates; and a clamping module, located opposite the seal manifold on another of the two clamp plates, wherein the clamping module includes: a plurality of pistons to hold the part against the seal manifold for the test operation.

In still another particular case, the robotic system may include: a gantry located above the plurality of test stations; a robotic module including: at least one moving mechanism configured to move along the gantry; and a robot gripper attached to each moving mechanism and configured to grip and transport the part.

In yet another particular case, the robot gripper may be configured to maintain the vertical orientation of the part.

In still yet another particular case, the system may include a pallet for carrying the part and wherein the robot gripper includes a lock/release mechanism configured to interact with the pallet.

In a particular case, the robotic system may include: a floor mount; and a robotic arm attached to the floor mount, wherein the robotic arm moves the part to and from the plurality of test stations.

In another particular case, the system may include at least one cleaning station comprising a spin mechanism for spinning.

In still another particular case, the spinning mechanism maintains the part in a vertical orientation.

In still yet another particular case, the system may further include: a plurality of test panels, wherein each of the plurality of test panels engage with one of the plurality of test stations such that each of the engaged test panels and test stations can be slidably removed from the system.

DETAILED DESCRIPTION

Generally the present disclosure relates to a system and method for testing in a pressurized and/or calibration in a pressurized and/or wet environment. In the following, the system and method are referred to as a system and method for testing but it will be understood that calibration may also be performed in appropriate embodiments/situations. Further, although the embodiments focus on a system and method for testing and calibration of a transmission control assembly, it will be appreciated that the principles and concepts disclosed can be used for testing and/or calibration of other parts, particularly parts that are tested or calibrated using the same or similar parameters as those in the embodiments shown and described herein.

The embodiments of the system and method described herein may allow for a more efficient, lower cost, lower floor space alternative to conventional systems and methods. In some embodiments, the cost reduction may be provided by replacing multiple conventional machines with one or two machines or systems that can operate on more parts at the same time. This may allow for a smaller number of duplicated sub-components and a more compact system.

Some embodiments of the system include a plurality of test stations configured to receive parts to be tested under pressure and, in some cases, in a wet environment under pressure. As noted above, the test stations may alternatively or also be calibration stations. In some cases, embodiments of the system include a cleaning station configured to clean the part after the part has been tested and/or calibrated in a wet environment and prior to loading the part on a conveyor or the like for further processing.

Further, some embodiments of the system and method for testing involve processing of a part in a generally vertical, upright orientation or position. Conventional systems typically process the part in a flat, horizontal or plane orientation or position because pressure clamping is typically performed using vertical presses. The use of a generally vertical orientation may enable a more compact footprint, an easier material handling robot, or fewer motions in the part handling and the test positions. This approach may provide lower costs and a compact machine. The vertical orientation may also allow the part to be put into the test clamp position somewhat like putting bread into a toaster and may reduce or eliminate extra motions, cycle time and the like that may be required in order to “lay flat” (i.e. make horizontal) a part inside a test clamp.

The system and method for testing may include a manifold with individual integrated piston clamp motions for the “test clamp”. Conventional systems typically use a large press type mechanism. The use of individual piston motion may enable a compact test clamp mechanism, and less motion. This may result in a compact packaging of multiple “test clamps” and may enable multiple clamps (or test stations) in a single machine, having fewer motions to control, and reducing or eliminating the need for multiple machines with single or double controlled test clamps. The use of individual piston motion may also allows for quick change of fixtures and fixtures may be tested off-line for different parts.

The system and method for testing may also include the use of a cleaning mechanism, for example, a spin mechanism or the like. This may provide a method to remove post-test residual oil, or other testing fluid, from the part. Using a spin mechanism may allow for a compact foot-print such that this spinning process can be performed in-line by the same system as the testing, which may provide more efficient and compact handling.

FIGS. 1 to 4illustrate an embodiment of a system for testing100. The system includes a loading/unloading station105, a plurality of test stations110(sometimes referred to as test fixtures or cells). In this embodiment, three test stations110are shown. The system100may optionally include a cleaning station115. Parts200are moved among the test stations100and cleaning station115by a gantry robotic module120provided to a gantry125above the stations.

