Manufacturing device with an automatic self-aligning connector for attachment to a docking station

A manufacturing device is disclosed which has a connector which automatically self-aligns with a mating connector of a docking station. The device includes a receptacle for receiving and holding an unfinished workpiece. At least one connector is provided for coupling the receptacle to at least one process input, such as electrical energy, pneumatics, hydraulics or the like, via the docking station, and an alignment mechanism is provided for automatically aligning the connector for attachment to a mating connector on the docking station when the receptacle is advanced toward the docking station.

BACKGROUND OF THE INVENTION 
The present invention relates to manufacturing devices for holding a 
workpiece and moving the workpiece to a docking station where a 
manufacturing operation is performed on the workpiece, and more 
particularly, to a novel die mold manufacturing device with electrical 
connectors capable of automatically self-aligning for coupling to mating 
connectors on a pre-heat station or docking station. 
In automated manufacturing systems, it is often necessary to move a 
workpiece to different stations where different operations may be 
performed on the workpiece. An important consideration, particularly where 
these different work stations may present a hazardous or harmful 
environment to a system operator or to delicate electronic devices or the 
like for controlling the manufacturing process, is the need for an 
arrangement for automatically connecting a transportation device, such as 
a die mold or the like, to an external source of energy, such as 
electricity, air, pneumatics, hydraulics or the like and automatic 
connection to devices or mechanisms for controlling the application of 
these process inputs. For example, an integrally electrically heated die 
mold requires electrical connection to the internal electrical resistive 
heating elements of each die mold portion from an external source of 
electrical power and also electrical connection to the heating control 
thermocouples in each mold portion for thermostatically controlling the 
heating of each die mold portion. The source of electrical power and the 
control devices for controlling the heating of the die mold portions are 
of necessity located remotely to the die mold portions because of the high 
heat which could damage these system components. 
Additionally, interconnection of these energy sources and control devices 
to the manufacturing apparatus or die mold can limit access of a system 
operator, such as for example, access for removing a workpiece from a die 
mold or preparing a die mold for molding of a subsequent workpiece. 
SUMMARY OF THE INVENTION 
It is, accordingly, a primary object of the present invention to provide a 
novel die mold manufacturing system which is not subject to the foregoing 
disadvantages. 
It is another object of the present invention to provide a die mold with 
automatic self-aligning connectors for connection to external sources of 
energy and control devices. 
It is a further object of the present invention to provide a novel die mold 
which per,nits substantially complete access to the die mold by a system 
operator. 
In accordance with the present invention, a manufacturing device for 
holding an unfinished workpiece and transporting the workpiece to a 
docking station for performance of a manufacturing operation on the 
workpiece includes a receptacle for receiving and holding the unfinished 
workpiece. A connector is provided to couple the receptacle to at least 
one source or process input, such as electrical power, pneumatics, 
hydraulics or the like, by way of the docking station. An alignment 
arrangement automatically aligns the connector, without the need for 
operator intervention, for attachment of the connector to a mating 
connector on the docking station when the receptacle is advanced toward 
the docking station. 
In accordance with an embodiment of the present invention, a die mold 
manufacturing device with an automatic self-aligning connector includes an 
upper die adapter plate or frame member and an upper die half attached to 
the upper adapter plate. A lower die adapter plate or lower frame member 
has a lower die half attached thereto with the lower die half being 
juxtaposed to the upper die half. The die mold device may be positioned at 
a die separator station for moving the upper die half between a first or 
non-operating position at a spacing from the lower die half for access to 
the mold and a second or operating position for docking to a pre-heat 
station and molding a workpiece in cooperation with the lower die half. An 
upper electrical connector means is provided for electrically connecting 
the upper die half to the docking or pre-heat station when the upper die 
half is in its second position, and a lower electrical connector means is 
provided for electrically connecting the lower die half to the pre-heat 
station when the upper die half is in its second position. The die mold 
further includes an alignment mechanism for aligning the upper connector 
means and the lower connector means with respective upper and lower mating 
connector means on the pre-heat station for interconnection of the 
respective connector means to supply electrical power to the die halves 
for internal heating thereof during a molding process and to also 
preferably provide connection to heating control means. The upper 
electrical connector means is movably mounted in relation to the upper die 
adapter plate and upper die half and the lower electrical connector means 
is movably mounted in relation to the lower die adapter plate and the 
lower die half to permit the upper and lower electrical connector means to 
move with respect to the die halves for alignment and interconnection with 
the mating connector means of the pre-heat station. Additionally, the 
upper connector means and the lower connector means are preferably 
interconnected with each other by an interlocking arrangement when the 
upper die mold half is in its second position to provide coordinated 
movement of the upper and lower connector means for alignment and 
connection to their respective mating connector means on the pre-heat or 
docking station. 
These and other objects of the present invention, together with the 
features and advantages thereof, will become apparent from the following 
specification when read with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring initially to FIG. 1, the die mold 10 of the present invention 
includes an upper die adapter plate 11 or upper frame member to which is 
attached an upper die mold half 12 and a lower die adapter plate 14 or 
lower frame member to which is attached a lower die mold half 16. 
Differently shaped upper and lower die mold halves 12 and 16 my be 
respectively attached to the upper and lower adapter plates 11 and 14 
depending upon the shape of the workpiece or charge (not shown) to be 
molded. The upper and lower die mold halves 12 and 16 each have a 
plurality of electrical resistive heating elements 18 mounted at selected 
locations within the die mold halves depending upon the shape of the 
workpiece to be molded and the desired distribution of heat energy 
necessary to mold the particular workpiece. 
