Fastener magazines, and related supply systems and methods

A rivet supply system supplies rivets to a rivet setting tool comprising a punch, an extendable nose arrangement and a die, and comprises at least one rivet delivery track for delivering the rivets to the nose arrangement, at least one rivet transfer device for holding or releasing the rivets received at the rivet-receiving zone, and at least one refillable magazine for storing the rivets in proximity of the setting tool. The magazine comprises a magazine portion of the rivet delivery track, wherein the rivets can be stored within the magazine, or can transit through the magazine to be delivered to the setting tool. The magazine also comprises at least one docking interface for refilling the magazine from for example a bulk feeder. The magazine is in rivet-supply relation with the nose arrangement so that it can supply rivets to the setting tool, and is moveable together with the nose arrangement.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a U.S. National phase application of International Application No. PCT/GB2018/053524 filed Dec. 5, 2018, which claims priority to Application No. GB 1720275.5 filed Dec. 5, 2017, the entire contents of both of which are incorporated by reference herein.

RELATED APPLICATIONS

The present application is being filed on the same date as applications titled “Nose Arrangements for Fastener Setting Machines, and Related Methods” (GB1720277.1) and “Fastener Handling Devices for Fastener Setting machines, and Related Methods” (GB1720248.2), the contents of which are fully incorporated herein by reference.

TECHNICAL FIELD

The present application relates to magazines for supplying fasteners such as rivets to a rivet setting tool. The present application also relates to systems for supplying rivets to a setting tool, the systems including one or more rivet magazines, and to related methods. In particular, the present application relates to magazines, systems and methods for supplying self-piercing rivets. More particularly, the present application relates to magazines, systems and methods of the type used for supplying rivets and/or self-piercing rivets to a setting tool having a nose arrangement and a punch for setting the rivets, the setting tool being mounted on a support such as a C-frame. The C-frame may be mounted on a movable arm, such as a robotic arm. These magazines store the fasteners in proximity of the setting tool, in readiness for any setting operations carried out by the setting tool. Although the focus of the present disclosure is on rivets (and, in particular, on self-piercing rivets), certain aspects are instead readily applicable to fasteners more generally, as it will be appreciated from the detailed description set out below.

BACKGROUND

Various systems and methods for setting fasteners such as rivets and self-piercing rivets are known which use a bulk-supply apparatus to supply the rivets to a setting tool. In some systems, the setting tool comprises a nose arrangement and a punch for setting the rivets. The setting tool is mounted on a support structure such as a C-frame. The C-frame can be mounted on a robotic arm so that a number of automatic operations can be carried out by the robot at the required locations.

The nose arrangement is generally disposed under the punch, and guides the punch and the rivets during a setting operation.

A die assembly is also usually provided on the support structure, opposite the nose arrangement, to react the force applied by the punch to the workpiece during a setting operation. In this way, the workpiece is sandwiched between the nose arrangement and the die assembly during a setting operation, and the punch is operated to set the rivet.

Systems of the type described herein typically feed the rivets to the nose arrangement through suitably profiled flexible delivery tubes. The rivets can thus be delivered to the setting tool by means of compressed air, and/or gravity.

The rivets are supplied singularly or in groups, and generally therefore require one or more rivet handling mechanisms along the supply lines so that only the required rivet or rivets are supplied when necessary. These mechanisms generally involve some form of mechanical interaction with the rivets, and this may happen at various stages along the path of the rivets from the bulk-supply apparatus to the setting tool.

The flexible delivery tubes may be connected to one or more magazines to locally store, closer to the setting tool, up to a predetermined number of rivets in readiness for installation. It is known to provide some sort of removable, replaceable magazines to simplify the supply operations. However, several problems are associated with the systems of the prior art.

The rivets, for example, are susceptible to jamming in the flexible delivery tubes due to ingress of dust or dirt, due to any portions of the flexible tubes presenting high curvature, or due to wear and tear of the tubes themselves. The flexible delivery tubes, for these very reasons, may require frequent replacement and this may cause unwanted downtime.

Further, the flexible delivery tubes may require a certain working envelope to operate flexibly, and this may necessitate special considerations about how to mount the setting tool on the robotic arm.

As a result, the systems of the prior art may operate not completely satisfactorily, and/or, at the very least, may lack the desired compactness.

It is therefore desirable to minimise, or do away with, the flexible delivery tubes.

It is also desirable to transfer the rivets with the least amount of disruption possible along the rivet supply lines.

It is also desirable to maintain the rivets on their path without dislocation.

It is also desirable to move the rivets seamlessly, so that they can, for example, be gently brought to a halt, and restarted, as and when necessary, along the rivet supply line.

If all the various communicating rivet-supply components in the rivet supply line are connected, and open to the transit of the rivets, it would be desirable to transfer the rivets to the nose arrangement in a continuous (ie uninterrupted), yet reliable, fashion.

There is accordingly also a desire to do away with any potential catch points for the rivets, especially in the above mentioned ‘open’ conditions.

When the rivets are supplied from the bulk-supply apparatus to the magazine, they typically pass through a docking interface that allows the magazine to be refilled when empty. The magazine may thus require a gate to open during the docking and/or loading operation, and close when full, to prevent any rivets from falling out, and to seal the magazine end, so that a compressed air source can then be coupled to the magazine to provide a rivet motive force, when required. Such gates are complex, particularly when the system is designed to operate under the motive force of compressed air, and may add considerable cycle time, and cost, to the operations.

It is also desirable to provide an improved design of magazine which does away with, or that at least reduces, any sealing requirements and/or which may work equally adequately under pressure or suction, or at atmospheric pressure.

There is accordingly also a desire to provide a rivet supply line, or at least a portion thereof, that can be effortlessly, or at least advantageously, sealed against air leakage and/or dust ingress.

After the rivets have completed their path through the rivet supply system, a rivet transfer system is typically provided to transfer the rivets to a stand-by position under the punch, in readiness for the setting operations. The transfer system may involve direct transfer by gravity, air propulsion, a mechanical pusher or probe and/or a dedicated transfer mechanism that traps and senses the rivets presence. Such a dynamic delivery of the rivets from the rivet supply system to the stand-by position is generally problematic in terms of rivet stability, dust ingress and sensing, and typically requires a number of moving mechanical parts that may also suffer wear and tear. This is undesirable, as it may lead to faults or can constitute another source of downtime.

It is therefore also desirable to improve the rapidity, efficiency and/or reliability of the transfer of the fasteners to the stand-by position, under the punch, in readiness for installation.

Known rivet supply systems and methods have only limited capabilities to handle different types of rivets and/or different sizes thereof.

It is thus also desirable to provide magazines, rivet delivery systems and methods which can simultaneously or interchangeably handle a variety of rivet types and/or sizes to provide maximised flexibility and customisation potential for the end user.

It is also, more generally, desirable to reduce the number of moving parts in the systems in question.

It is also, more generally, desirable to improve the performance of the systems referred to herein with respect to the prior art.

SUMMARY

According to an aspect of the present disclosure, there is provided a rivet supply system for supplying rivets to a rivet setting tool comprising a punch for setting the rivets, a nose arrangement defining at least one rivet-receiving zone for receiving the rivets in preparation for setting operations, and a die provided opposite the nose arrangement for reacting the punch, the nose arrangement being movable towards the die to engage with a workpiece, the rivet supply system comprising:at least one rivet delivery track for delivering the rivets to the rivet-receiving zone;at least one rivet transfer device for holding or releasing the rivets received at the rivet-receiving zone;at least one refillable magazine for storing the rivets in proximity of the setting tool,the magazine comprising at least a magazine portion of said rivet delivery track, wherein the rivets can be stored within the magazine, or can transit through the magazine,the magazine comprising at least one docking interface for docking the magazine to a bulk-supply apparatus for refilling the magazine,wherein the magazine is in rivet-supply relation with the nose arrangement and is supported so as to be moveable together with the nose arrangement; and,wherein a substantially undeformable rivet delivery track length extends to said rivet-receiving zone.

Therefore, the rivet supply system minimizes or does away with any lengths of flexible feed tubing.

Where it is said that at least one rivet transfer device is for holding or releasing (or configured to hold or release) the rivets received at the rivet-receiving zone, the at least one rivet transfer device may be configured to hold, and subsequently release, the rivets received at the rivet-receiving zone;

The rivet-receiving zone refers to a zone in which a rivet awaits transfer under the punch in preparation for a setting operation.

The delivery track (and hence rivet delivery track length) is upstream of the rivet-receiving zone. The rivet transfer device is upstream of the rivet-receiving zone.

Optionally the magazine further comprises the rivet transfer device. Optionally the rivet transfer device is disposed at a distal end of the magazine.

The rivet supply system may be adapted to be operated by gravity.

The rivet supply system may be adapted to be operated by suction generated by a vacuum pump.

The docking interface may comprise an inlet for receiving the rivets which is fluidly open to atmosphere.

The magazine may be removably supported on the setting tool and/or on a C-frame that supports the setting tool.

The magazine may be replaceably supported such that a replacement magazine can replace said replaceable magazine.

The magazine may otherwise be permanently installed on the setting tool.

The system may comprise two such magazines and two such undeformable lengths disposed in mirror configuration on opposed sides of the setting tool.

Each magazine may comprise a first elongated body part extending generally parallel to an axial direction defined by the punch and/or the setting tool.

Each magazine may comprise a second elongated body part disposed downstream of the first elongated body part and angled towards said nose arrangement.

Said first and/or second elongated body parts may comprise at least a portion of said undeformable rivet delivery track length.

The first elongated body part of the magazine and/or the magazine portion of the rivet delivery track may be substantially parallel to said axial direction.

The rivet supply system may further comprise a chute, the chute comprising a chute portion of the rivet delivery track which comprises at least part of said substantially undeformable rivet delivery track length, wherein the magazine is in rivet-supply relation with the nose arrangement via said chute.

The magazine may be directly coupled to the chute.

The magazine and the chute may be coupled via a flexible feed tube.

The magazine may be pivotally supported on the setting tool.

The magazine may comprise multiple independent magazine portions of the rivet delivery track.

The multiple rivet delivery track portions may be selectable for supplying the rivets to the rivet-receiving zone according to corresponding angular orientations of the magazine on the setting tool.

At least one of the multiple rivet delivery track portions may have a curved longitudinal extension to facilitate the refilling of the rivets into the magazine and/or the supply of the rivets from the magazine to rivet receiving zone in the nose arrangement.

At least two of the multiple rivet delivery track portions may be provided with said curved longitudinal extension.

The respective curves may define opposed concavities that tend to converge towards a pivot of the magazine.

The pivot may be generally located at a centre of the magazine.

The magazine may comprise three of said multiple rivet delivery track portions.

The three portions may comprise a first straight portion extending substantially longitudinally. The second and third portions may have said curved longitudinal extensions. The second and third portions may be disposed on either side of the first portion.

The magazine may comprises two or more rivet handling devices each associated with one of said multiple magazine rivet delivery track portions for selectively stopping, trapping and/or releasing one or more rivets on the respective magazine portion of the rivet delivery track.

The rivet handling devices may be disposed at a distal end of the magazine.

The rivet handling devices may each be in the form of an actuated in-line rivet selection device.

The actuated in-line rivet selection device may comprise a rotary cam escapement for selectively stopping, trapping and/or releasing one or more rivets on the respective magazine portion of the rivet delivery track based on a rotation angle of the rotary cam escapement.

The rotary cam escapement may comprise a rotatable cam member for selectively stopping, trapping and/or releasing one or more rivets on said respective magazine portion of the rivet delivery track based on a rotation angle of said rotatable cam member.

The rotatable cam member may comprise an arcuate cam.

The actuated in-line rivet selection devices may be each resiliently biased to a default configuration.

The default configuration may optionally be a default rotary configuration of the rotary cam escapement and/or of the rotatable cam member, for stopping and/or trapping the rivets on said respective magazine portion of the rivet delivery track.

Each rivet handling device may be generally disposed at a distal end of the magazine.

Each rivet handling device may be configured to be actuated via an actuated pin mechanism disposed on said chute.

The actuated pin mechanism may be received on corresponding one or more apertures also provided at the distal end of the magazine.

The actuated pin mechanism may be configured to register the magazine in place according to a predetermined angular orientation.

The actuated pin mechanism may be configured to actuate the rivet handing device.

The magazine may comprises at least one rivet handling device associated with the magazine portion of the rivet delivery track for selectively stopping, trapping and/or releasing one or more rivets.

The one or more rivets may be stopped, trapped and/or released on said rivet delivery track portion.

The rivet handling device may be located at a distal end of the magazine.

The rivet handling device may be in the form of an active in-line rivet selection device.

The active in-line rivet selection device may be as described hereinabove.

The active in-line rivet selection device may be resiliently biased to a default configuration.

The default configuration may be a default rotary configuration of the rotary cam escapement and/or of the rotatable cam member and/or of the arcuate cam, for stopping and/or trapping one or more rivets.

The rivet handling device may be generally disposed at a distal end of the magazine.

The rivet handling device may be configured to be actuated via an actuated pin mechanism disposed on said chute and received on a corresponding aperture also provided at the distal end of the magazine.

The actuated pin mechanism may be configured to register the magazine in place.

The actuated pin mechanism may be configured to actuate the rivet handing device.

The rivet handling device may be disposed part-way along the magazine portion of the rivet delivery track.

The system may comprise two or more independent magazine portions of the rivet delivery track.

Two or more independent rivet handling devices may be associated one with each of the two or more magazine portions of the rivet delivery track for selectively stopping, trapping and/or releasing one or more rivets.

The one or more rivets may be stopped, trapped and/or released on the two or more portions.

The two or more independent magazine portions of the rivet delivery tracks may be upper magazine portions.

The upper magazine portions may be configured to supply rivets to a common lower segment of the rivet delivery track.

At least part of said common lower segment of the rivet delivery track may be disposed within the magazine.

The magazine may comprise an actuated track selection device for selecting one of the two or more independent upper magazine portions of the rivet delivery tracks for supplying the rivets to said common lower segment of the rivet delivery track.

The magazine may comprise a docking device disposed at the docking interface for permitting or inhibiting refilling of the rivets into the magazine from the bulk-supply apparatus.

The docking device may be a passive in-line rivet release device adapted to permit said refilling when the magazine is docked to the bulk-supply apparatus.

The docking device may be adapted to inhibit flow of refilled rivets out of the magazine when the magazine is undocked from the bulk-supply apparatus.

The passive in-line release device may comprises at least one resiliently biased jaw member disposed on a side of the magazine portion of the rivet delivery track.

The release device may be disposed at a proximal end of the rivet delivery track and/or at a proximal end of the magazine.

The passive in-line release device may comprise a pair of opposed resiliently biased jaw members.

The resiliently biased jaw members may be disposed on opposed sides of the magazine portion of the rivet delivery track.

The resiliently biased jaw members may be disposed at a proximal end of the rivet delivery track and/or of the magazine.

The system may further comprise a docking block comprising one or more delivery or feed tubes for connecting the magazine to the bulk-supply apparatus.

The docking block may be adapted to dock with said magazine via said docking interface.

The delivery or feed tubes may be flexible, rigid or semi-rigid.

The rivet transfer device may be a passive in-line rivet release device adapted to hold or release the rivet at the rivet-transfer zone. The rivet transfer device may be a passive in-line rivet release device adapted to hold, and subsequently release, the rivet at the rivet-transfer zone.