The loading/unloading station105is positioned to receive a conveyor130for moving parts200to and from the system100. The gantry robotic module120provided to the gantry125moves a part200from the conveyor130to one of the plurality of test stations110. As noted above, the test stations110may perform calibration processes as well as testing processes on the part200. The embodiment shown inFIGS. 1 to 4shows the gantry robotic module120with two moving mechanisms135and robotic grippers140. In this way, the gantry robotic module120can more efficiently both load and unload the parts200from the test stations110as the gantry robotic module120moves along the gantry125. For example, one moving mechanism135removes a part200while the other moving mechanism135places a part200in the test station110.

Each test station110includes a container145. The container145also contains a clamping mechanism150, as illustrated in greater detail inFIG. 4and also described further herein. In some embodiments, the container145may be configured to be filled with fluid, for example, oil.

With reference toFIG. 4, the clamping mechanism150includes a clamp frame155, a clamping module160(sometimes referred to as a manifold), and a seal manifold165(sometimes referred to as a base). The clamp frame includes two clamp plates170that are connected by a plurality of clamp bars175. The clamp bars175securely hold the clamp plates170at a distance relative to each other with sufficient force to hold against the pressure generated in the test.

The clamping module160and seal manifold165are provided on the inner surfaces of the clamp plates170, opposite from each. This can allow the part200to be positioned between the manifold160and the seal manifold165. The clamping module160includes a plurality of hydraulic high pressure pistons190. The pistons190can be activated to provide pressure and hold the part200in place against the seal manifold165for the test operation. In this particular embodiment, the plurality of pistons are configured to match with bolt locations on the part200. The clamping module160and seal manifold165may be removably attached to the clamp plates170. Removability may allow for ease of maintenance or changing of test operations. Further, in some embodiments, the clamp plates170may be incorporated into the container145.

Each test station110is configured in a modular way so that test stations110can be added/removed from a system100depending on the part throughput required. In the embodiment ofFIGS. 1 to 4, three test stations110are provided but, depending on the test or calibration requirements, the system100could be adapted for fewer or more test stations110and/or could be designed for a larger number than are actually in use initially to allow for larger volumes in the future.

When testing or calibrating in a wet environment, following a test/calibration operation, the part200may be coated with excess liquid, for example, oil. In this case, the part200can be moved by the gantry robotic module120to the cleaning station115to remove excess liquid. The cleaning station115includes a container180and, in this embodiment, a spinning mechanism185in the container180. The container180may include a lid (not shown) that can be closed during operation. The spinning mechanism185is configured to receive and hold the part200following test/calibration. The spinning mechanism185rotates at an appropriate rate for an appropriate time to remove excess oil that remains on the part200following test/calibration. The use of a cleaning station115may help to reduce oil dripping from the part200following the test/calibration. In some embodiments, the part200may have some residue after being cleaned (e.g. depending on the subsequent processing). As with the test station110, the cleaning station115may be designed in a modular fashion. This may help with maintenance and interchangeability with cleaning stations in other systems. In some embodiments, other methods of removing/reducing excess liquid may be used depending on the application, including, for example, air drying, shaking, or the like.

Following either testing, calibration or cleaning (as appropriate), the part200is moved by the robotic module120from the cleaning station115to the conveyor130, where the part will be advanced for separate processing.

FIG. 3illustrates a power station250, for example an electronic control panel configured to provide power to the test stations110and the cleaning station115, and a control station255, for example a data acquisition panel, for the system100.FIG. 3further illustrates test panels260, which house test circuits for each of the test stations110. The test panels are at the side of the system100and may be at some distance from the actual test stations110. When a test station110requires a change or a repair, the test station110may be removed from the system. To remove the test station110, lines (not shown but may include electrical and hydraulic connections or the like) connecting the test station110and the test panels260will generally need to be disconnected, which may take additional time and effort. Further, the new or repaired test station110will not be able to be operated until it is reconnected to the test panel260.

As shown inFIG. 5, a plurality of the systems100may be operated in parallel. In some embodiments, the plurality of systems may use the same conveyors130for providing parts to the systems.

