HIGH SPEED VINYL WELDING AND CLEANING LINE OPERATION

A manufacturing system for manufacturing rectangular frames of plastic material includes a horizontal frame welder configured to weld lengths of a plastic material together to form a rectangular frame. A corner cleaning station is configured to remove excess flash created in the welding process at the horizontal frame welder. A gantry is configured to automatically remove the rectangular frame from the horizontal frame welder after it is welded, move the rectangular frame to the corner cleaning station, and automatically place the rectangular frame in the corner cleaning station.

BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

The present disclosure relates to manufacturing rectangular frames of plastic material, for example, vinyl casements, door frames, and window frames (e.g., sashes) and specifically relates to manufacturing apparatus and process steps relating to welding stations and cleaning stations.

Discussion of Prior Art

In past disclosures, systems of machines for welding and cleaning vinyl sashes or frames have been provided. However, these known systems of machines faced a number of problems including, but not limited to, relatively slow output speeds, relatively large footprint areas, and relatively large operating personnel requirements, etc. As such, improvements are desired, and the present disclosure addresses at least some of these drawbacks of the prior disclosures.

SUMMARY

In some embodiments, a manufacturing system for manufacturing rectangular frames of plastic material includes a horizontal frame welder configured to weld lengths of a plastic material together to form a rectangular frame. The manufacturing system also includes a corner cleaning station configured to remove excess flash created in the welding process at the horizontal frame welder. The manufacturing system further includes a gantry configured to automatically remove the rectangular frame from the horizontal frame welder after it is welded, move the rectangular frame to the corner cleaning station; and automatically place the rectangular frame in the corner cleaning station.

In some embodiments, a method of fabricating the corner of a plastic rectangular frame includes providing a horizontal frame welder for welding rectangular frames of plastic material. The method also includes loading a plurality of associated frame members into the horizontal frame welder. The method further includes welding the plurality of associated frame members to create the rectangular frames. The method still further includes providing a gantry apparatus for moving the rectangular frames. The method also includes using the gantry to automatically remove the rectangular frames from the horizontal frame welder. The method further includes moving the rectangular frames overhead. The method still further includes providing a corner cleaning station to remove excess flash from the rectangular frames. The method also includes using the gantry to automatically place the rectangular frames into the corner cleaning station.

DETAILED DESCRIPTION

The claimed subject matter is now described with reference to the drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident, however, that the claimed subject matter may be practiced without these specific details. In other instances, structures and devices are illustrated in block diagram form in order to facilitate describing the claimed subject matter.

Referring toFIG. 1, a perspective view of a system of machines100for welding plastic rectangular frames102is illustrated. For the purposes of this disclosure, the term “plastic material” can include, but is not limited to, vinyl, polyvinyl chloride (PVC), polyurethane, ABS/ASA, cellular PVC, etc. At the left is a horizontal frame welder104that can weld four rectangular frames102(e.g., sashes) at a time. At the right is a corner cleaning station106configured to remove excess flash from the rectangular frame102after it is welded together. A gantry system108is shown above the horizontal frame welder104and the corner cleaning station106.

As shown, the system of machines100can include a base framework110. Each of the horizontal frame welder104, the corner cleaning station106, and the gantry system108can be mounted to the base framework110. In some examples, the base framework110can enable movement of the entire system of machines100as a single unit, if necessary, while providing a rigid frame for the system of machines100.

Referring toFIG. 2, an example horizontal frame welder104is illustrated. The horizontal frame welder104includes a plurality of welding heads200,202,204, and206. As in the shown example, there can be four welding heads200,202,204, and206wherein one of the welding heads is stationary. For example, welding head200can be stationary and provide a known location which can serve as an origin for accurate coordinate measuring of lengths of associated frame components.

The horizontal frame welder104can include a plurality of motion devices (not shown) wherein a single motion device is connected to (e.g., mounted to) an individual welding head. For example, one motion device is mounted to each of the welding heads202and204. Any suitable motion device is contemplated, but an example motion device is a servo motor. The servo motor can apply a force to selectively move (e.g., position) the welding head. In the illustrated example, two welding heads202,204are supported by a slide or slides208attached to the base framework110. The slide208can guide the welding heads202,204as they are individually urged into motion by the motion devices. In the shown example, the motion devices can selectively translate welding heads202,204toward and away from stationary welding head200. In the figure, the described translation of “toward and away” for the combination of welding heads202,204is generally represented in the upper left to lower right and lower right to upper left directions ofFIG. 2as represented by arrow210.