The rivet release device may comprise at least one resiliently biased jaw member as described herein. The resiliently biased jaw member may be disposed on a side of the rivet delivery track. The resiliently biased jaw member may be disposed at a distal end of the rivet delivery track.

The rivet transfer device may be in the form of an active in-line rivet selection device configured to selectively stop, trap and/or release one or more rivets at the rivet transfer zone.

The rivet selection device may comprise a linear-pin escapement.

According to an aspect of the present disclosure, there is provided a machine for setting rivets comprising the rivet supply system as described herein.

According to an aspect of the present disclosure, there is provided a method of supplying rivets to a rivet setting tool having a punch for setting the rivets, a nose arrangement defining at least one rivet-receiving zone for receiving the rivets in preparation for setting operations, and a die provided opposite the nose arrangement for reacting to the punch, the nose arrangement being movable towards the die to engage with a workpiece, the method comprising:feeding at least one rivet through at least one rivet delivery track for delivering the rivet to the rivet-receiving zone;holding and/or releasing the rivet at the rivet-receiving zone by means of at least one rivet transfer device;storing and/or transiting the rivet in a refillable rivet magazine in proximity of the setting tool,the magazine comprising at least a magazine portion of said rivet delivery track,the magazine comprising at least one docking interface for docking the magazine to a bulk-supply apparatus for refilling the magazine,wherein the magazine is in rivet-supply relation with the nose arrangement and is supported so as to be moveable together with the nose arrangement;wherein a substantially undeformable rivet delivery track length extends to the rivet-receiving zone.

According to an aspect of the present disclosure, there is provided a refillable replacement magazine for storing and supplying rivets to a rivet setting tool having a punch for setting the rivets, and a nose arrangement for receiving the rivets in preparation for setting operations, the magazine comprising:at least one inlet for receiving the rivets disposed at a proximal end of the magazine;at least one outlet for supplying the rivets to the nose arrangement of the setting tool, the outlet being disposed at a distal end of the magazine;at least one rivet delivery track extending from said inlet to said outlet, wherein the rivets can be stored within the magazine, or can transit through the magazine, said rivet delivery track being substantially undeformable;at least one docking device generally located at said proximal end of the magazine and arranged to cooperate with said inlet for refilling the magazine from a bulk-supply apparatus;at least one rivet dispensing device for dispensing the rivets to or towards the nose arrangement through said outlet. This design of replaceable yet serviced magazine allows many control options for feeding the rivets as and when required.

The magazine may be adapted to be directly coupled to the nose arrangement.

The magazine may be adapted to be couplet to a chute.

The chute may be directly coupled to the nose arrangement.

The nose arrangement may be movable and the magazine may be adapted to be supported so as to be moveable together with the nose arrangement generally in the direction defined by the punch.

The magazine may be adapted to be supported on the setting tool and/or on a C-frame for supporting the setting tool.

The magazine may be adapted to be slidably guided within a bracket provided on, or supported by, the C-frame as the magazine moves together with the nose arrangement.

To move the rivets within the magazine, the magazine may be adapted to accept as a rivet motive force:gravity;and/or, suction.

The suction may be originated by a vacuum pump in fluid communication with the rivet delivery track at the distal end of the magazine.

The magazine may thus be unsealed.

The magazine may comprise a first elongated body part extending generally longitudinally.

The rivet delivery track may also extend generally longitudinally through said first elongated body part.

The magazine may comprise a second elongated body part disposed downstream of the first elongated body part and forming an angle therewith.

The angle may be more than 90 degrees and less than 180 degrees.

The first and second elongated body parts may be connected by a curved elbow.

The magazine may comprise a pivotal attachment for attaching the magazine to the setting tool.

The magazine may comprise two or more of the rivet delivery tracks.

The rivet delivery tracks may be independent and may be arranged to be selectable for supplying the rivets to the nose arrangement depending on an angular orientation of the magazine on the setting tool.

At least one of said multiple rivet delivery tracks may have a curved longitudinal extension to facilitate the refilling of the rivets into the magazine and/or the supply of the rivets from the magazine towards the nose arrangement.

At least two of said multiple rivet delivery tracks may have the curved longitudinal extension, and the respective curves have opposed concavities tending to converge towards said pivot attachment.

The pivotal attachment may be generally located at a centre of the magazine.

The magazine may comprise three of said multiple rivet delivery tracks.

The three tracks may comprise a first straight track extending substantially longitudinally.

The second and third tracks may have the curved longitudinal extensions and may be disposed on either side of the first track.

The magazine may comprise two or more rivet dispensing devices each associated with one of said rivet delivery tracks.

The rivet dispensing devices may be each in the form of a rivet handling device for selectively stopping, trapping and/or releasing one or more rivets on a respective track as described herein.

Alternatively, the rivet dispensing device may be in the form of a rivet handling device associated with the rivet delivery track for selectively stopping, trapping and/or releasing one or more rivets on said track as described herein.

Alternatively, the rivet dispensing device may be in the form of a passive in-line rivet release device adapted to hold or release the rivet to the nose arrangement as described herein.

The magazine may further comprise a rivet handling device disposed part-way through the rivet delivery track for selectively stopping, trapping and/or releasing the rivets on said track as described herein.

The rivet handling device may define upper and lower portions of the rivet delivery track.

The magazine may comprise two or more independent upper portions of the rivet delivery track.

Two or more respective rivet handling devices may each associated with one of the independent upper portions.

The magazine may be configured such that said two or more independent upper portions can each feed one or more rivets onto the lower portion of the rivet delivery track.

The magazine may comprise an actuated track selection device for selecting one of the two or more independent upper rivet delivery track portions to supply the one or more rivets to the lower portion of the rivet delivery track.

The docking device may be in the form of a passive in-line rivet release device. This device may be adapted to permit said refilling when the magazine is docked to the bulk-supply apparatus. This device may be adapted to inhibit flow of refilled rivets out of the magazine when the magazine is undocked from the bulk-supply apparatus.

The rivet release device may comprise at least one resiliently biased jaw member as described herein. This may be disposed at the proximal end of the magazine.

The magazine may comprise one or more magnetically patterned surfaces.

The magazine may comprise a patterned magnet, which may be a permanent magnet.

The magnetically patterned surface may be a first correlated-magnets surface for magnetic interaction with one or more second correlated-magnets surfaces. These may be disposed on a support structure for supporting the magazine. The support structure for supporting the magazine may be provided on the setting tool. Alternatively, the support structure may be provided as an independent support structure, other than the setting tool.

According to an aspect of the present disclosure, there is provided a rivet supply system comprising the magazine as described herein.

According to an aspect of the present disclosure, there is provided a rivet setting tool comprising the rivet supply system as described herein.

According to an aspect of the present disclosure, there is provided a method of supporting the magazine, the method comprising:providing a support structure comprising one or more of said second correlated-magnets surfaces for supporting the magazine on said support structure;disposing said first and second correlated-magnets surfaces in magnetic engagement;optionally, wherein said support structure for supporting the magazine is provided on the setting tool;optionally, wherein said method of supporting the magazine further comprises docking the magazine in rivet-supply relation on the setting tool;optionally, wherein said method of supporting the magazine further comprises replacing a magazine on the setting tool with the supported magazine;optionally, wherein said support structure for supporting the magazine is provided as a bracket provided on a C-frame that supports the setting tool;alternatively, wherein said support structure is provided as an independent support structure for supporting the magazine, other than on the setting tool;optionally, wherein said method of supporting the magazine further comprises refilling the supported magazine.

According to an aspect of the present disclosure, there is provided apparatus for replacing a rivet or other fastener magazine on a rivet or other fastener setting tool, the apparatus comprising:a rivet or other fastener setting tool;first and second rivet or other fastener magazines having respective first and second connection features for connecting each magazine to a complementary connection feature, the first magazine being mounted on the setting tool;a robotic arm for moving the setting tool and the first magazine within a work area, the setting tool being mounted on said robotic arm;a first support structure located within said work area and comprising a first such complementary connection feature;a second support structure also located within said work area and comprising a second such complementary connection feature, said second magazine being supported on said second support structure by the respective second connection features;wherein,the robotic arm is operable to cause the first magazine to transfer from the setting tool to the first support structure in cooperation with the first connection features of, respectively, the first magazine and the first support structure; and/orthe robotic arm is operable to cause the second magazine to transfer from the second support structure to the setting tool in cooperation with the second connection features of, respectively, the second magazine and the second support structure. Thus automatic replacement of the magazines may be enabled or facilitated.

The first and/or second support structures may be fixed support structures.

The magazine may be a rivet magazine.

The setting tool may be a rivet setting tool.

The fixed support structures may comprise one or more stands or posts.

The stands or posts may be grouped to form one or more racks for supporting a plurality of magazines.

The one or more stands or posts may be remote stands or posts for refilling the magazines from a bulk-supply apparatus.

The first and/or second support structures may be movable support structures. The movable support structures may be provided on one or more carousels. Each carousel may be adapted to support a plurality of magazines.

The setting tool may comprise one or more brackets adapted to support the first magazine on the setting tool.

The first magazine may be adapted to be magnetically supported on said brackets.

A pair of correlated-magnets surfaces may one be provided one on an external surface of said first magazine, and the other on at least one of said brackets.

The setting tool may comprise a C-frame.

The setting tool and the C-frame may be mounted on the robotic arm.

At least one of said brackets may be disposed on said C-frame.

The one or more brackets may be disposed on a longitudinally extending body portion of the C-frame.

The first magazine may be disposed in a rivet supply engagement on the setting tool.

The setting tool may comprises a punch for setting the rivets, a nose arrangement for receiving the rivets in preparation for setting operations, and a die provided opposite the nose arrangement for reacting the punch.

The nose arrangement may be movable towards the die to undock the first rivet magazine from the rivet supply engagement on the setting tool, thereby facilitating the transfer of the first rivet magazine from the setting tool to the first support structure.

The first rivet magazine may be supported so as to be movable together with the nose arrangement.

The nose arrangement may be movable towards the die to undock the first rivet magazine from rivet supply engagement on the setting tool when the first rivet magazine is supported on the first support structure.

The first and/or second magazine connection features may each comprise a magazine plate-like structure.

The magazine plate-like structure may be in the form of a magazine pad provided on said magazine.

The magazine pad may comprise a layer of a compliant material.

The magazine plate-like structure may be grooved or ridged so as to form a key-like profile.

The magazine plate-like structure may be magnetic.

The magazine magnetic plate-like structure may comprise a permanent magnet.

The magazine magnetic plate-like structure may comprise a magnetically patterned surface.

The first and second complementary connection features may each comprise a support plate-like structure.

The support plate-like structure may be in the form of a support pad provided on said first and/or second support structure.

The support pad may comprise a layer of a compliant material.

The support plate-like structure may be complementarily respectively ridged or grooved with respect to the magazine plate-like structure so as to form a complementary key-like profile.

The support plate-like structure may be magnetic.

The magnetic plate-like structure may comprise a permanent magnet.

The magnetic plate-like structure may comprise a magnetically patterned surface.

The magazine and support plate-like structures may comprise at least one further pair of correlated-magnets surfaces.

The further pair of correlated-magnets surfaces may be adapted to magnetically align the first rivet magazine in place on the first support structure and/or the second rivet magazine in place on the second support structure.

The further pair of correlated-magnets surfaces may be adapted to magnetically latch the first magazine in place on the first support structure and/or the second magazine in place on the second support structure.

The further pair of correlated-magnets surfaces may be adapted to magnetically release the first magazine from the first support structure when the first magazine and the first support structure are brought in misalignment one with respect to the other.

The further pair of correlated-magnets surfaces may be adapted to magnetically release the second magazine from the second support structure when the second magazine and the second support structure are brought in misalignment one with respect to the other.

The apparatus may further comprise at least one further magazine having a further connection feature for connecting the further magazine to a further complementary connection feature different than, and not compatible with, the complementary connection feature related to the first and second magazines, and at least one further support structure located within said work area, said further support structure comprising one such further complementary connection feature.

The further connection features may comprise a pair of magnetically repulsive surfaces.

The magnetically repulsive surfaces may each comprise a magnetically patterned surface.

According to an aspect of the present disclosure, there is provided a method of replacing a rivet or other fastener magazine on a rivet or other fastener setting tool, the method comprising:providing first and second rivet or other fastener magazines having respectively first and second connection features for connecting each magazines to a complementary connection feature, wherein the first magazine is mounted on the setting tool;providing a robotic arm for moving the setting tool and the first magazine within a work area, the setting tool being mounted on said robotic arm;providing a first support structure located within said work area and comprising a first such complementary connection feature;providing a second support structure also located within said work area and comprising a second such complementary connection feature, said second magazine being supported on said second support structure by the respective second connection features;operating the robotic arm to cause the first magazine to transfer from the setting tool to the first support structure in cooperation with the first connection features of, respectively, the first magazine and the first support structure; and/or operating the robotic arm to cause the second magazine to transfer from the second support structure in cooperation with the second connection features of, respectively, the second magazine and the second support structure.

According to an aspect of the present disclosure, there is provided a replacement magazine for storing rivets or other fasteners for supply to a rivet or other fastener setting tool, the magazine comprising:at least one magnetically patterned surface.

The magazine may have an elongated, generally tubular shape.

At least one rivet delivery track may extend internally through the magazine.

The magnetically patterned surface may be provided on an external surface of the magazine.

The magnetically patterned surface may be provided on a plate-like structure provided on the magazine.

The plate-like structure may be in the form of a magazine pad comprising a layer of a compliant material.

The magnetically patterned surface may be a first correlated-magnets surface for coupling with a second correlated-magnets surface provided on a magazine complement.

According to an aspect of the present disclosure, there is provided a magazine as described herein, in combination with the magazine complement.

The magazine complement may be a magazine refill device.

The refill device may comprise a rivet feed tubular member.

The magazine may comprise a plurality of upper tracks.

The rivet feed tubular member may comprise a corresponding plurality of rivet feed passageways.

The first correlated-magnets surface may be provided on a magazine docking interface provided on the magazine for docking/undocking the magazine to a rivet supply line extending through said magazine refill device.

The magazine docking interface may be provided on an upper face of the magazine.

The magazine docking interface and refill device may be adapted to sealing engage to reduce or prevent air loss therebetween during magazine refill operations that use compressed air as a rivet motive force.

Said second correlated-magnets surface may be disposed on a refill docking interface provided on said refill device.

The refill docking interface may be provided on a lower face of the refill device.

The first and second correlated-magnets surfaces may be adapted to generate an alignment force between the magazine and the refill device upon magnetic engagement thereof, such that rivets can be transferred from the refill device to the magazine.

The first and second correlated-magnets surfaces may be adapted to generate a repulsive release force between the magazine and the refill device upon magnetic disengagement thereof.

The rivet refill device may be supported on at least one compliant mount.

The rivet refill device may be supported on a plurality of compliant mounts.

The rivet refill device may comprise a first support structure and a second support structure, and the one or more compliant mounts may be disposed between respective distal and proximal ends of the first and second support structures.

The first support structure may be a tripod, and the three compliant mounts may be disposed between said tripod and the second support structure.

The first support structure may comprise at least one first rhomboid plate and the second support structure may comprise at least one second rhomboid plate disposed externally with respect to said first rhomboid plate.

The one or more compliant mounts may be adapted to absorb a force generated by contact between the refill device and the magazine when the magazine and the rivet refill device are coupled to refill the magazine with rivets.

The one or more compliant mounts may be adapted to return the refill device to an initial position of equilibrium after that the refill device has been displaced from said initial position of equilibrium.

The refill device may comprise stop means for constraining movement of the refill device within a predetermined range of positions in at least one direction.