FIGS. 6 to 9illustrate another embodiment of a system300for testing and calibration. The system300may include a load and unload station305configured to receive parts200from a conveyor330. The system300includes a first and a second gantry325aand325band a first and second row of test stations310aand310b. The first and second gantry325aand325bare placed in-line with the test stations310aand310b. Generally speaking, there may also be a first and second cleaning station315aand315bprovided as well. Although not shown, embodiments of the system such as shown inFIGS. 6 to 10may also be arranged with other similar systems and having appropriate feeder conveyors to allow greater throughput of parts. In some cases, the first gantry325amay take parts from a first lane of the conveyor130and the second gantry325bmay take parts from the second lane of the conveyor130. Overall, the system300ofFIGS. 6 to 9is similar to the system100ofFIGS. 1 to 4but with two lanes of test stations310aand310b.FIG. 10illustrates a variation of the system300ofFIGS. 6 to 9with an alternate feeding mechanism.

FIGS. 11 to 13illustrate still another embodiment of a system400for testing. This embodiment provides for the movement of the parts200in the system400to be performed by a robotic module420that includes a floor mount435and a robotic arm440, rather than a gantry, moving mechanism and gripper, to move the parts among a load/unload station405, at least one test station410, and at least one cleaning station415.

FIG. 14illustrates a top view of an embodiment having a plurality of systems similar to those inFIG. 11operating in parallel.

FIG. 15illustrates an embodiment of a system500for testing that is somewhat similar to that of the system100ofFIGS. 1 to 4. One difference is that the system500has been modified such that each test station510can contain multiple parts200, in this case, two parts, for example a part “A”200A and a part “B”200B, at the same time. This may allow for either simultaneous testing or for alternating testing or the like. In this embodiment, depending on the configuration, the test station510may be loaded with either different types of parts (in order to allow flexibility in manufacturing operations) or the same type of parts (for higher throughput of the same type of part). It will be understood that it may be useful to also modify a cleaning station515to be able to handle multiple parts in a similar manner.

FIG. 16illustrates another embodiment of a system600with a similar modification to that ofFIG. 15but based on the system300ofFIGS. 6 to 9.

FIG. 17illustrates an embodiment of a pallet system700for carrying a part for loading into an embodiment of a system, such as that ofFIG. 1. In particular, the part200is loaded having a vertical orientation or upright position. The pallet system700includes an adapter705to be connected during the test/calibration. The adapter705may be picked up with the part200by the robotic module. A fixture710on the pallet700includes a lock/release mechanism715that allows the robotic gripper to grip the part and maintain its orientation during gripping and movement. In some cases, the lock/release mechanism715may be a hook mechanism configured to allow the robotic gripper to connect to and lock with the hook. In other cases, the lock/release mechanism715may be configured to provide for a magnetic lock, or a friction fit with the robotic gripper. In still other cases, the lock/release mechanism may have retractable pins configured to engage the robotic gripper. The base720of the pallet system100may remain on the conveyor130during processing of the part200.

FIGS. 18A and 18Billustrate an embodiment of a gripper800for gripping the part200and moving the part200among the stations in the system. The gripper800is configured to maintain the orientation of the part200and adapter705during movement and is also provided with a gripper lock/release mechanism805that interacts with the pallet lock/release mechanism715such that control of the part200is maintained. In some cases, the gripper lock/release mechanism805may be configured to lock to a hook, or may include a magnetic lock or friction fit in order to engage the lock/release mechanism715. In other cases, the gripper lock/release mechanism805may include retractable pins configured to engage the lock/release mechanism715. In this manner, the gripper800may take the part to be tested into the test station and the pallet may remain on the conveyor130.

FIG. 19illustrates the interaction of the gripper800and the pallet700while loading/unloading the part200.

FIGS. 20 to 22illustrate further detail for an embodiment of the test station110. Each test station110includes a container145and at least one clamping mechanism150.FIGS. 21 and 22illustrate the clamping mechanism150removed from the container145. As noted above, the clamp plates170(sometimes referred to as fixture plates) are held in fixed orientation while the part200is loaded between the clamping module160and the seal manifold165(sometimes referred to as a seal plate). The clamping module160is then activated such that pistons190move forward to hold the part against the seal manifold165with appropriate force placed in the correct positions to hold the part in place during testing. The hydraulic force for the pistons190is provided by hydraulic cables or piping (not shown) that enter the clamping module160and drive the pistons190. In other embodiments, the pistons190may be driven by another power source such as pneumatic or electrically driven pistons or the like.