Similarly, the welding heads204,206, can be supported by a slide or slides212attached to the base framework110. The slide212, can guide the welding heads204,206as they are individually urged into motion by the motion device(s). In the shown example, the motion devices can selectively translate welding heads204,206toward and away from stationary welding head200. In the figure, the described translation of “toward and away” for the combination of welding heads204,206is generally represented in the lower left to upper right and upper right to lower left directions ofFIG. 2as represented by arrow214. As shown inFIG. 2, the stationary welding head200can be the welding head in the upper left corner of the horizontal frame welder104, however, this is only an example, and the stationary welding head can be located at any of the other positions shown inFIG. 2.

A plurality of welding heads200,202,204,206are mounted to the base framework110as previously described. More than one welding head (e.g.,202,204,206) of the plurality of welding heads200,202,204,206is movable relative to the base framework110and more than one welding head202,204,206of the plurality of welding heads is movable relative to each of the other welding heads200,202,204,206. As previously described, this enables the stationary welding head200to provide a known location which can serve as an origin for accurate coordinate measuring of lengths of associated frame components used to create a rectangular frame102. With this design, the horizontal frame welder104can accommodate a number of sizes (e.g., dimensions) of rectangular frames102.

In some examples of systems of machines100, the welded rectangular frames102are stacked during the welding process, in other words, the horizontal frame welder can accommodate multiple frames such that frame components can be welded into multiple rectangular frames102in one machine cycle. In some examples, the frame components are manually loaded into the horizontal frame welder by an operator. After welding, the rectangular frames102are unloaded from the horizontal frame welder104using an automated gantry108that first carries a bottom rectangular frame102(e.g., the lowest rectangular frame within the horizontal frame welder104) away from the horizontal frame welder104(e.g., the rectangular frame is ejected to the gantry). The gantry108then takes the next lowest rectangular frame102and so on, until the horizontal frame welder104is devoid of finished rectangular frames102and is to be manually loaded for the following welding cycle.

In some previously known examples, the corner cleaner has two rectangular frames in process during a given welding cycle of operation. During the single cycle, the corner cleaner will clean the two trailing corners from a first rectangular frame and the two leading corners from the second rectangular frame. The corner cleaner then ejects the first rectangular frame and moves the second rectangular frame to the position previously occupied by the first rectangular frame to begin the cycle again with the second rectangular frame and a third rectangular frame.

Referring toFIG. 3, a detail of the system of machines100is illustrated. In some examples, the system of machines100for welding rectangular frames102eliminates the need for a traditional accumulator conveyor or other conveyor system that otherwise occupies manufacturing floor space. Instead, the system of machines100utilizes the overhead gantry system108to accumulate rectangular frames102. In traditional rectangular frame construction processes, a corner cleaning station having a slower cycle time than a welding station is a common occurrence. As such, work in process pieces can accumulate on the manufacturing floor or in accumulating conveyors or the like. However, in conjunction with the present disclosure, this floor accumulation of rectangular frames can be eliminated. For example, after a set of rectangular frames102is completed at the horizontal frame welder104, the gantry108is configured to remove the welded rectangular frames102. For the purposes of this disclosure, a set of rectangular frames102can include one, two, four, or any suitable number of rectangular frames. In the shown example ofFIG. 3, the gantry108is in place to automatically remove four rectangular frames102from the horizontal frame welder104.

Remaining withFIG. 3, the gantry108can include a vertical arm300extending from a cross arm302toward the horizontal frame welder104. In some examples, there are multiple vertical arms300. The cross arm302can be attached to a vertical post304that can traverse the base framework110in directions represented by arrow306. While not shown, it is to be understood that the system of machines100can include a track configured to cooperate with the gantry, suitable motive force devices, etc. to properly control and guide the gantry108between a plurality of locations relative to the base framework110.

The vertical arm300includes a gripping device310configured to cooperate with a portion of at least one rectangular frame102. In some examples, the gripping device310can be aligned with an edge of a rectangular frame102where a portion of the gripping device310can be actuated to grip the rectangular frame102such that there is little or no relative motion between the rectangular frame102and the gripping device310. In some examples, motion of the vertical arm300and/or the gantry108can effect rotation or translation of the gripping device310into a desired location to cooperate (e.g., grip) the rectangular frame102without requiring an actuated portion of the gripping device310. Additionally, any suitable number of gripping devices310may be employed to grip the rectangular frame102. When one or more rectangular frames are secured to the gripping device(s)310, at least one of the gripping devices310or the vertical arm300can be moved in an upward direction (e.g., away from the horizontal frame welder104). The gantry108then continues to move upward into the space above the horizontal frame welder104and the corner cleaning station106) so that an operator can manually load the horizontal frame welder104with frame components for the next welding cycle.