The stop means may comprise two spaced apart ring members for limiting vertical positions of the rivet feed tubular member.

The magazine complement may be a chute for docking the magazine to a nose arrangement of the rivet setting tool.

The first correlated-magnets surface may be provided on a magazine docking interface provided on the magazine for docking/undocking the magazine to a rivet supply line extending through said chute.

The magazine docking interface may be provided on a lower face of the magazine.

The second correlated-magnets surface may be disposed on a chute docking interface provided on said chute.

The chute docking interface may be provided on an upper face of the chute.

The magazine complement may comprise a bracket.

The first correlated-magnets surface may be provided on a setting tool-facing side of the magazine.

The bracket may be provided on the setting tool or on a C-frame supporting the setting tool.

The second correlated-magnets surface may be provided on a recess for accommodating the magazine provided on said bracket.

The magazine complement may comprise an independent support structure, other than the setting tool.

The magazine support structure may comprise a support plate-like structure as described herein.

The first correlated-magnets surface may be provided on an outwardly facing side of the magazine.

According to an aspect of the present disclosure, there is provided a method of supporting a replacement magazine on a structure, the method comprising:providing a first magnetically patterned surface on said magazine;providing a second complementary magnetically patterned surface on said structure;magnetically engaging said surfaces to connect the magazine to said structure.

The magazine and said structure may be adapted to define a mechanical engagement designed to facilitate said magnetically engaging said surfaces to connect the magazine to said structure, such that the magazine and the structure are mechanically connected in addition to being magnetically connected when the replacement magazine is supported on said structure.

The mechanical engagement may comprise an abutment between said magazine and said structure.

The abutment may comprise first and second complementary key-like profiles provided respectively on the magazine and on said structure.

The first and second key-like profiles may be provided respectively on said first and second magnetically patterned surfaces.

The mechanical engagement may define at least one possible direction for magnetically engaging said surfaces to connect the magazine to said structure.

The mechanical engagement may define a sole direction for magnetically engaging said surfaces to connect the magazine to said structure.

The magnetically patterned surfaces may be adapted to magnetically engage one with the other if said surfaces are spaced apart within a predetermined maximum distance.

The magnetically patterned surfaces may be adapted to magnetically align said magazine and said structure upon engagement.

According to an aspect of the present disclosure, there is provided a method of disconnecting a replacement magazine from a structure, the method comprising:providing a first magnetically patterned surface on said magazine;providing a second complementary magnetically patterned surface on said structure;wherein said magazine and said structure are magnetically connected by said surfaces;magnetically disengaging said surfaces to disconnect the magazine from said structure.

The magazine and the structure may be adapted to define a mechanical engagement as described herein designed to facilitate said magnetically disengaging said surfaces to disconnect the magazine from said structure, such that the magazine and the structure are mechanically disconnected in addition to being magnetically disconnected when the replacement magazine is disconnected from said structure.

The mechanical engagement may define at least one possible direction for magnetically disengaging said surfaces to disconnect the magazine from said structure.

The mechanical engagement may define a sole direction for magnetically disengaging said surfaces to disconnect the magazine from said structure.

The method may further comprise moving the magazine and/or said structure relative to each other further than a predetermined minimum distance.

The magnetically patterned surfaces may be adapted to magnetically mutually repel said magazine and said structure upon disengagement.

According to an aspect of the present disclosure, there is provided riveting apparatus comprising:a rivet setting tool;one or more magazines for storing rivets, each magazine carrying information associated with a type and/or size of the rivets stored in the magazine;a reader for reading said information carried on the magazines;a controller operably associated with said rivet setting tool and said reader; wherein,the controller is configured to control the rivet setting tool in response to a signal received from the reader.

The one or more magazines may be in rivet-supply engagement on the rivet setting tool.

The one or more magazines may be each as described herein.

Each magazine may comprise an electronically readable tag carrying said information.

The reader may comprise an electronically readable tag reader.

The electronically readable tag may be located on a tool-facing side of the magazine.

The electronically readable tag reader may be located on a bracket for supporting said one or more magazines in said rivet-supply engagement on the rivet setting tool.

The rivet setting tool may be mounted on a robotic arm.

The controller may be configured to control the robotic arm.

The magazine may be replaceable.

The controller may be configured to control said robotic arm to carry out a magazine replacement operation.

The controller may be configured to control said robotic arm to carry out a magazine replacement operation as described herein.

The rivet setting tool may comprise a replaceable and/or adjustable die assembly.

The controller may be configured to control the setting tool to replace and/or adjust said replaceable and/or adjustable die assembly.

According to an aspect of the present disclosure, there is provided a method of riveting, the method comprising:providing a riveting apparatus as described herein;reading by means of said reader said information carried on the one or more magazines;controlling via said controller the setting tool in response to a signal received from the reader.

According to an aspect of the present disclosure, there is provided a method of riveting, the method comprising:providing a riveting apparatus as described herein;reading by means of said reader said information carried on the one or more magazines;controlling via said controller the robotic arm in response to a signal received from the reader to carry out a magazine replacement operation.

According to an aspect of the present disclosure, there is provided a method of riveting, the method comprising:providing a riveting apparatus as described herein;reading by means of said reader said information carried on the one or more magazines;controlling via said controller the setting tool to replace and/or adjust said replaceable and/or adjustable die assembly in response to a signal received from the reader.

According to an aspect of the present disclosure, there is provided a method of riveting as described herein, the method further comprising:identifying a joint for riveting.

According to an aspect of the present disclosure, there is provided a method of manufacturing a vehicle or a part thereof by setting one or more rivets, wherein said method comprises any of the procedures described herein.

The present invention will now be described in connection with the appended drawings in which:

DESCRIPTION

In the present description, first the meaning associated to certain terms or phrases used herein will be introduced. The context of the presently described fastening operations will also be briefly discussed.

Reference will then be made toFIGS.1-17to describe the most important features of the present disclosure.

Finally,FIGS.18-50will also be described, albeit to less extent thanFIGS.1-17, particularly to discuss a number of alternative arrangements to those described with reference toFIGS.1-17.

Introduction

We describe in particular self-piercing rivet setting machines of the type that set self-piercing rivets, for example, on plates of various thicknesses, for manufacturing vehicle bodies such as automobile frames and/or panels. Nonetheless, the skilled person will understand that at least some of the teachings herein are equally applicable to different setting tools, and/or to a more general description of fasteners.

The self-piercing rivet setting machines described herein are usually incorporated into a robotic arm so that they can travel and be positioned where required within a working area, according to many different orientations. To achieve this, a rivet setting tool, which has a punch for setting the rivets, is mounted on a C-frame which is in turn mounted on the robotic arm. The robotic arm may be operable to translate and/or rotate the setting tool according to several degrees of freedom. The robotic arm is only schematically shown in the drawings and will not be described herein in further detail. However, the operation of the robotic arm will be described in some further detail in connection with certain aspects of the present disclosure. It will be apparent that the rivet supply arrangements described herein are particularly suited to setting tools mounted on such C-frames and/or robotic arms.

As described herein, “nose arrangement” identifies the arrangement of the working end of the rivet setting tool. The punch travels through the nose arrangement to guide a rivet towards the workpiece and sets it into the workpiece. The nose arrangements described herein are mounted on a piston/cylinder arrangement operated by a servo mechanism on the setting tool. The nose arrangements described herein are thus movable and extend away from the setting tool to come into contact with the workpiece, thus preparing for a setting operation.

In or adjacent such nose arrangements, there are provided one or more designated “rivet-receiving areas” or “rivet transfer areas” where the rivets (having reached the end of their travel from a bulk feeder, or other-bulk storage system, to the nose arrangement, along the rivet supply system) await so that they can then be, in turn, transferred to a stand-by position under the punch to be set into the workpiece one at a time.

“Nose assembly” identifies a sub-assembly of the nose arrangement that more specifically serves to guide the rivet and the punch, after that the punch has engaged the rivet during a rivet setting operation. The nose assembly is not described herein in detail.

The action of the punch on the workpiece during a setting operation is resisted by a “die assembly” located at a receiving end of the C-frame. Certain die assemblies are described herein in some detail.

As mentioned above, “rivet setting operation” identifies the travel that the punch undertakes for setting a rivet into the workpiece. However, the mechanics of these operations is not described herein in detail since the present specification is mainly concerned with how the rivets are stored, and then supplied to the setting tool, and with how the rivets can be replenished in the magazine(s) when required.

Since the rivet supply systems described herein are suited to the supply of rivets from a bulk-storage apparatus to a setting tool, attributes such as “proximal” and “distal” are generally referred to the one-way direction of travel of the rivets through the supply system. Thus, for example, the “proximal end” of a rivet magazine identifies the end of the magazine where the rivets enter the magazine. The “distal end” of the magazine identifies the end of the magazine where the rivets exit the magazine to or towards the nose arrangement.

The various features shown in the Figures have been assigned reference numerals as customary. For clarity, however, where the same or an equivalent feature has been shown in connection with different arrangements, this feature (at least in the vast majority of cases) has been assigned the same reference numeral.

Multiple instances of the same feature shown in the drawings have been labelled using small-case letters suffixed to the reference numeral assigned to that feature. For example, multiple magazine portions of the rivet delivery track are labelled11a,11b,11c. However, when general reference has been made to that feature, the reference numeral may have been used without the small-case letter suffix. For example, to designate in general said multiple magazine portions of the rivet delivery track reference numeral11may have been used.

The self-piercing rivets described herein are labelled with capital letters, for example A, B, C, etc. However, it will be apparent that other fasteners may be suited to be supplied to a setting tool according to the principles described herein. Nonetheless, the fasteners being in the form of rivets or self-piercing rivets are preferred features of at least some aspects disclosed herein.

Different positions or orientations assumed by a given component have been labelled using apexes following the reference numeral assigned to that component, or to a feature identifying said position. For example, the pivotal magazines in the positions shown inFIG.21have been labelled10a′,10b′, with reference numeral10identifying the magazines in general, and reference numerals10a,10breferring to the individual magazines on the right and left-hand sides of the setting tool. The leading and trailing rivets A shown inFIGS.10A-Bare likewise designated A′ and A″, given their different positions.

The attribute “independent” with reference to any rivet tracks, or portions thereof, has been used to mean that said independent tracks/portions do not intersect, or otherwise interact with regards to the flow of the rivets therethrough. In other words, these tracks/portions do not share any segments in common. Accordingly, the passage of the rivets in these independent tracks/portions can be independently regulated or controlled on each independent track/portion.

The attribute “independent” with reference to any described external means for supporting the magazines has been used to mean that such means are provided as separate entities with respect to the setting tool, the C-frame and/or the robotic arm on which the C-frame is mounted.

The attribute “passive” referred to a mechanism denotes the absence of a dedicated actuator operated by external means. Thus for example a pair of resiliently biased jaws for controlling the refill of rivets at the proximal end of the magazine are classed as a passive mechanism for the purposes of the present specification even though the jaws are initially biased in a closed position by a set of springs, and can be opened by the abutment (ie coupling, or docking) of the magazine with, for example, a magazine refill device such as a docking block, as will be further described herein.

The attribute “active” referred to a mechanism instead denotes the presence of a dedicated actuator operated by external means (eg an electric servo-mechanism, or a pneumatic mechanism operated by pneumatic lines) to control the position and/or the configuration of one or more elements of the mechanism itself according to an external command or signal. Thus for example a rotary cam mechanism that operates on a rivet delivery track to selectively release one or more rivets on said track upon operation of a dedicated actuator, which is in turn operated upon receipt by a controller or the like of an appropriate signal or command, is classed as active.

The term “replaceable” refers to a rivet magazine disposed in rivet-supply relation or rivet-supply engagement in the rivet supply line, and which can thus be removed to be replaced, ie substituted, with another identical or similar magazine, for example with another magazine which stores rivets, of the same or a different type, while the replaceable magazine is empty. This other magazine is instead referred to as a “replacement” magazine. The attribute “replacement” when used in conjunction with one or more magazines thus denotes one or more magazines that are ready for replacing a replaceable magazine, for example because the replaceable magazine is empty (for example because all of the fasteners initially stored therein have been used) and the replacement magazine is full, or partly full. It is understood that examples are not limited to the replacement of a replaceable, empty magazine with a replacement, full magazine. Alternatively, it may be necessary to substitute a partially full magazine with a magazine storing rivets of a different type and/or size, as a requirement for example of a particular fastening sequence. The replacement magazine may be full, or may have been only partly filled with the rivets. Alternatively, the substitution may be between an operable magazine and a magazine which is known to have been damaged, or which cannot operate, for any occurring reasons.

Each magazine described herein, in its most basic form, is a generally elongated tubular structure with a portion of the rivet supply line that runs internally through it. The rivets can thus be stored, as a line or a queue, in the magazine and, when required, can be released from the magazine to supply the setting tool. The cross-sectional shape of the rivet supply line described herein is a “T-shape” adapted to generally conform, with clearance, to the shape of the self-piercing rivets described herein. The rivets thus travel generally transversally with respect to the generally longitudinal extension of the rivet supply line through the magazine. However, other cross-sectional shapes are in principle possible, and these will mainly depend on the shape and/or dimension of the fasteners. Further, the rivets, or other types of fasteners, could in principle be made to travel maintaining a longitudinal orientation rather than travelling transversally. However, in the self-piercing rivet fastening applications described herein this alternative may not be preferred.

The magazines described herein are generally constructed by joining together back and front plate members each formed with suitable grooves to obtain the T-shaped cross sections of the rivet delivery tracks when the plate members are joined together to form the magazines. We will not provide any additional details relating to the specific construction of the magazines throughout this description, but, as will be apparent, a variety of magazine designs, constructions and materials are possible, including traditional materials, such as metals, including ferromagnetic metals, or non-ferromagnetic materials such as suitable polymeric materials.

The magazines, and other accessory structures described herein, may include one or more “patterned magnets”, that is magnets having surfaces patterned with regions characterized by opposed magnetic polarities or signs (ie “north” and “south”, or “plus” and “minus”) as a result of magnetic structures (ie magnetic domains) arranged in alternate order within the patterned magnets.

Patterned magnets concentrate their resulting magnetic field closer to their surface than traditional magnets. Patterned magnets may thus be used to generate dense, local magnetic fields which may be used to strongly attract a ferromagnetic material disposed in close proximity to said magnets without affecting other spaced away ferromagnetic elements. The exposed surfaces of these patterned magnets are referred to herein as “magnetically patterned surfaces”.

It is possible to arrange the above patterns/surfaces to achieve different resulting magnetic fields. It is thus also possible to program pairs of magnetically patterned surfaces to generate location-dependent forces to achieve various desired mechanical effects between such magnets and, therefore, between the structures that accommodate such magnets. We thus also refer to these pairs of patterned magnets as “correlated” magnets or “programmed” magnets. Pairs of “correlated” magnetically patterned surfaces or “complementary” magnetically patterned surfaces of this type may thus be designed to achieve a variety of mechanical performances that go beyond simple magnetic attraction, or magnetic holding force. We describe herein certain mechanical performances that can be obtained by providing suitable pairs of magnetically correlated surfaces which are advantageous, for example, in applications such as docking a rivet magazine to a refill station, or to a setting tool, or supporting a rivet magazine on a support structure provided on the setting tool, or elsewhere. These magnetically correlated patterned surfaces are also referred herein as “correlated-magnets surfaces”, because of their mutual magnetic correlation. Reference is made to the research carried out by Larry W. Fullerton about a decade ago, the results of which are known from literature, including from patent literature.