It is intended for the part200to be loaded in a vertical position, similar to a “toaster” type insertion into the clamping mechanism150. A connector slide205advances making electrical connection. In some cases, the clamping module160and seal manifold165are configured to be removable from the clamping frame155and quickly replaced.

FIG. 23illustrates an embodiment of the test station510that is configured to hold two parts200(same type or different type). The part200may be held at either the same time or as required based on manufacturing need. This type of test station510could be used with the systems500and600described above.

FIGS. 24 to 26Billustrate further detail of an embodiment of the cleaning station115. In particular,FIGS. 25 and 26A and 26Billustrate a spinning mechanism185configured to receive, hold and spin a part to remove excess liquid. In some cases, the spinning mechanism may be drum that is spun by a motor. Similar to the pallet having a lock/release mechanism, the spinning mechanism185also includes a lock/release mechanism and interacts with the gripper to maintain part orientation and control.

FIG. 27illustrates a method1000for testing. At1005, the part200, for example a transmission control assembly or other part to be tested or calibrated arrives at the load/unload station of the system.

At1010, the robotic module removes the part from the load/unload station and transports the part to the test station while maintaining or orienting the part in a generally vertical or upright orientation. The robotic module may include at least one moving mechanism with a gripper that grips the part to transport the part200to the test station.

At1015, the part200is tested in the test station. The part200is placed into a clamping mechanism of the test station in a vertical orientation. The clamping mechanism is then operated to apply pressure to the part200during testing (e.g. pressure may be applied horizontally, on a generally horizontal plane). In cases where the part is tested in a wet environment, for example, when submerged in oil, the test station may already contain oil or be filled with oil in order to carry out the test, which may include calibration. Once the test and/or calibration is complete, the part is removed by the robotic module.

At1020, the part200may be cleaned at a cleaning station. In cases where the part200was tested in a wet environment, for example, when submerged in oil, the part200may be cleaned at the cleaning station to remove excess liquid from the part200. In some cases, the part200may be cleaned by a spinning mechanism housed within the cleaning station.

At1025, the part200is transported by the robotic mechanism to the load/unload station in order to be returned to the conveyor.

FIGS. 28 and 29illustrate yet another embodiment of a system1100for testing and calibration of a part200. In this embodiment, the system1100is generally similar to the system600ofFIG. 15. One difference is that the plurality of test panels1105are configured to connect with the test stations, for example test stations110. In particular, a test valve1110can be configured to connect to the test station110. The test panels1105may be located proximate to the test stations which may reduce the required floor space around the system100. The test panels1105may be removed together with the test stations when a repair or replacement is needed. In particular, the test station and test panel can be slidably removed, which may allow for a replacement unit to be inserted more quickly and efficiently. The test station remains engaged with the test panel and a new part or repair can be completed outside the system while allowing the remaining test stations to continue production. As shown inFIG. 30, the test panels1105may include a plurality of test valves1110, which may be mounted to either or both sides of the test panel. This may allow easier changeover during repair replacement and/or provide greater throughput.

FIG. 31illustrates the system1100as included as a component in an assembly line1115. After processing by the system1100, the part200is unloaded onto an unload conveyor130. A transfer gantry1120is able to retrieve the part200and transfer it to the assembly line1115. The transfer gantry1120includes a “Z” axis picker1125which may pick the part off the pallet and transfer the part200to a buffering area1130. The buffering area1130may allow for further drying time for the part200(e.g. if the part200was processed in fluid). The “Z” axis picker1125may then pick parts200out of the buffering area and present the part directly in front of an assembly line operator1135and the assembly line operator1135to place the part200on the assembly line1115. In some cases, there may be at least two “Z” axis pickers1125, for example, one to move the part200from the unload conveyor130to the buffering area1130and a second to move the part200from the buffering area1130to the assembly line1115. In some cases, the “Z” axis picker1125may move the part directly to the assembly line1115.