Referring toFIG. 4, the system of machines100is illustrated showing the gantry108accumulating rectangular frames102between the horizontal frame welder104and the corner cleaning station106. After leaving the horizontal frame welder104, the rectangular frames102are accumulated (e.g., held as work-in-process) in a space above the horizontal frame welder104and the corner cleaning station106. Here, the rectangular frames102can remain in place until an automated interlock associated with the corner cleaning station106indicates that the gantry108can begin placing the rectangular frames102into the corner cleaning station106. As noted previously,FIG. 4shows four (4) rectangular frames102accumulated in the gantry108, however other numbers of rectangular frames102are also contemplated.

Referring toFIG. 5, the system of machines100is partially illustrated showing the gantry108having moved to the corner cleaning station106. In some examples, the distance between the horizontal frame welder (not shown inFIG. 5) and the corner cleaning station106is about ten (10) feet. At least one of the vertical arm300or the gripping device310have been actuated in a downward direction to locate at least one rectangular frame102into the corner cleaning station106. In some examples, the gantry108and its associated components can automatically place the rectangular frames102into the corner cleaning station106. In other examples, an operator can manually remove the rectangular frames102from the gantry108and place the rectangular frames102into the corner cleaning station106. In some examples, the rectangular frames102can be placed into the corner cleaning station106individually (e.g., one at a time). Obviously, certain benefits can be realized by including automated placement of the rectangular frames102into the corner cleaning station106.

In these examples, it can be beneficial to have the corner cleaning station106have a cycle time for each rectangular frame102such that the sum of the cycle times of a particular number of rectangular frames102equals or is nearly equal to the cycle time to weld that particular number of rectangular frames102in the horizontal frame welder104. In other words, it can be beneficial to design the cycle time for the horizontal frame welder104and the corner cleaning station106to be equal or nearly equal when processing the same number of rectangular frames. This can eliminate or help to eliminate production bottlenecks and increase speed of the production process.

In other examples, the total cycle time of the corner cleaning station106for a number of rectangular frame(s)102can be equal to or nearly equal to the cycle time of the horizontal frame welder104for the same number of rectangular frame(s) plus the time required to move the rectangular frame(s)102from the horizontal frame welder104to the corner cleaning station106. For the purposes of this disclosure, the term nearly equal can mean within 15 seconds of each other. In further examples, the term nearly equal can mean within 10 seconds of each other. These time quantities can vary due to the proficiency of the operator and other causes. In the shown examples, the number of rectangular frames is four (4) such that the corner cleaning station106cycle time is equal to or nearly equal to one-fourth (¼) of the horizontal frame welder104cycle time. Of course, other numbers of rectangular frames102can be used and cycle times modified to satisfy the frame manufacturer's desire.

As the gantry108places a rectangular frame102into the corner cleaning station106, the gripping devices310can undergo the reverse process described above to remove the rectangular frame102from the horizontal frame welder104. In other words, when in position, the gripping devices310can have a portion that actuates to release the rectangular frame102. In other examples, at least one of the vertical arms300and the gripping devices310can rotate or translate away from the rectangular frame102to place the rectangular frame102into the corner cleaning station106. The corner cleaning station106can then complete a cycle to clean a single rectangular frame102, after which, the gantry can place the next rectangular frame into the corner cleaning station106.

At the completion of a corner cleaning cycle, the rectangular frames102can drop onto a discharge conveyor (not shown) below the corner cleaning station106(this can be an automated conveyor process). Then, the gantry108places the next rectangular frame102into the corner cleaning station106.

The described arrangement enables removal of the accumulator system from rectangular frame manufacturing process as is common in many known manufacturing processes. In some examples, the overhead gantry108is the accumulator. In some examples, manufacturers can save up to forty linear feet of floor space and a significant area of floor space. The described system of machines100can also promote faster cycle times because the relatively slow-moving accumulating conveyors are eliminated. Instead, the relatively fast-moving gantry system is relied upon for the transfer of rectangular frames102. Additionally, some opening and closing movements in the corner cleaning station106can be eliminated, further reducing cycle time.