For the purposes of the present description, magnetically correlated surfaces or correlated-magnets surfaces may be obtained in a number of different manners, including using permanent magnets, electromagnets or other equivalent field emission structures (although the latter may be less preferred in the rivet fastening applications described herein). Further, such correlated-magnets surfaces may vary widely as regards the specific geometry of their patterns. Moreover, such surfaces can be part of one or more magnetic inserts, such as one or more patterned magnets incorporated into, for example, the magazines. Alternatively, as mentioned above, they can potentially be induced (in a way akin to ‘printing’) on any of the magazine surfaces, if the magazines are made, at least partly, of a ferromagnetic material.

Induced or printed individual magnetic elements (also known as “maxels”) may thus be arranged to form correlated pairs of patterned magnets that interact via their correlated-magnets surfaces. These magnetically correlated surfaces can be designed to achieve the desired mechanical functions and can have different sizes, and be disposed in a number of different ways. It is not within the scope of the present application to describe any particular patterns or geometries related to said correlated-magnets surfaces and their mechanical functions. Instead, it is noted that adequate patterned magnets for forming pairs of useful correlated magnets can readily be purchased, for example, from Correlated Magnetics Research, LLC, at the time of writing the present specification from website www.polymagnet.com. Suitable correlated-magnets surfaces may otherwise be fabricated.

Product reference 1001107 from www.polymagnet.com, for example, is a two-dimensional (2D), one inch-square alignment patterned magnet which can be paired with another patterned magnet of the same type via opposed faces having complementary (ie correlated) polarity patterns. Thus one face has a given polarity pattern on the one patterned magnet, and the opposed paired face has a corresponding, negative-image polarity pattern on the other patterned magnet. Pairs of 1001107 correlated magnets can thus provide a two-dimensional alignment function with a holding force and an alignment shear resistance. This means that when the correlated-magnets surfaces of these patterned magnets are perfectly aligned, a holding force perpendicular to the magnetically engaged surfaces of the 2D magnets is generated together with a small, or null, alignment (shear) force. When the magnets are brought out of alignment (this can be done with a relatively small force), starting from the position of perfect alignment, the holding force decreases. Simultaneously, the alignment force increases and tends to realign the magnets.

Contact between engaged magnetic surfaces is not a requirement for magnetic interaction between a pair of correlated magnets, although contact may be a preferred feature. For example, holding perpendicular and shear forces of similar magnitude between the correlated magnets described above would nevertheless be generated if a small gap was present between the respective magnetically correlated surfaces. However, the resulting forces would be correspondingly weaker. This could be the case if a layer of a protective or compliant material, such as a protective film, was used to coat the correlated-magnets surfaces. The mechanical performance of the correlated magnets may also be affected by other characteristics, for example the presence and/or size of a layer of backing material disposed on the back of the correlated magnets.

Pairs of different correlated magnets having different magnetically correlated surfaces provide different mechanical functions defined by different sets of magnetically generated forces which depend on the relative positioning between the correlated magnets as well as on the actual shape of the patterns. Note that to achieve some of these function, the correlated magnets may have to be constrained in at least one degree of freedom.

The magnetically generated mechanical forces described herein may fulfil different functions including “alignment”, as seen above in the case of correlated magnets 1001107. However, other possible mechanical functions may also be useful for the purposes set forth in the present description, for example:“coupling” (also referred to herein as “connection”), that is the generation of a substantially attractive holding force (with shear and/or perpendicular components). Note that coupling is also achieved by the above ‘alignment’ correlated magnets 1001107. For example, when the alignment magnets 1001107 are perfectly aligned, they develop a coupling (or connection) force;“latch”, which involves the switch between a mildly repulsive force and a relatively stronger coupling force, as two correlated magnets are moved closer to each other;“spring”, which involves the generation of a stronger attractive or repulsive force, as two correlated magnets are moved further away or closer to each other in an axial direction, respectively. This function can be used, for example, to bias a magazine towards a docking interface, and this will be described in further detail below; and“release”, which involves instead the generation of a relatively strong repulsion force as the two correlated magnets are sheared away one from the other.

The above list is not exhaustive. For example, similar functions are contemplated which relate to angular positioning, or degree of rotation, between the correlated magnets (eg “torsional alignment”, “torsional spring” or “torsional latch”).

It will further be appreciated that the above general mechanical behaviours are not mutually exclusive in that a given pair of correlated magnets may simultaneously behave according to multiple behaviours at a given time, depending on the relative positioning between the magnets.

As mentioned above, importantly the mechanical behaviour of correlated magnets generally changes with the relative positioning of the magnets to provide an overall ‘mechanical experience’. At any given position, however, one of the above behaviours may be predominant. Within the scope of the present application, various possible practical uses of mechanical performances described in connection with and achieved by pairs of correlated magnets are presented, within the broad context of fasteners supply and storage applications.

“Docking interface” as used herein refers to a surface of a component (this could be for example the magazine) that has appropriate features to establish a rivet-supply communication with another component presenting a corresponding or complementary docking interface provided on that other component. The term “docking”, therefore, is in the present description always used in connection with at least one rivet supply track. For example, a rivet supply track may be disposed in rivet-supply relation with a bulk-supply apparatus by docking the magazine directly to the bulk-supply apparatus, or by docking the magazine to an intermediate docking device that has a suitable docking interface. This docking device could, for example, be a docking block connected to the bulk-supply apparatus via one or more lengths of flexible tubes.

When instead mechanical connections are more generally described for the purpose of supporting a component, for example a replacement magazine, on a support structure such as a stand, general terminology such as “support”, “supported”, “connection”, “connected”, or more specific terminology indicating the manner of said support or connection such as “latch”, “latched”, “guide”, “guided” is used. Thus, a replacement magazine may be supported on a stand while it is in non-rivet supply relation within a rivet supply line, for example while the magazine is not docked to the rivet supply line. To support the magazine on the stand, a magnetic pad may for example be provided on the magazine. The magnetic pad may comprise a patterned magnet. The stand may comprise a correlated patterned magnet. Alternative supporting means are however also possible. To dock the magazine to the nose arrangement, a U-shaped guide may for example be provided on the C-frame to guide the magazine in a direction substantially parallel to the punch.

A number of passive and active rivet handling devices are described herein which serve a variety of purposes at different stages of the progress of the rivets through a rivet delivery line. It is not within the scope of the present application to describe these devices in detail. However, their role in connection with the handling of the rivets through the rivet supply line will be described.

The first type of rivet handling devices encountered henceforth can be defined as “active in-line rivet selection devices”. These devices are actuated via an external actuator and their purpose is, at the required time, to release a selected rivet on the rivet delivery track. Examples of active in-line rivet selection devices are “rotary cam escapements” and “linear pin escapements”. Both will be briefly described herein. The main difference between these two types of devices is that the rotary cam escapement utilises rotary actuation of a cam device to release the selected rivet, while the linear pin escapement utilises linear actuation to move one or more pin-shaped barriers to release the selected rivet. The cam devices and pin-shaped barriers can in principle have many different forms, and some are described herein in some detail.

The second example of rivet handling devices briefly described herein can be defined as “active track selection devices”. These devices are also actuated via an external actuator and their purpose is to connect one or another of multiple upper portions of a rivet delivery track to a common, lower portion of the rivet delivery track within the magazine. An example of an active track selection device is a “rotary track selector”. In the rotary track selector, a rotary member rotates to join one of many possible upstream portions of the rivet delivery track with a common downstream portion of the rivet delivery track via a curved rivet delivery track portion located in the rotary selector, so that rivets can be transferred from the selected upper (or upstream) track to the common lower (or downstream) track. However, different active track selection devices would be possible.

The third type of rivet handling devices briefly described herein can be defined as “passive in-line rivet release devices”. These devices are not actuated in the sense required by the devices identified above. Rather, these passive devices are by default biased to a default position, such as a close position. Depending on their use, in the closed position these devices may, for example, prevent one or more rivets from exiting the magazine, or may prevent one or more rivet from entering the magazine. These devices may be switched to their open position by, for example, contact of the magazine with other mechanical parts of the system designed to cooperate with the magazine, for example with a rivet transfer device provided in the nose arrangement, or a docking interface, to respectively transfer a rivet in the stand-by position under the punch, or to refill the magazine with fresh rivets.

It will by now be clear that the emphasis of the present patent specification is on the storage and supply of rivets in proximity of the setting tool. A complete rivet supply line usually extends from the bulk-storage apparatus to the setting tool. However, we do not focus on the bulk-supply end of such rivet supply lines. Rather, we focus on the last portion of these rivet supply lines, close to the setting tool, and we provide at least one (typically removable and replaceable) magazine to store a quantity of rivets close to the setting tool. The magazine(s) are, in use, in rivet-supply relation with the nose arrangement of the setting tool. It is thus possible, and in some cases preferable, to mount the magazines so that they are supported by the nose arrangement, which is part of the setting tool. The setting tool is, however, ultimately supported by the C-frame, and the magazine(s) is/are also, therefore, ultimately supported by the C-frame.

The C-frame usually incorporates appropriate brackets, guides or other like mechanical elements to guide and facilitate docking between a magazine and the nose arrangement, or between the magazine and an accessory such as a chute or the like, disposed between the magazine and the nose arrangement. Further, following a reverse sequence, these components may also facilitate the replacement of a docked magazine. In this way, the replaceable magazine is undocked from the setting tool. These support components may be provided according to a large variety of designs. Only a few such designs are described herein in some detail. A further function of these brackets is, in preferred designs, to guide the magazine so that the magazine is adequately supported when it moves in unison with the nose arrangement to prepare for a setting operation. This will be further described below.

Referring now toFIGS.1-2, there are shown some key components of the presently described arrangements, in particular a rivet supply system1as described herein. The system1is for supplying rivets to a rivet setting tool2. The rivet setting tool has a punch (not shown) for setting the rivets. The setting tool is mounted on a C-frame3, as known in the art. The C-frame3is provided at the working end of a robotic arm200.

The setting tool2comprises a nose arrangement4that defines at least one rivet-receiving zone or rivet-transfer zone5a,5bwithin or adjacent to it. Here, two rivet-transfer zones5a,5bare defined on, respectively, the left-hand side and the right-hand side of the setting tool2as shown inFIG.2. At each of these zones, a delivered rivet awaits transfer under the punch in preparation for a setting operation. A die assembly6is provided opposite the nose arrangement4. The nose arrangement4is mounted on piston/cylinder mechanism7which is part of the setting tool2, and is thus movable to approach (and retract from) the die assembly6.FIG.2shows the nose arrangement4in an extended configuration with respect to the configuration shown inFIG.1, with the piston/cylinder mechanism7clearly shown in extended position, as evidenced by the distance between the nose arrangement4and the upper working end9of the C-frame. The C-frame3can be moved so as to locate a workpiece (not shown) between the nose arrangement4and the die assembly6. This is in preparation for a rivet setting operation carried out by the setting tool2.

Two magazines10a,10bare provided in mirror configuration on the left and right-hand sides of the setting tool2as shown inFIG.1. Accordingly, two rivet delivery tracks8a,8bare provided through the magazines10a,10bin this arrangement, one on each side of the setting tool2. These tracks8extend internally, through the magazines10, in axial/longitudinal directions substantially parallel to the punch. The magazines10a,10bare each docked to a respective chute16a,16b. The chutes16thus connect in rivet-supply engagement the magazines10to the nose arrangement4. In the mirrored-supply configuration shown inFIGS.1-2, two rivet supply lines are provided one opposite the other, and the rivets can be supplied to the nose arrangement4from either the left or right-hand sides.

At the distal ends13a,13bof the chutes16a,16b, two passive in-line rivet transfer devices (not shown inFIGS.1-2, but shown inFIGS.11A-C) hold and then release, as and when required, any rivets that have been delivered from the magazines10to the chutes16. The rivet magazines10shown inFIGS.1-2can be docked to and undocked from the respective chutes16, and this feature will be described in further detail below. However, the chutes16and the magazines10may otherwise be formed as integral or ‘single-piece’ magazines disposed on the right-hand side and/or the left-hand side of the setting tool. These integral magazines would be docked directly to the nose arrangement4. One such magazine is shown for example inFIGS.11A-C.FIG.11C, in particular, shows a rivet transfer device14of the type described herein disposed at the distal end of the magazine10rather than at the distal end13of the chute16. This is the same transfer device which, although not visible, is disposed in the arrangement ofFIGS.1-2at each distal end13a,13bof each chute16a,16b.

Each rivet delivery track8a,8bthus extends through a corresponding magazine10a,10band, further, through the corresponding chute16a,16b, if the chutes16are provided. It is accordingly possible to identify a magazine portion11of the rivet delivery track8in each magazine10. In the arrangement shown inFIGS.1-2, consequently, there is also defined on each side of the setting tool2a chute portion33(visible inFIGS.5and6) of the rivet delivery track8. The chute portion33of the rivet delivery track8extends through the chute16in exactly the same way as the magazine portion11of the rivet delivery track8extends through the magazine10. On each side of the setting tool2, the magazine portion11of the rivet delivery track and the chute portion33of the rivet delivery track8together define a complete rivet delivery track8as described herein. It is not essential that two (or more) rivet delivery tracks8supply rivets to the setting tool. In alternative configurations, there is only one magazine10disposed on one side of the nose arrangement4(see for example the arrangement shown inFIG.32) to supply the rivets to the setting tool2.

Each magazine10a,10bdefines at its proximal end15a,15ban upper docking interface12a,12bfor refilling the magazine10a,10bfrom a bulk-storage apparatus (not shown). The magazines10can thus be refilled in-situ, if required, by docking the magazines10to the bulk-storage apparatus via the upper docking interfaces12according to any one of various possible refilling procedures, some of which will be described in the paragraph below.

A docking block70(one is shown inFIG.13) with a mating docking interface66can for example be provided to dock with the magazine10in-situ. Alternatively, the C-frame3can be moved, and together with it the magazine10, by the robotic arm200close to the bulk-storage apparatus and then the magazine can be connected to the bulk storage apparatus directly. Alternatively, the magazine10can be removed from the setting tool and refilled at a separate location, or the magazine10can be refilled while still mounted on the setting tool2but at an intermediate refill station which is in turn refilled from the bulk-storage apparatus, or continuously fed from the bulk-storage apparatus.

As can also be seen inFIGS.11A-C, in the described arrangements the magazines10are each equipped with a docking device114that cooperates with the upper docking interface12of the magazine to control admission of rivets into the magazine. In the described arrangement, the docking device114is provided in the same form as the rivet transfer device14described above, ie it is provided as a passive in-line rivet release mechanism—with the only difference being in the position and role performed by these devices. The rivet transfer device14is provided to hold and then to release a rivet for transfer under the punch. The docking device114is provided to prevent spillage of rivets from the magazine during inversion of the setting tool, and to provide access to the magazine10for the refilling thereof when the magazine10is docked to the bulk-supply apparatus. It will be apparent, however, that other rivet transfer and/or docking devices would be possible.

The magazines10are supported on the setting tool2and on the C-frame so as to be movable together with the nose arrangement4to prepare a setting operation. At the distal ends20a,20b, the magazines10a,10bare each connected to the proximal end17a,17bof the respective chute16a,16b. The chutes16are rigidly connected to the nose arrangement4so that when the nose arrangement4moves towards the die assembly6, the nose arrangement4causes the magazines10to move with it in direction “v” shown inFIG.1.

A set of brackets18attached to each chute16a,16bis provided to dock the magazines10to the respective chutes16. These brackets18move with the nose arrangement4, guided by a pair of C-shaped brackets19attached to the upper working end9of the C-frame3on either side of the setting tool2. The brackets18,19ensure that each magazine is adequately maintained in rivet-supply engagement with the chute16as the nose arrangement4is moved to prepare for a setting operation, as shown inFIG.2. InFIG.2, it is to be noted the augmented vertical distance between the C-shaped brackets19and the proximal ends17a,17bof the chutes16a,16b, which denotes an extended configuration of the nose arrangement4. Other support configurations that would ensure adequate mobility of the chutes16and magazines10together with the nose arrangement4, while appropriately maintaining in rivet-supply engagement the magazines10on the respective rivet supply lines8, would however be possible. For example, in some applications each magazine10could be designed to be self-supported on the respective chute16, without any bracketry18,19similar to that shown inFIGS.1-2.

In the described arrangement, therefore, on each side of the setting tool2a complete rivet delivery track8, that is a magazine portion11of the rivet delivery track8and a chute portion33of the rivet delivery track8, moves in unison with the nose arrangement4to prepare for a setting operation. Accordingly, there is no requirement for any flexible tubing, at least downstream of the upper docking interfaces12of the magazines10.

Further, the setting tool2may perform multiple riveting operations with continuity of supply from the magazines10without retracting, or without fully retracting, since the rivet-supply engagement with the magazines10is always maintained.

In other arrangements, the magazines10may be supported so as not to follow the movement of the nose arrangement4, in other words so as to be fixed relative to the setting tool2and/or the C-frame3. For example, the magazine(s)10may be mounted on the C-frame3. These magazine(s)10can still be operated to release and feed one or more rivets to the chutes16. However, they can only do so when the magazine(s)10are docked to the chute(s)16. The rivets can then wait at the rivet-receiving zone(s)5, and thereafter the nose arrangement4can be moved in unison with the chute(s)16to prepare for setting operations, without displacing the magazine(s)10. In this case, only a limited number of riveting operations are possible before the nose arrangement4has to be fully retracted to load more rivets.

In other arrangements, small lengths of flexible, semi-rigid or rigid delivery tubing may be used between the magazine(s)10and the chute(s)16. In these arrangements, however, the magazine(s) and the chute(s) would move together with the nose arrangement4when the nose arrangement4is extended. The delivery tubing would move accordingly with the magazine(s) and the chute(s) as a single body, or it could accommodate a differential movement between the magazine(s) and the chute(s), including in the case when the magazine is fixed with respect to the tool and the chute moves with the nose arrangement. Alternative chute arrangements than those illustrated and described herein could be devised. For example, the chute(s) could be arranged perpendicularly with respect to the punch axis and could include a substantially right angle bend to dock with the magazine(s).

The magazines10described herein are replaceable in that they can be removed from the respective chutes16and supports18,19provided therefor on the setting tool2and the C-frame3. Referring now toFIGS.3-6, there are shown the magazines10ofFIGS.1-2in partially (FIGS.3-4) and fully (FIGS.5-6) detached/undocked configurations. For clarity of representation, a portion of a face of the proximal end17of the right-hand side chute16has been cut away to reveal details of the distal end20of the right-hand magazine10. As best seen fromFIG.6, the distal end20of the magazine10incorporates a rivet handling device21in the form of a rotary cam mechanism31for selectively stopping, trapping or releasing one or more rivets from the magazine10. An actuated pin mechanism22is disposed at the proximal end17of the chute16and operates said rotary cam mechanism31. Basic details of the operation of this device31will be described further below.

The operation of the rotary cam mechanism31ofFIGS.4-6is explained in more detail in connection withFIGS.7-10. A pin member23associated with and actuated by said actuated pin mechanism22is received in an aperture provided on a bottom docking interface24of the magazine10. The pin member23is moved by appropriate amounts of compressed air transmitted via suitable pneumatic lines25to the actuated pin mechanism22. The pin member23operates a rotary cam member26arranged in the rotary cam mechanism31to release one rivet A at a time from the magazine10.

Referring now toFIGS.8-10, a through-beam optical sensor27is also mounted on each chute16to check and confirm rivet presence before the rotary cam mechanism31is operated. The through-beam optical sensor27shines a beam of light through corresponding apertures28provided through the magazine10as seen in any ofFIG.8B,9B or10Bin a transmitter-receiver fashion, as known in the art. Interruption of the beam signals the presence of a rivet A′ in a leading position. The leading rivet A′ is engaged by an arcuate cam29as seen inFIGS.8B-Cand is thus stopped from proceeding further in the magazine portion11of the rivet delivery track8.

The leading rivet A′ can also be “trapped” rather than “stopped” by the arcuate cam29in the leading rivet position following a slight anti-clockwise rotation from the default configuration shown inFIGS.8A-C. This option would be used if there was the necessity to hold the leading rivet A′ trapped in the leading position, for example in case of operation of the supply apparatus1by gravity and inversion of the setting tool2.

If inversion of the setting tool2is not contemplated, then the trapping function may be redundant and the rotary cam mechanism31is operated in binary fashion as follows:the rotary cam29is initially rotated to a default configuration which is that shown inFIGS.8B-Cby a resiliently biased pin member30which impinges upon a suitable profile32on the front face of the rotary cam member26; and,the pin member23is pneumatically actuated, when the rivet A′ is sensed as being present, by the actuated pin mechanism22to rotate the rotary cam member26and thus the arcuate cam29disposed on the back face of the rotary cam member26to the position shown inFIG.9B.

Accordingly, the leading rivet A′ is released and the trailing rivet A″ (and any other queuing rivets) is stopped by the arcuate cam29.FIGS.10A-Bare equivalent toFIGS.9A-C, but the perspective allows the relative positions of the leading and queuing rivets A′, A″, of the arcuate cam29, and of the magazine portion11of the rivet track to be better visualized. The magazine portion11of the rivet track8defines a recess47to accommodate the rotary cam member26as shown inFIG.10B.

Considering nowFIGS.5,3and1in sequence, it can be described how on each side of the setting tool2a magazine10can be docked to the chute16. This is done by first disposing the magazine10bsuch that the magazine portion11bof the rivet delivery track8bis aligned with the chute portion33bof the rivet delivery track, as seen inFIGS.5and6; then by moving linearly the magazine10bin direction “v” towards the chute16buntil the pin member23of the actuated pin mechanism22engages the aperture on the magazine lower interface24, as seen inFIG.5; and, by finally docking the magazine10bin place on the chute16b, as seen inFIGS.3and1. Alternatively, the setting tool2may be moved towards the magazine10by the robotic arm200, and/or the setting tool2and the magazine10may move relative one to the other in the docking direction.

To facilitate the initial alignment of the magazine10bwith the chute16b, the elongated body34bof the magazine10bis received in a U-shaped portion35bof the brackets18provided with the chute16b. The magazine10bcan then be smoothly guided down until docking is complete. Alternative or additional features for facilitating the docking of the magazine10bonto the chute16bare possible, for example utilising patterned magnets on the magazine10band/or on the chute16b, or on the magazine10band/or on the brackets18, or correlated magnets between the magazine10band the chute16b, or between the magazine10band the brackets18. These features may include coupling, alignment and/or latching via respective correlated magnets surfaces. One example will be described in more detail in connection withFIG.14.

To undock the magazine, the reverse sequence is applied, for example as described by referring sequentially toFIGS.1,3and5, until the magazine10btherefore becomes completely detached from the proximal portion17bof the chute16bon the right-hand side of the setting tool2, as seen inFIG.5. At this stage, the magazine10can be removed by moving it for example in direction “h” also shown inFIG.5. Alternatively, the magazine can be held in place, and the robotic arm200can move the C-frame3away also in direction “h”, away from the magazine10b. Alternatively, both the setting tool2and the magazine10can be moved one away from the other.

An external pad36bprovided about half-way along the magazine10bas seen inFIGS.1,3and5aligns with the U-shaped portion35bof the brackets18to visually signal docking of the magazine10bin place on the setting tool2to an operator. The external pad36bcould however be provided further up or further down along the magazine10b. Each pad36is essentially a plate covered with a compliant material such as a thin layer of rubber (or other material). Note that the pad36bcan be adapted to constitute a mistake-prevention (also referred to as “Poka-Yoke”) feature for visual inspection from the operator. For example, the external pad36bmay be colour coded, or bar coded, to correspond to a specific type and/or size of rivets supplied by that magazine10b. This information can be readily verified by an external operator, for example an operator carrying a bar-code reader, or trained to interpret the visual information provided by the colour coded pad36b. Other possible uses of these external pads36in connection with replacement operations of the magazines10on the setting tool2will be described below.

A colour coded label, bar code or other Poka-Yoke feature (including one or more fully mechanical, electro-mechanical or electronic Poka-Yoke features) may alternatively be provided elsewhere on the magazine. For example, a fully mechanical Poka-Yoke feature could be provided by the fit (or lack thereof) between the distal end20of the magazine10and the proximal end17of the chute16. Accordingly, certain chutes16could be adapted such that the setting tool2may only accept certain types of magazines10corresponding to predetermined types and/or sizes of rivets. Alternatively, the brackets18supporting the magazines10on the setting tool2could be so adapted.

As another example, a rivet information reader201in the form of an electro-mechanical rivet check device may be provided on the setting tool2as shown inFIG.14. For example, this could be a device comprising one or more levers or buttons located on a longitudinally extending member181of the brackets18provided on the setting tool2to support the magazines10. These levers or buttons could be actuated, thereby confirming a correct (or incorrect) type of rivets or other fastener stored in the magazine10, by corresponding features (such as ridges, slots or the like) formed on a tool-facing side203of the magazine10. The tool-facing side of the magazine203is indicated inFIG.33. Note that, by way of example only,FIG.33also shows and indicates a bar code202as the magazine Poka-Yoke feature. The electro-mechanical rivet check device201is able to generate and transmit one or more signals to a controller1203, as also show inFIG.14by the downward-pointing arrow. These signals are associated with and/or are representative of the type and/or size of rivets stored in the magazine10.

The controller1203can be the controller of the robotic arm200, or a separate controller that is however operatively coupled to the robotic arm200. In its most basic form, the controller1203will include a processor and a memory. These details are not however discussed further in this disclosure. The skilled person will, however, recognise that a large variety of suitable controllers are possible, for example including one or more personal computers, which could be dedicated to the operation of the robotic arm200or that operate the robotic arm200in addition to other machines (such as the fastener setting tool2and/or bulk feeder apparatus). Further, the controller1203and the reader device201could be provided as parts of a same machine, or could be implemented on different machines in communication between them.

Said one or more signals issued by the rivet information reader201may be representative of a condition of the setting tool2whereby the setting tool2is capable of delivering the rivets required for a predetermined setting operation. This is, in the present disclosure, associated with the capability of the rivet setting tool2to read rivet type and/or size information from the correct magazine10docked to the setting tool2. This capability is implemented by the presence of the rivet information reader201described herein. Alternatively, said one or more signals issued by the rivet information reader201may be representative of a condition of the setting tool2whereby the setting tool is not capable of delivering the correct rivets. This is, in the present disclosure, associated with an incorrect magazine10being docked on the setting tool2. Note that it may be possible to adapt the rivet information reader201such that absence of any signals generated by it may signify a correct or incorrect fastener type and/or size being stored in the magazine10loaded on the setting tool2.

The magazine controller1203is configured to receive and interpret any information received from the rivet information reader201. In response thereto, if the fasteners stored in the magazine10are not of the type and/or size required for a current fastening application, the controller1203generates one or more signals (again, this may include a nil signal) to instigate the robotic arm200to undertake a magazine replacement operation as described herein. If instead the magazine10in question is correct (ie it stores one or more rivets of the type and/or size required in the instant fastening operation), then the controller1203may issue one or more signals that positively support a fastener setting operation. For example, the controller1203may issue a signal triggering a fastener setting operation as described herein. Alternatively, the controller1203may issue a signal triggering motion of the robotic arm200for relocating the setting tool2to a location where the installation of a rivet is required, or a signal signifying that any one of the above operations can be carried out by the robotic arm200and/or setting tool2at a later moment. In this case, the system has recognised that the correct rivet is available and thus the system is not inhibited from carrying out rivet setting operations. In other words, it is not necessary to first replace (or refill) any of the magazines10docked to the setting tool2. These signals are schematically represented by the arrow pointing to the right inFIG.14.

As it will be apparent, electronic Poka-Yoke features may be preferred. For example, to check the appropriateness of a tool-mounted magazine10in respect of a current or ongoing fastening operation, a rivet information reader201in the form of a bar code reader, or RFID reader, could be used. In this case, the magazines10would correspondingly have to be bar code tagged or RFID tagged. For example, inFIG.33the magazine10is bar code tagged (see bar code202) and inFIG.14the rivet information reader201is represented by a bar code reader. Other chips may however equally be used, such as for example Near Field chips. Any of these chips and devices may or may not require contact for a reading to take place. Contactless chips and chip reading devices may be preferred.

Any of the above measures may contribute to ensure security of rivet type supply—provided that the magazines have correctly been filled with the intended type and/or size of rivets or other fasteners.

With reference toFIG.12, a rotary magazine carousel37and a rotary die assembly carousel38are provided on either side of a setting tool2like that shown, for example, inFIGS.1-6. The magazine and die assembly carousels37,38support a number of replacement magazines10b,10c,10d,10f,10g,10hand a number of replacement die assemblies for replacing, respectively, the replaceable magazines10a,10emounted on the setting tool, and the replaceable die assembly6.

InFIG.12, each magazine10has a magnetically patterned surface39for holding the magazine on attachment points40provided on supports41situated on the magazine carousel37. The attachments points could be plates made of a ferromagnetic material. These plates could be coated with, for example, a layer of a compliant material, such as rubber, and thus be also referred to as “pads” instead of plates (conversely, the magazine pads described herein could be just plates). However, in the arrangement described, all the magazines10including the replaceable magazines10a,10ehave respective magnetically patterned surfaces39a,39efor connecting with magnetically correlated surfaces44a,44eprovided on free attachment points40a,40elocated on spare support structures41a,41e. The attachment points40including free attachment points40a,40eare provided in the form of support pads43a,43eof equal size than the external pads36a,36eprovided on the magazines10a,10e. However, alternative forms would be possible. The magnetically patterned surfaces39are provided on the magazines10on the respective pads36purely for convenience. Said magnetically patterned surface39could alternatively be provided, at least in principle, on any portion of outwardly-facing surfaces42of the docked magazine10a. Providing dedicated pads36for this purpose is, however, preferred.

An undocking procedure for undocking the right-hand side replaceable magazine10ais now described. The C-frame3can be moved by the robotic arm200towards any of the two magazine carousels37in direction “h”. The C-frame is moved to the right to undock right-hand side magazine10auntil the corresponding pads36a,43aare in proximity one next to the other. In this configuration, magnetically correlated surfaces39aon the magazines10ais nearly magnetically engaged with corresponding correlated surface44aon the attachment point40aon the right hand side of the setting tool2. The C-frame3may then undertake small movements in directions coplanar with the support pads36a,43ain directions “v” and “p” shown inFIG.12, or out of plane, in direction “h”, also shown inFIG.12, until the magazine10abecomes properly magnetically attracted to, and eventually held on, the attachment point40aon the spare support structure41a. Once connected to the support41a, the magazine10acan be undocked from the setting tool2by withdrawing the setting tool2downwards in direction “v”. The magazine is held in position against any downward forces exerted thereon at the time of withdrawing the setting tool in direction “v” by a shear force generated by correlated-magnets surfaces39a,44a. Alternatively or additionally, the magazine may be held in position on the magazine carousel37by reaction key-like abutments or protuberances provided on the support plates43. These features (not shown) could be provided so as to work in both the docking and undocking directions along direction “v” shown inFIG.12. For example, these key-like abutments or protuberances could be provided on the upper and lower edges of the support plates43. Approach to the rotary magazine carousel37to undock the magazine10could alternatively be in direction “p”.