Referring toFIG. 6, a detail view of an example gripping device310arrangement is illustrated. As shown, four (4) gripping devices310can be used to grip the rectangular frames102. In some examples, two (2) gripping devices310can be mounted to each vertical arm300, although any suitable arrangement is satisfactory. In some examples, the gripping device310defines an opening600that is designed and engineered to cooperate with an edge of a rectangular frame102. In such examples, the vertical arms300can be automatically controlled to locate the gripping devices310adjacent the rectangular frame102and then the vertical arm300can be translated toward the rectangular frame102in the direction of arrow602in order to engage (e.g, grip) the rectangular frame102for movement or further processing. As noted previously, this is meant to be but one example of a gripping device310, and is not meant to be limiting.

Referring toFIG. 7, a method for utilizing the described apparatus will now be discussed. The method includes providing a welding apparatus for welding rectangular frames of plastic material (e.g., vinyl). The method also includes loading a plurality of associated frame members into the welding apparatus. The welding apparatus then takes the action of welding the plurality of associated frame members to create the rectangular frames.

The method also includes providing a gantry apparatus for moving the rectangular frames. This can be in a space above the welding apparatus and the corner cleaning apparatus. Next, the method continues by using the gantry to automatically remove the rectangular frames from the welding apparatus and moving the rectangular frames overhead. The method further includes providing a corner cleaning apparatus to remove excess flash from the rectangular frames. Finally, the method includes using the gantry to automatically place the rectangular frames into the corner cleaning station.

Referring toFIGS. 8 and 9, a method for utilizing the described apparatus will now be discussed.FIGS. 8 and 9are divided for clarity, and are two parts of a single flow chart. In this flow chart, the term “rectangle” and the term rectangular frame102are used interchangeably. Additionally, the terms “welder” and “cleaner” are used interchangeably with the terms horizontal frame welder104and corner cleaning station106, respectively.

As with many flow charts, this particular flow chart represents progression of time as the reader moves down the flow chart. Note that the flow chart has a central portion and portion on the left that graphically show the cycle timing of the horizontal frame welder and the corner cleaning station are equal or nearly equal in length. The method includes a load welder operation when an operator places frame components into the horizontal frame welder for welding. The welder then cycles to create at least one and perhaps multiple rectangular frames in one cycle of operation. The gantry then unloads the welder, moving the rectangular frames from the welder to the space above the welder and the cleaner for accumulation as work in process. The gantry then moves the rectangular frame(s) to the cleaner.

This paragraph includes method steps at the corner cleaning station that operate concurrently with some steps at the horizontal frame welder that are described in the very next paragraph. Concurrent operations involving gantry travel are described in the paragraph two below this paragraph. The gantry places one rectangle into the cleaner. The cleaner operates one cycle to remove extraneous material from the rectangle and then discharges the rectangle onto a conveyor. The gantry then places another (second) rectangle into the cleaner. The cleaner then operates one cycle to remove extraneous material from the second rectangle and then discharges the second rectangle onto a conveyor. The gantry then places another (third) rectangle into the cleaner. The cleaner then operates one cycle to remove extraneous material from the third rectangle and then discharges the third rectangle onto a conveyor. The gantry then places another (fourth) rectangle into the cleaner.

During the timed period of the method steps of the previous paragraph, between the gantry moving to the cleaner and the placement of the fourth rectangle into the cleaner, the welder is hand loaded with frame components and the welder operates one cycle. In some examples, one cycle of the welder welds multiple rectangles. The welder portion of the flow chart then returns to the method step of the gantry unloading the welder.

Additionally, when the gantry places the last rectangle (e.g., the fourth rectangle) into the cleaner, the gantry can return to the welder. The gantry returns to the welder prior to or at the same time as the welder cycle time is complete so that the gantry can remove the rectangles.

Finally, to return to the step of the fourth rectangle being placed in the cleaner, the cleaner then operates one cycle to remove extraneous material from the fourth rectangle and then discharges the fourth rectangle onto a conveyor. As with each of the previous rectangles, the conveyor takes the fourth rectangle to further assembly operations.

The described system of machines and associated methods can provide a number of benefits over known welder systems. For example, the described apparatus and methods can provide faster throughput than currently available welder systems. As such, the number of completed welded and cleaned frames per hour for the particular system can be increased. Further, the elimination of a transfer conveyor and/or accumulator conveyor between the welder and the cleaner can reduce the footprint of a typical vinyl welder system. Additionally, the manufacturing process can also reduce staffing needs in the manufacturing process, as an operator does not need to be dedicated to hand load the corner cleaning station. Each of these benefits can reduce the time and cost of manufacturing rectangular frames of various materials (e.g., plastic, vinyl, etc.).

Many modifications may be made to the instant disclosure without departing from the scope or spirit of the claimed subject matter. Unless specified otherwise, “first,” “second,” or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first item and a second item may generally correspond to item A and item B or two different or two items or the same item.