In the described arrangement it is the robotic arm200that moves the C-frame3and the setting tool2towards the magazine carousel37for undocking the magazine10a. However, in principle, the carousel37could instead be moved toward the setting tool2. Once undocked, the magazine10arests on previously spare support structure41ain exactly the same way as other replacement magazines10b,10c,10drest on corresponding additional support structures41b,41c,41don the right hand side of the tool2as shown inFIG.12.

The same procedure can be applied to undock replaceable magazine10e, so that it will then be supported on spare support structure41eon the left-hand side carousel37. This other carousel supports the three other replacement magazines10f,10g,10h, as also shown inFIG.12.

By following a reverse sequence it is instead possible, for example, to dock one of the replacement magazines10f,10g,10hon the left-hand side of the setting tool2. For this purpose, assuming that replacement magazine10fis chosen between the available replacement magazines10f,10g,10hon the left-hand side of the setting tool, the magazine body34fis first accommodated by moving the robotic arm and/or the carousel37, as the case may be, within U-shaped portion35fof the brackets18on the setting tool2. Note that the left-hand side magazine carousel37shown inFIG.12may have to be rotated 90 degrees clockwise to facilitate this operation. The empty setting tool2and/or the movable nose arrangement4are then moved upwards in direction “v” to dock the magazine10fon the distal end17eof the chute16e. The magnetic attraction force between the attachment point40fon support structure41fand the external pad36fof replacement magazine10fis such to permit the magazine10fto detach from the carousel37. Once the magazine10fis docked in place on the chute16e, the magazine10is constrained by the chute16eand the setting tool2can therefore be moved away from left-hand side carousel37in direction “h” and/or “v” to overcome the magnetic force between the correlated-magnets surfaces39f,44fthat hold the magazine10fin place on the corresponding support pad43f. Alternatively or additionally the docking procedure may involve the key-like abutments or protuberances described above in connection with the undocking procedure, and the docking procedure would then follow an inverse process with respect to that undocking procedure.

The magnetic holding force that holds the replacement magazine10fon the support41fmay be relatively high. Thus it may not be advisable to break the magnetic force between the magazine10fand the support pad43fby suddenly moving away the setting tool2in a predetermined direction as this could in principle damage the magazine10for the chute16e(or both) as undue stress on the joint between the magazine10fand the proximal end of the chute17emay be generated. It may be possible first to perform small movements of the setting tool2in direction “p”, or in direction “v”, to bring the magazine pad36fin slight misalignment with the support pad43fon the support41f. This may suitably weaken the magnetic bond between magnetically correlated surfaces39f,44fwhen the pads36f,43fare in perfect alignment, and this may in turn facilitate the release of the magazine10ffrom the carousel37. This feature can be enabled by the characteristics of the magnetic forces generated by the correlated-magnets on the replacement magazine10fon one side and the support structure41fon the other side. Replacement magazine10fhas now replaced replaceable magazine10eon the left-hand side of setting tool2.

Each magazine carousel37comprises four support structures41, disposed in quadrant arrangement, one or more of which may be free to receive a replaceable magazine10a,10eas exemplified inFIG.12. Otherwise, the four support structures41on each carousel37may simultaneously support four magazines10, for example at the start of a new setting procedure when the setting tool2has not yet been loaded. The magazine loading/unloading operations are facilitated by the fact that the carousels37can be rotated. Thus, an empty support structure41aor a required replacement magazine10b,10c,10dcan be disposed to face the setting tool2in preparation for the loading/unloading operations described above.

While any magazines10are supported on the carousels37, refill can take place. Meanwhile, the loaded setting tool2is ready for new setting operations, until any of the replaceable magazines10a,10ewill need to be replaced by any of the available replacement magazines10b,10c,10d,10f,10g,10h. InFIG.12, all the magazines contain the same rivets, but it will be appreciated that different magazines may contain different rivets and share the same magnetically patterned surface39on the external pads36.

The pairs of magnetically correlated surfaces39,44provided, respectively, on the magazines10and on the supports41provided on the carousels37can be designed to facilitate the docking and undocking operations described above. For example, said pairs of magnetically correlated surfaces39,44may provide for mechanical alignment of the respective pads36,44in addition to magnetic holding. Alternatively or additionally, mechanical latching as described above could also be implemented. In addition, mechanical release could also be implemented, for example triggered by bringing the pads36,44out of alignment further than a predetermined distance.

Further, the properties of the magnetically correlated surfaces39,44could also in principle be used as a Poka-Yoke feature, that is to ensure that only predetermined magazines having appropriate magnetically correlated surfaces can be supported on any specific supports41. This could be achieved, for example, by specifying a spring-type mechanical function between those magazines and any supports41not intended for that magazine. A coupling function can instead be specified between these magazines and the supports intended to support them on one of the carousels37.

A process of refilling the replacement or replaceable magazines10is now described with reference toFIGS.13,15,16and17A-C.FIG.13illustrates a set up similar to that ofFIG.12. However, in the arrangement ofFIG.13the replacement magazines10b,10c,10d,10f,10g,10hare supported on upright racks41on the right and left hand sides of the setting tool2instead of being supported on rotating carousels37. Docking blocks70are provided to refill simultaneously up to four replacement magazines10on each upright rack41. Each docking block70has a lower docking interface66as shown inFIG.13with docking features for coupling with up to four upper docking interfaces12of corresponding magazines10while they are all supported on one of the racks41. Correspondingly, four rivet feed flexible tubes71extend away from each docking block70and feed rivets to the magazines10via the lower docking interface66of the docking block. Pairs of through-beam optical sensors27can be used in conjunction with the replacement magazines10as shown inFIG.13for confirming that the magazines have been filled with fasteners. The sensors, however, are not mounted on the magazines10. Instead, they can be provided as an accessory to the docking block70. The operation of these optical sensors has already been described in some detail above in connection withFIGS.8-10, and it will not be described again. However, it is noted that the magazines10each define aligned pairs of suitable apertures in light-transmitting communication with the magazine portions11of the rivet delivery tracks8at their proximal ends15, as shown for example inFIG.13. The magazines10can thus be filled with rivets which are then stored in said magazine rivet delivery track portions11until the sensors27confirm that the magazines10are full. Alternatively, the magazines10can be weighed while on-stand to check the level of replenishment. Weighing the magazines to establish fill level constitutes an absolute measure of their replenishment. Therefore, this process can be considered to be more reliable, and thus preferable, with respect to the above method of counting the number of discrete rivets passing through the optical sensors.

While various docking mechanisms are possible, preferred methods involve providing the upper docking interfaces12of the magazines10with respective magnetically patterned surfaces45for connection and, more preferably, connection and alignment with, one or more corresponding magnetically correlated surfaces46provided on the lower docking interface66of the docking block70shown inFIG.13, or on the lower docking interface of another refill device48such as that shown inFIG.15.

In the arrangement shown inFIG.15, the refill device48is a rivet feed tubular member49with a pair of internal passageways50for delivering rivets from a bulk-feeder to the magazine10. The magazine is a dual-track magazine10with two upper magazine tracks60which can be refilled simultaneously once the magazine10has been docked to the refill device48. The two upper tracks60of the magazine10could be independent, or merge and share a common lower magazine track, as for example shown inFIGS.35-38,41and42. These magazines will be further described below. Only the proximal end15of the magazine10is shown inFIG.15, since this is the only relevant portion of the magazine10for the refill operations. Positioning and alignment of a robotically mounted magazine10may require a high degree of accuracy and repeatability by the robotic arm200. In turn, this may require considerable programming skills to bring two faces together when account is taken of up to six degrees of freedom for the position of the magazine10. Therefore, it is desirable to mount the refill device48in such a way that it has small freedom of movement, but for a relatively larger freedom of movement in a translational direction, for example the vertical direction inFIG.15. It is also desirable to provide for a predetermined at-rest position of the refill device48, ie a reset position that the refill device48is able to achieve when the magazine10is not docked thereto. The rivet feed tubular member49is thus mechanically constrained in the axial (vertical) direction by mechanical stop means51, which in the arrangement shown are a pair of spaced-apart rings52which allow some axial (vertical) movement. One or more mechanical springs (not shown) may additionally be provided in this arrangement so as to centre the rivet feed tubular member in the at-rest position. The rivet feed tubular member49can thus move vertically only within a predetermined range of vertical positions, as permitted by the spaced apart rings52, and will return to a default position when no magazine is docked thereto.

The rivet feed tubular member49is supported on a first support structure53which, in the shown arrangement, is in the form of a tripod54(only two arms of which are shown in the purely schematic representation ofFIG.15). The tripod54is mounted on a second support structure55via three compliant mounts56. The second support structure55is a fixed stand59in this example. However, in other examples, the second support structure55could be mounted on a robotic arm, or movable vehicle. Various types of compliant mounts56are possible, for example using mechanical means such as springs or layers of compliant material such as rubber. The compliant mounts56shown inFIG.15are instead provided by three pairs57of spring-type correlated-magnets surfaces58. Note that only two of these pairs57are shown inFIG.15. For each pair57, a first correlated-magnets surface58ais disposed at a distal end68of the tripod54; a second correlated-magnets surface58bis disposed at a proximal end69of the stand59. The three pairs57of compliant mounts56are thus arranged to provide omnidirectional compliancy so that the magazine10cannot be damaged by the refill device48when the magazine10is docked or undocked thereto. Further, it will be apparent that the compliant mounts56may in addition be designed to replace some of the one or more springs referred to above, which may be used to centre the refill device48between the pair of spaced apart rings52.

The arrangement is such that when the magazine10hovers close to the correlated-magnets surface46provided on the refill device48, the refill device48is gently drawn in contact with the docking interface12of the magazine10, with the refill passageways50aligned with the two upper magazine tracks60in readiness for the magazine to receive rivets from the bulk feeder (not shown). This performance is made possible by the alignment function performed by the pair of correlated-magnets surfaces45,46disposed, respectively, on the magazine docking interface12and on the lower docking interface66of the refill device48as shown inFIG.15. The correlated-magnets surfaces45,46are obtained by inserting pairs of correlated magnets63,35on the respective docking interfaces12,66on the magazine10and on the rivet feed tubular member49as shown inFIG.15. The arrangement shown inFIG.15is preferred for refilling a magazine mounted on the setting tool. The docking process for refilling the magazines10is thus quick, simple and accurate. However, this arrangement can potentially also be used for refilling replacement magazines supported, for example, on the carousels37shown inFIG.12or on the upright racks41shown inFIG.13.

When the refill operation is complete, as the refill device48is released (this can for example be determined by relative shear movement between the magazine10and the refill device48), the compliant mounts56, in cooperation with any additional springs provided for this purpose, return the rivet feed tubular member49to its default position shown inFIG.15. The magazines10can thus be undocked by moving, for example, the setting tool2laterally to bring the interfaces12,66out of alignment to overcome the alignment forces generated by the magnets63,65to realign the interfaces12,66. The magnets may preferably be patterned so as to generate a repulsive release force when the misalignment exceeds predetermined limits. Alternatively, the magazine10may be driven in the axial (vertical) direction to break the magnetic holding force.

FIG.16shows an alternative arrangement for the compliance mounts56. Each compliance mount is again provided as a pair57of magnetically correlated surfaces58a,58bcapable of performing at least a compression spring-type function and, preferably, also a vertical alignment-type function. First correlated surfaces58aare provided on respective internal faces75of an external cluster of first rhomboid plates76inclined with respect to the axial (vertical) direction. First rhomboid plates76are equivalent to tripod54ofFIG.15. Second correlated surfaces58bare provided on respective external faces77of a corresponding internal cluster of second rhomboid plates78, generally parallel to the first rhomboid plates76, arranged as shown inFIG.16. Some or all of the second rhomboid plates78could be used to mount a refill device48similar to that ofFIG.15. The second rhomboid plates78are equivalent to the support structure55inFIG.15. The refill device could then be attracted downwardly by the approaching magazine as described above. Such attraction would displace the first cluster of rhomboid plates76and accordingly the first correlated-magnets surfaces58afrom the default position shown inFIG.16. Second correlated-magnets surfaces58bwould then give rise together with displaced first correlated-magnets surfaces58ato a return or realignment vertical force. In case of horizontal displacement of the first cluster of rhomboid plates76due to the action of the magazine10on the refill device48, displaced first correlated-magnets surfaces58awould then give rise together with the second correlated-magnets surfaces58bto a return or realignment horizontal force.

FIG.17Ashows schematically two patterned magnets65mounted on the lower docking interface66of the refill device48ofFIG.15and the resulting magnetically correlated docking surface46. Two permanent magnet inserts with the same magnetic pattern are used. It will thus also be clear that the expression magnetically correlated surface does not mandate that said surface be completely magnetically patterned. Rather, a magnetically correlated surface as described herein is intended as a surface that is at least in part magnetically patterned to achieve a required mechanical function or overall user experience.

FIG.17Cshows an alternative arrangement showing schematically the same patterned magnets65disposed, however, on a portion of the lower docking interface66arranged at right angles with respect to the portion of the docking interface on which the outlets of the rivet feed passageways50depicted inFIG.15are located. This arrangement may be convenient in that the outlets and the magnets65do not lie on the same plane. Accordingly, this may prevent dust or debris from accumulating on the magnets thus potentially compromising the mechanical function or user experience provided by them. This may thus also in principle affect the alignment of the outlets50of the refill device48and the upper portions60of the rivet tracks in the magazine10.

FIG.17Bshows instead a magazine upper docking interface12designed for docking with the interface66ofFIG.17C. The patterned magnets63on the magnetically correlated surface45have complementary patterns with respect to those of correlated magnets65, as shown inFIGS.17B-C(although it will be noted that the representation of the patterns inFIGS.17A-Cis merely schematic, and is not in agreement with patterns which would be used in practice). The upper docking interface12fits in a recess77defined by the lower docking interface66as shown inFIG.17C.

The correlated magnets65may be mounted flush with the recessed mounting surface shown inFIG.17C, or slightly underflush without an appreciable impact on magnetic performance. This may however favour an accurate positioning of the interfaces12,66and thus of the magazine with respect to the refill device.

The arrangement inFIGS.17B-Cdiffers from that ofFIG.17Afor three additional reasons:a) it reduces the force required for disconnecting the docking interfaces12,66by allowing a shearing force to act on the coupled magnets when the magazine is withdrawn axially (it will be recalled that shear forces in given patterned magnets are typically about one fifth of the axial holding force);b) it provides for patterned magnets positioned further away from the rivet (or other fastener) delivery path to avoid any magnetic interference with the fasteners; and,c) it generally improves the compactness of, and therefore the accessibility to, the proximal end of the magazine.

FIG.14is similar toFIGS.12and13in that it shows a setting tool2predisposed for magazines10of the type described herein. A set of four fixed vertical posts41a,41n,41c,41dsurrounds the setting tool2: two posts41a,41dare located on the right-hand side of the setting tool2and two41b,41con the left-hand side; two posts41a,41bare located at the back of the setting tool2, and two41c,41dat the front thereof.

Each vertical post41has features similar to the supports41described in connection with the magazine carousels37ofFIG.12, or the upright racks41described in connection withFIG.13. Thus, each post41a,41b,41c,41dhas an attachment pad43a,43b,43c,43dfor supporting a magazine10. Each attachment pad43a,43b,43c,43ddefines a respective attachment point40a,40b,40c,40das indicated inFIG.14. The attachment points40could in principle include a variety of attachment means. However, it is preferred that the magazines10be supported via corresponding magnetically patterned surfaces44a,44b,44c,44das described above provided on said attachment pads43a,43b,43c,43d. Magazines10made of ferromagnetic material could thus be attached to the attachment pads43via the magnetic field generated by the corresponding patterned magnets. Alternatively, the attachment pads could include a ferromagnetic material and the magazine could incorporate one or more patterned magnets. However, it is preferred to provide magnetically correlated patterned surfaces39on the respective external surfaces42of the magazines10, as shown inFIG.14for interaction with corresponding correlated magnets surfaces on the vertical posts41. Further, it is preferred to provide said correlated-magnets surface39on a corresponding external pad36on each magazines10. These external pads have already been described above and four such pads36a,36b,36c,36dare also shown inFIG.14. The correlated-magnets surfaces39,44will not be further described herein, but they can have any of the features described above in connection, for example, withFIGS.12,13, and15-17.

Magnetically patterned surfaces to aid with the docking of the magazines10could also be included in any one or more of the recess faces of the U-shaped portions35of the brackets set18on the setting tool2. These recesses are clearly shown inFIG.14. The magazines10would then include on the corresponding face(s) corresponding magnetically patterned surfaces. The mechanical functions performed by these correlated magnets could be a combination of coupling, alignment, latching, spring biasing and/or release, to suit the docking manoeuvre.

The arrangement shown inFIG.14in addition has two racks80for supporting replacement magazines10on either side of the C-frame3. Each rack80can support up to four replacement magazines10. Fewer or more magazines10are however possible and this will generally depend on the overall size of the magazines10and the size of the C-frame3and the setting tool2. The posts41could each represent a remote magazine refill station. Thus the robotic arm can be used as described in connection with the supports and upright racks41ofFIGS.12and13to offload any replaceable magazines mounted on the setting tool or any of the replacement magazines10supported on the racks80on any one or more remote magazine refill stations41for refilling the magazines10remotely.

In addition, the arrangement ofFIG.14allows the robotic arm200to carry out a complete magazine replacement operation in cooperation with one or more of the refill stations. Any replaceable magazines mounted on the setting tool2can first be offloaded at one or more of the posts41. Optionally, these magazines can then be refilled and then loaded back on one of the racks80provided on the C-frame. The robotic arm200can then offload one or more replacement magazines10located on any one of the racks80at one or more of the posts41. Finally, the robotic arm200can select any of the replacement magazines supported on the posts41and then dock them in rivet supply engagement on the setting tool with a procedure similar to that described in connection withFIGS.12and13. The arrangement ofFIG.14is thus advantageous because any replacement magazines are carried on the C-frame, and the robot can then autonomously replace any replaceable magazines with any of the replacement magazines when required (for example when the rivets of the replaceable magazines have run out) by cooperating with one or more external structures such as the posts41shown inFIG.14that have been provided for this purpose.

The utilisation of correlated-magnets surfaces in the procedures for refilling and/or replacing the magazines may conveniently reduce the positioning accuracy requirements on the robotic arm200. Thus the robotic arm200may only be requested to dispose the magazines generally close to, for example, the refill device48ofFIG.15or any one of the supporting structures41shown inFIGS.12-14. Docking between the docking device48and the magazine10is then facilitated by the correlated magnets surfaces on the one and on the other of these components. Likewise, connection between one support41and the magazine10is facilitated by the presence of correlated-magnets surfaces.

With reference toFIGS.18-24there is shown an alternative setting tool2comprising a pivotal magazines10a,10bdisposed, respectively on the right and left-hand sides of the tool2. The right hand side magazine10aincludes three independent magazine portions11a,11b,11cof the corresponding rivet delivery track8a, as shown inFIG.18. The rivet delivery track8aextends further than the magazine10ato reach the nose arrangement4, as in the previous arrangements. The rivet delivery track8aalso includes a corresponding chute portion33a(indicated inFIG.24) of the rivet delivery track8a. The magazine10ais supported so as to be movable with the nose arrangement4as it extends towards the die assembly6. The same considerations apply to left hand side magazine10b.

The pivotal arrangement of the magazines10a,10bis used to select supply of rivets from any one of the three independent magazine portions11of the rivet delivery tracks8on each side of the setting tool. For example, in the configuration shown inFIG.18, on the right hand side it is the central magazine portion11bof the rivet delivery track8awhich is in rivet-supply relation with the chute16a. Any rivets present in the other magazine tracks11a,11care held within the magazine by respective rivet handling devices21located at the distal end20aof the magazine10a. Three rivet handling devices21are provided on each magazine at the distal ends20thereof. These will not be described again, since they are each in the form of the rotary cam escapement31described above. InFIG.18, three rotary cam escapements31a,31b,31care visible, each associated with a respective independent magazine track portion11a,11b,11c.

FIG.19illustrates the extension of the magazine track portions11a,11b,11cwithin the pivotal magazines10ashown inFIG.18. There is a central track portion11bwhich has a substantially straight extension along a central axis of the magazine10a. On either side thereof, second and third curved tracks11a,11cextend with opposed curvatures as shown inFIG.19. At the proximal ends of the tracks11, three docking devices114a,114b,114cof the same type described in conjunction withFIG.11Bare provided to permit refill of the magazine from a bulk feeder (not shown), and to prevent spillage of rivets in case of magazine inversion. Thus, the upper docking interface12aof the magazine10ais predisposed for docking with the lower docking interface66of a docking block70(shown inFIGS.29-31) similar to that shown inFIG.13, but with the lower docking interface66curved to match the curvature of the magazine docking interface12a.

The docking devices114are also represented in enlarged form inFIG.20A, which shows the proximal end15aof the magazine10ain greater detail. The round apertures28a,28b,28cvisible inFIG.20Arepresent intakes for respective beams of light emitted by through-beam optical sensors as described above (but not shown herein). Each transmitter-receiver pair of said sensors can be used to check whether each of the three independent magazine tracks11on each of the magazines10has been fully filled with rivets.

At the distal end20aof the magazine10a, which is shown in more detail inFIG.20B, three arcuate cams29a,29b,29cof the respective rotary cam escapements31a,31b,31cdescribed above are visible. In the configurations shown inFIGS.19and20B, these arcuate cams stop corresponding rivets Ba, Bb, Bc located at the distal ends of the respective tracks11a,11b,11c. The rotary cam escapements31are operated in similar fashion as the rotary cam escapement described above, for example, in connection withFIGS.7-8. The operation of the rotary cam escapements31of the pivotal magazine10is briefly further described below in connection withFIGS.25-28.

By rotating the magazine10aaround its pivot81(indicated inFIG.19), and by operating the actuation mechanisms22aprovided therefor, it is therefore possible to select supply of rivets B from any of the three independent magazine tracks11a,11b,11c, on either side of the rivet setting tool2, in the mirror magazine configuration ofFIGS.18-24.FIG.21, in particular, shows the pivotal magazines10a′,10b′ ofFIG.18in clockwise-rotated configuration. Thus inFIG.21independent magazine track11cis selected on the right hand side pivotal magazine10a′. It is noted that the rivets B stored on each of these tracks11may be the same or may have different shapes and/or sizes.FIG.22is a front view of the setting tool2in the configuration shown inFIG.21. This Figure allows a better appreciation of the position of the respective pivots81a,81bof the magazines10a,10b. The actuated pin mechanisms22a,22bon either side of the setting tool2can also be better visualized.

With continued reference toFIG.22, a rivet B thus enters, for example, magazine10bon the left hand side, via docking interface12b. The rivet B is stored and transits through one of the corresponding magazine tracks11in the magazine10b, depending on the pivotal configuration of the magazine10bat the time the rivet B enters the magazine10b. Release of the rivet B from the magazine10bto the nose transfer area5bis decided by operation of one of the rotary cam escapements31associated with the magazine10b, when the appropriate track11is in rivet-supply communication with the respective chute16b. The rivet enters the chute16band transits therethrough from the proximal end17bto the distal end13buntil reaching the rivet transfer area5b. This describes the path of the rivet through the left hand side supply system1b. A similar path would occur on the right hand side supply system1a.

FIG.23shows additional constructive details of the pivotal arrangement of the magazines10a,10b. A pivotal key82ais provided on the right hand side for coupling with a corresponding recess (now shown) provided on the right hand side magazine10a. The pivotal key82bof the left hand side magazine10bis visible inFIG.23, disposed around the magazine pivot81b. A rotary actuator such as an electric motor83ais responsible for the pivotal configuration of the magazine10aon the right hand side and, therefore, for selection between the independent rivet tracks11a,11b,11cprovided on the magazine in connection with any rivet refill, or rivet supply operations, to and from the magazine10a.

FIG.24is an enlargement of parts ofFIG.23with the nose arrangement4in an extended configuration to reveal the chute portions33a,33bof the rivet delivery tracks8a,8b. In the arrangements described herein, the pivotal magazines10a,10bare supported so as to be movable with the nose arrangement4when the nose arrangement4is extended in preparation for a setting operation. However, alternatively the pivotal magazine could be fixed with respect to the setting tool and/or C-frame and load one or more rivets into the chute in preparation for one or more setting operations.

As mentioned above,FIGS.25-28show in sequence the operation of one31bof the rotary cam escapements31a,31b,31cassociated with a pivotal magazine10. The operation is entirely consistent with the rotary cam escapement described in connection withFIGS.7-10. Accordingly, the aspects already described above will not be repeated and express reference is instead made to those parts of the present description, and toFIGS.7-10. In the arrangement ofFIGS.25-28, however, the pin member23of the actuated pin mechanism22also registers in place the magazine10before a rivet is released from the magazine10on the chute16in preparation for a setting operation. Thus, with reference toFIG.25, the magazine is rotated on its pivot to select the required magazine track. This is the central magazine track as shown inFIG.25. The pin member23is then partially extended by the actuator22as shown inFIG.26. A successful outcome of this part of the actuation routine signals registration in place of the selected magazine track with respect to the proximal end of the chute17. The magazine10and the chute16are now in rivet-supply relation. The proximal end of the chute17is in the present arrangement in the form of a chute block rather than a chute sleeve, as was the case for the non-pivotal magazines previously described. If registration in place of the pivotal magazine10is not successful, the electric motor83is operated accordingly until registration is achieved. The pin member23can then be extended fully (refer toFIG.27) to operate the rotary cam member26of the rotary cam escapement31. The rotary cam member has a profile32which, in cooperation with the movement of the pin member23, determines clockwise rotation of the rotary cam member26which, in turn, determines rotation of arcuate cam29to release a rivet. The rotary cam mechanism then regains its default, rivet-stopping position due to the retraction of the pin member23(refer toFIG.28) and the passive, contrary action of the corresponding resiliently biased pin member30bon the profile32of the rotary cam member26.

InFIG.29, the pivotal magazines10are each docked to a respective docking or refill block70. Each refill block70is permanently connected to a bulk feeder device via three flexible refill tubes71. Each tube exclusively serves one of the independent magazine tracks11that run through the magazine10. Note that this could be a permanent arrangement for supplying rivets from a bulk feeder to the magazines10while they are mounted on the setting tool2. Alternatively, the refill block70could be releasable (refer toFIG.30) and could be docked to any magazines when required. For example, one of the magazines10could be supported on a support structure41as shown inFIGS.30-31. Further, the magazines shown inFIGS.30-31could be supported on the corresponding support structures41by means of a patterned magnet mounted on the magazine's back face or on the support structure41. This requires the other of said parts10,41to be made of a ferromagnetic material. Alternatively, the magazines and the support structures41could be supported via correlated-magnets surfaces exactly as discussed in connection withFIGS.12-17, and reference is made herein to the corresponding parts of the present description.

FIGS.32-35show alternative magazines10which do not require a chute. Each of these magazines10is directly docked to the nose arrangement4. Each of these magazines thus includes at the outlet thereof a rivet transfer device14of the type already described in connection withFIG.11(although not visible inFIGS.32-35).

InFIG.32, a single magazine arrangement is shown whereby rivets would be supplied to the rivet setting tool2only from the right hand side. To provide adequate support for the arrangement, the bracket18that supports the magazine10is extended on the left hand side to reach and connect with the nose arrangement4. This prevents the rivet transfer area on the left hand side of the nose arrangement from being unnecessarily exposed to dust from outside. Further, this arrangement clearly allows the supply system1to be symmetrically supported on the setting tool despite the presence of a single magazine10. It will be understood that the extension of said bracket18, which effectively acts as a dummy magazine, can at any time be replaced with an actual magazine10, for example, but not exclusively, with another magazine of the same type. This brings us to the configuration shown inFIG.33.

InFIG.33, a dual-sided arrangement includes two mirrored single-track magazines10of the type also represented inFIG.32. It is to be noted that each magazine is predisposed for, but not equipped with, a rivet handling device in connection with a lateral enlargement of the magazine body34located about half way along the extension of the magazine10. At that location, front and back cover plates84,85can be removed to provide access for the installation of a rivet handling device such as those shown inFIG.34.

FIG.34is a dual-sided arrangement including two mirrored single-track magazines10a,10beach equipped with a linear-pin escapement21a,21bdisposed about half-way along the magazine. The linear-pin escapement will be described briefly below.

FIG.35is a dual-sided arrangement including two mirrored double-track magazines10a,10b, each equipped with two rivet handling devices21aa,21ab,21ba,21bbin the form of linear-pin escapements96(indicated inFIG.37) disposed on each of upper tracks (similar to those described in connection withFIG.15) of the magazines10a,10b. Each magazine10,10bfurther includes a track selection device90a,90bfor selecting from which of the two upper rivet tracks to supply one or more rivets to the nose arrangement4. In the described magazine, the track selection device90is in the form of a rotary track selector91and this will be briefly described below.

FIGS.32-35also show a number of other features of the magazines10described herein which have already been described above. These features will not be described again, but are listed herein for ease of reference toFIGS.32-35. Each magazine has a lower docking interface24at the distal end20of the magazine for docking with the nose arrangement4. Next to the docking interface24a vacuum connection92which communicates with the rivet delivery track11inside the magazine provides a rivet motive force in the magazine10. Accordingly, the magazines10are not required to have a sealing feature at the upper docking interface12, as would normally be required if positive pressure was used to move the rivets through the rivet supply system1. The magazines are generally tubular structures comprising a body34and a magazine track11extending therethrough, from a corresponding magazine inlet93to an outlet94. In the case of the magazines ofFIG.35, the magazine track11bifurcates to accommodate two upper magazine portions60of the magazine track11, as shown inFIG.15and as will further be described in connection withFIG.41below. Accordingly, two inlets93aa,93aband a single outlet94aare defined in this magazine10a. The upper tracks60merge into a lower portion95(refer toFIG.41) of the magazine track11where all the rivets delivered by that magazine10transit. The magazines10may be equipped with one or more rivet handling devices21and, where multiple independent upper tracks60of the magazine track11are present, a track selection device90.

FIG.36shows two magazines10a,10bof the type shown inFIG.35mounted in mirror configuration on a setting tool2to provide a complete rivet supply system1as described herein. The nose arrangement is shown in the retracted configuration inFIG.36. However, as described above, this can extend toward the nose assembly6in preparation for one or more rivet setting operations. The magazines10a,10bare supported so as to be movable with the nose arrangement4by means of bracket set18(of slightly different mechanical construction than those described above). The magazine's distal ends20a,20bare adapted so as to be guided and slide through corresponding C-shaped brackets19a,19bprovided on the C-frame3, as also shown inFIG.36. Accordingly, the magazines10a,10bmaintain their rivet-supply relation with the nose arrangement4without any undue stresses while moving, especially at the lower edge where they dock with the nose arrangement4. Further, as for the magazines described above, the movement of the nose arrangement4can be used to disengage the magazines10a,10bfrom the setting tool2, if the magazines10aa,10bare appropriately connected to an attachment point40for example provided on an external post41as described above. The use of patterned magnets and correlated-magnets surfaces can also be extended to this type of magazines10a,10b, as will be apparent to the skilled person based on the teachings in the present specification.

FIGS.37A-Bshow a magazine10of the same type shown inFIGS.35and36, and show in more detail some external features of the linear-pin escapements96. These escapements are essentially constituted by a set of pin barriers mounted on a common plate (refer toFIGS.43-45). Linear actuation of this common plate provides the required rivet stop, trap and release functions, similar to the functions of the rotary cam escapement31described above.FIG.37Bin particular shows two external housings97each associated with one linear-pin escapement96and respective pneumatic first and second lines98,99to actuate the plate to move in the required directions. This will be described further below in connection withFIGS.43-45. Alternatively, electrical actuation may be provided, for example employing solenoid-based electrical actuators.

FIGS.38A-Bshow a variation of the magazine10illustrated inFIGS.37A-B, with two rotary cam escapements31replacing the linear-pin escapements. These escapements31are similar to those described above, and therefore reference is made to the corresponding previous passages of the present description. However, it is noted the different manner of actuation which, in the present case, involves pneumatic first and second lines98,99similar to the first and second lines described above. The first pneumatic line causes movement (of the linear pin escapement) or rotation (of the rotary cam escapement) in one way. The second pneumatic line causes movement (of the linear pin escapement) or rotation (of the rotary cam escapement) in the opposite direction. The corresponding housing97is similar to that described above in that it is required to provide an appropriate seal to allow the rotary cam escapement31to be actuated by the associated first and second pneumatic lines98,99. However, as mentioned above, alternatively the actuation may be electrical for example via an electric motor or solenoid-based electrical actuator.

FIGS.39A-Bshow a single track magazine10in isolation. The magazine10is equipped with a single linear-pin escapement96acting on the single rivet delivery track8,11all of which extends through the magazine10to provide a complete rivet supply system1as described herein. The housing97and the first and second rivet supply lines98,99are as described above.

FIGS.40A-Bshow a further single track magazine10in isolation. This magazine10is however equipped with a single rotary cam escapement31acting on the single rivet delivery track8,11, all of which extends through the magazine10to provide a complete rivet supply system1as describe herein. The housing97and the first and second rivet supply lines98,99are also as described above.

FIGS.41and42A-B show in detail the operation of the rotary track selector91. Rotary track selector91includes a rotary member101designed to be in selective rivet supply engagement with either of the upper magazine tracks60. In the example ofFIGS.41and42A, the right hand side upper track60is selected, while in the example ofFIG.42Bthe left hand side upper track60is selected, for feeding rivets C to the nose arrangement from the one or the other of the upper magazine tracks60.

Selection of the required upper track60is performed by rotating rotary member101in one direction, or in the opposite direction, of about 145 degrees, as can be appreciated in particular referring toFIGS.42A-B. Accordingly, rotary member portion102of the magazine track11can be put in selective rivet-supply relation between the required upper magazine track60and the common, lower portion95of the magazine track11, as also shown in these Figures. It will be appreciated that in the configuration ofFIG.42A, a first end103of the curved track portion102that passes through the rotary member101is in rivet-supply communication with the right hand side upper magazine track60, and a second end104of said curved track portion102is in rivet supply communication with the lower magazine track95. In the configuration ofFIG.42B, the first end103of the curved track portion102is instead in rivet-supply communication with the lower magazine track95while the second end104is in rivet supply communication with the left hand side upper magazine track60.

Actuation of the track selection device90is via a pair of dedicated actuation lines88,89as also shown inFIGS.41and42A-B. Thus, by admitting compressed air in a first actuation line88the rotary member101is rotated in one direction by 145 degrees, and by admitting compressed air in a second actuation line89the rotary member101is rotated in the other direction by 145 degrees. Although this may not be a preferred feature, it would in principle be possible to arrange the rotary track selector to allow the rotary member101to rotate different angles to remove any rivet-supply engagement between the upper tracks60and the lower track95, for example by rotating the rotary member101of about 45 degrees instead of 145 degrees anticlockwise starting from the configuration shown inFIG.42B.

FIG.41also shows a pair of sensors100for detecting the presence of rivets C′ ready for supply to the nose arrangement. The sensors100are each integrated within a respective rotary cam mechanisms31. In the described arrangement, the sensors are each a proximity sensor. However, different sensors can be used including magnetic, optical, eddy currents etc.

FIGS.43-45explain the operation of the linear-pin escapement96.FIG.43Adepicts a single-track magazine10(disposed in horizontal configuration for illustration purposes) with one such escapement96.FIG.43Bis a cross sectional representation through the linear-pin escapement96and portions of the magazine10shown inFIG.43A. A lead pin120is provided to stop or release rivets D stored in the magazine10. The lead pin120is connected to a plate121located inside housing97, above the magazine track11, as seen inFIG.43B. In the configuration ofFIG.43B, three rivets D′, D″, D′″ are queued at the linear-pin escapement96. Leading rivet D′ is ready to be released so that it can then reach, under the action of gravity or suction applied by vacuum connector92, rivet transfer device14located at the lower docking interface24of the magazine10. From there, the rivet D′ can transferred under the punch when required, although this is not described herein.

The plate121is connected via a rod122to a piston actuator123disposed within a portion of the housing97of the linear-pin escapement96located below the magazine10, as also visible inFIG.43B. The piston actuator123is displaced up or down as required by compressed air supplied via the first and second pneumatic lines98,99to displace the plate121within a sealed chamber126in the housing97. This predisposes the magazine10(which is equipped with a linear-pin escapement96) for positive or negative pressure transportation of the rivets D, if required, so that any rivet motive air supplied through the magazine track11is not leaked through the linear pin escapement96. This can be achieved relatively easily in the described arrangement by sealing the chamber126around perimeter interface127against an outer surface of the magazine. Other sealing configurations, however, may be possible. As the piston actuator123is moved, the plate121and thus the lead pin120are actuated via the connecting rod122. Note that the actuator123may be provided above rather than below the rivet track11. The described configuration is preferred for reasons of optimum envelope with respect to the space occupied by the magazine10on the tool2.

FIGS.44A-Cand45A-C provide further details of the operation of the linear-pin escapement96.

With reference toFIG.44C, the same arrangement ofFIGS.43A-Bis depicted showing three rivets D′, D″, D′″ queued at the lead pin120.FIG.44Calso clearly reveals how the depth of the rivet delivery track8is greater than the length of the rivets D shown inFIGS.44A-C. Thus, rivets of different lengths could also be stored on the same magazine10and transported on the T-shaped tracks8described herein, the rivets D being supported by the T-shaped profile of the rivet delivery tracks8around their heads rather than their stems. The presence of the leading rivet D′ is sensed by a sensor100, similar to the sensor described above. When the presence of the leading rivet D′ is sensed, at the correct time this can be released for a setting operation.

FIGS.44A-Breveal the arrangement of a pair of profiled pins125comprising pin sections of large diameter128and pin sections of narrow diameter129disposed upstream with respect to the lead pin120, and sideways with respect to the magazine track11. The large diameter pin sections128are such that they can stop the rivets D from flowing through the magazine10. The narrow diameter pin sections129are such that they can let the rivets D flow. The two profiled pins125are thus arranged such that when the lead pin120is in the configuration ofFIG.44C, the trailing rivets D″, D′″ are free to flow and thus come into contact with the leading rivet D′. In this configuration, therefore, the lead pin120stops all the rivets D′, D″, D′″ from flowing. The plate121and the actuator123are in their lowermost configuration as also shown inFIG.43B.

When the lead pin120is retracted as shown inFIGS.45A-C, the leading rivet D′ is released and under the action of an appropriate motive force (gravity, suction or positive pressure) reaches the rivet transfer device14at the lower docking interface24of the magazine10, as discussed above. Retraction of the lead pin is effected by upwards movement of the piston actuator123, connecting rod122and plate121. This also determines movement of the profiled pins125to the configuration best shown inFIG.45A. The large diameter pin sections128are now disposed within the magazine track11to effectively restrict passage therethrough for the rivets D. Accordingly the trailing rivets D″, D′″ are now stopped in the magazine10, while the leading rivet D′ flows to the nose arrangement. Note that, as shown inFIG.45B, the large sections128of the pair of profiled pins125interact with the head of the rivet D″ rather than with its stem. The plate is actuated to cycle through its lowermost position shown inFIGS.44A-Cand its uppermost position shown inFIGS.45A-C. After the leading rivet D′ has been released, the plate121is returned by the piston actuator123to its lower most position and the first trailing rivet D″ is now in contact with the lead pin120to be released next. The trailing rivet D″ at this stage moves forwards just the short distance that separates the lead pin120and the pair of profiled pins125as the narrow sections129are moved to occupy the position just next to the magazine track11. The rivets D are thus cycled through the various configurations of the liner-pin escapement with minimum ‘slicing’ force imparted on them by the linear-pin escapement96. In particular, in the configuration ofFIGS.45A-Cthe trailing rivet D″ is gently held by the action of the profiled pins125on opposed sides of the rivet's head, as best seen fromFIG.45A. In the configuration ofFIGS.44A-C, the trailing rivet D″ is held in its position solely by the lead pin120, thus excluding any further catch points. The magazine track11is minimally affected by the presence of the linear-pin escapement and the flow of the rivets D may thus be controlled with minimal invasiveness.

Possible options for the replacement and/or adjustment of the die assembly6are described briefly below in connection withFIGS.46-50. It is noted that the replacement or adjustment of the die assembly6may be required pursuant to the replacement of a replaceable magazine10with a replacement magazine10filled with rivets of a different type, as described herein. These rivets may require a different die geometry and/or die volume. The die assembly may be replaced and/or adjusted manually by an operator considering that such a replacement and/or adjustment may be necessary for the setting operations. Alternatively, the die assembly may be replaced and/or adjusted automatically or semi-automatically in response to one or more signals generated by the controller1203described herein. The controller1203may thus be configured to issue one or more signals for replacing and/or adjusting the die assembly6based in response to information identifying the magazine10and, hence, the type and/or size of rivets stored therein and thus now available to the setting tool.

InFIG.46there is shown a setting tool2as described herein with a rivet supply system1constituted by two replaceable double-track magazines10in mirror configuration. The die assembly6provides for an adjustable die volume135. The die volume135is adjusted using an external/independent spanner tool130. The spanner tool130can be engaged to the die assembly6via a number of slots131formed in the spanner tool130. Each slot131can be coupled to an adjustment head132provided on the lower end of the die assembly6. Relative movement (rotation) of the spanner tool130and adjustment head132results into a die volume change. How this is achieved is the object ofFIGS.49A-Cdescribed below. The C-frame can be mounted on a robotic arm (not shown) for this purpose. Alternatively, the spanner tool may be mounted on a robot (not shown).

A method of ensuring that the correct die volume has been set may be advisable. This might be achieved by a combination of mechanical registration and/or software control. Thus for example only one of the multiple slots131of the spanner tool130may at any one time register together with the adjustment end132provided on the die assembly6. The software may then determine the next required die volume135for the riveting process. The angular position of the adjustment end132will then need to be adjusted accordingly. When a successive die volume adjustment operation is required, the previous position of engagement between the spanner tool130and the adjustment end132of the die assembly6is recalled by the software from a memory. Alternatively/additionally, the spanner tool130could have slots131which are each associated with a specific die volume135. Thus the robotic arm could be used to engage the adjustment end132of the die assembly6by any of these predetermined slots131. A predetermined angular rotation could then also be associated to each slot. Therefore, upon engagement of the end132with a predetermined slot131, a predetermined angular rotation would take place to achieve the desired die volume135.

InFIG.47, the die volume135is changed by changing the die assembly6. The die assembly6is released by an external release mechanism in the form of a release pin137. This is described further in connection withFIGS.50A-C.

InFIG.48, the die volume135is changed by operation of an on-board motorised means such as an on-board motorised die adjustment actuator136.

With reference toFIGS.49A-C, the die assembly6comprises a centre pin140located in and guided by a die sleeve141. The axial position of the centre pin140can be adjusted by an adjustment cam mechanism142having discrete cam platforms143located below the centre pin140. Each cam platform143has a different height with respect to the die assembly6. Each cam platform143corresponds to a predetermined axial location of the centre pin140and, thus, to a predetermined die volume135.

When switching active cam platforms143, the centre pin140may have to be retained in the position corresponding to its minimum die volume135to allow the adjustment cam mechanism142to be rotated.

With reference toFIGS.50A-C, the die assembly6includes a die sleeve141similar to that shown inFIGS.49A-C. Different die volumes135are associated to different dies153with semi-hollow construction as shown inFIGS.49B-C. The die153is retained in place on the die assembly6by the action of two C-shaped split collets150which exert a transversal force on an inner cavity154of the die153, also shown inFIGS.49B-C. The C-shaped split collets are urged outwardly by a tapered end152of a central mandrel151that extends through said sleeve141. The mandrel151and its tapered end152are pulled downwards by the action of a resiliently biased sphere158that acts on an inclined surface159formed on a protruding pin157that is at one end coupled to said mandrel151, and at the other end protruding from the die assembly6, as also shown inFIGS.50B-C.

To replace the die153, the protruding pin157is pushed upwardly by release pin137against the downwards force exerted on it by the resiliently biased sphere158. This in turn releases the split collets150so that the die153is no longer gripped to die sleeve141. The die153can be replaced with another die with different die volume135bay external means, including by manual intervention of an operator.

The invention thus provides a simple yet flexible magazine-based rivet supply system that can seamlessly handle self-piercing rivets of different shapes and sizes.

Any requirement for portions of flexible tubes within the rivet supply systems is reduced or eliminated.

The rivets are stored in magazines which are conveniently located at all times close to the nose of the setting tool.

Further, the magazines incorporate multiple rivet handling features which maximise control of the flow of the rivets through the supply system.

While the magazines described herein are preferably used with gravity or vacuum as the rivet motive force, these can also easily be adapted to accept compressed air, as it will be apparent to the skilled person.

The magazines can also be easily replaced and/or refilled, and these operations can further be conveniently carried out automatically by the robotic arm without the need for external intervention.

Further, the accuracy requirements relating to the robotic arm are advantageously reduced.

Further, it is possible, upon identification of a joint to be created, to call up a desired rivet type from one of the magazines docked on the setting tool, or from one or more replacement magazines, and, based on that selection, change or reconfigure the die assembly accordingly.

If a replacement magazine is required, the tool can prevent or signal inadvertent docking of an incorrect replacement magazine, and/or confirm that a correct replacement magazine that stores the intended rivets in terms of their type and/or size has been successfully selected and docked on the tool.

The invention has been described above purely by way of example. Protection is sought within the scope of the appended claims.