As best shown in FIG. 2A, the die mold 10 is positioned at a die separator 
station 19 to permit movement of the die mold halves 12 and 16 between a 
first or non-operating position, as shown in FIG. 1 at a spacing from each 
other to permit operator access to the interior of the die mold halves 12 
and 16, and a second or operating position, as shown in FIGS. 2A and 2B, 
wherein die mold halves 12 and 16 are moved toward each other for docking 
to a pre-heat or docking station 21 (FIG. 2B) and to cooperate in molding 
a workpiece received and held between the die mold halves 12 and 16. The 
die separator station 19 may include four ball screw and nut combinations 
20 which are each positioned at the opposite corners of the die mold 10. 
Flanges 22 hook over the upper and lower die adapter plates 11 and 14 to 
facilitate movement of the die mold halves between the first and second 
positions. A plurality of alignment pins 23 are mounted to upper die 
adapter plate 11 and a plurality of guide bushings 24 are mounted to lower 
die adapter plate 14 to receive alignment pins 23 when the upper die mold 
half 12 is moved to its second or operating position to cooperate with 
lower die mold half 16 to mold a workpiece or charge. 
In accordance with the present invention, an upper electrical connector 26, 
such as an electrical plug as shown in the figures, is mounted to a 
mounting plate 28. As shown in FIG. 4, a plurality of electrical plugs 26 
may be required depending upon the number of heating elements 18 and the 
distribution of the heating elements within upper die mold half 12. 
Thermocouple connectors 30 are also provided to permit connection to 
thermocouples (not shown) mounted within upper die mold half 12 to permit 
control of the electrical heating of the upper die mold half 12. 
In accordance with the present invention, as shown in FIG. 4, a pair 32 of 
elongated vertical slots is formed in the mounting plate 28 at a spacing 
from each other with the electrical connectors 26 and thermocouple 
connectors 30 disposed there between. The mounting plate 28 is fastened to 
a mounting bracket 34 (see also FIG. 1) by a pair 36 of shoulder bolts 
extending through each of the slots 32 and threadedly received in mounting 
bracket 34. Each of the elongated vertical slots 32 has a selected width w 
which is wider than the shoulder of the mounting bolts 36 to permit the 
upper mounting plate 28 to slide vertically along the mounting shoulder 
bolts 36 with respect to mounting bracket 34 and upper die mold half 12. 
The width w of the slots 32 are about 0.3" wider than the shoulder 
mounting bolts 36; this additional width also permits the upper mounting 
plate 28 and the electrical connectors 26 and 30 mounted thereon to move 
about .+-.0.125"0 in the horizontal plane to permit docking of the die 
mold 10 with the docking or pre-heat station 21 as best shown in FIGS. 2 
and 3. Mounting bracket 34 is attached to the upper die mold adapter plate 
11 by suitable fasteners (not shown in the figures). 
The electrical connectors or plugs 26 and the thermocouple connectors 30 
are connected to the upper die mold half 12 by suitable conductors 40 as 
shown in FIGS. 1 and 2. The connectors 26 and 30, the mounting plate 28, 
the mounting bracket 34 and the insulation of conductors 40 are preferably 
made from materials which are resistant to the high heat encountered 
during a molding operation. 
A lower electrical connector 42 and thermocouple connectors 44, as shown in 
FIGS. 1 and 4, are mounted to a lower mounting plate 46, for supplying 
electrical power to lower die mold half 16 and for controlling the heating 
of lower die mold half 16, respectively. A pair of electrical connectors 
42 and a pair of thermocouple connectors 44 are shown in FIG. 4; however, 
those skilled in the art will note that fewer or more electrical 
connectors 42 and thermocouple connectors 44 may be required depending 
upon the heating requirements and the distribution of the heating elements 
and thermocouples within the die mold half 16. 
The lower mounting plate 46 is mounted to a lower mounting bracket 48, and 
mounting bracket 48 is in turn mounted to the lower die adapter plate 14 
by suitable fasteners (not shown). The lower mounting plate 46 is mounted 
to lower mounting bracket 48 by a plurality of shoulder bolts 50, 
preferably four shoulder bolts 50 disposed substantially in quadrature 
relative to one another, as best shown in FIG. 4. The mounting holes 52 
formed in mounting plate 46 through which shoulder bolts 50 are received 
are a selected width w' which is larger than the diameter of the mounting 
shoulder bolts 50. The selected width w' is about 0.30" wider than the 
diameter of hole 50 to allow about .+-.0.125" of docketing tolerance or 
movement of the lower mounting plate 46 in any direction from a position 
in which the centerlines of shoulder bolts 50 are aligned within the 
centerlines of the mounting holes 52. This permits slight movement of the 
lower mounting plate 46 and the electrical and thermocouple connectors 42 
and 44 mounted thereon to permit alignment with mating connectors 54 on 
the docking or pre-heat station 21 as best shown in FIGS. 6 and 7. A 
plurality 56 of electrical conductors interconnects electrical and 
thermocouple connectors 42 and 44 to lower die mold half 16 to supply 
electrical power to die mold half 16 and to permit control of the mold 
heating during a molding operation. 
In accordance with the present invention, as shown in FIGS. 4 and 5, upper 
mounting plate 28 has a recess 58 formed therein in a bottom edge 60 
thereof and lower mounting plate 46 has a top edge 62 which is shaped to 
matingly fit within the upper mounting plate recess 58 when the upper die 
half 12 is in the second position for molding a workpiece as shown in FIG. 
5. In this position, the upper mounting plate 28 is interlocked with lower 
mounting plate 46 to cause the plates 28 and 46 and the upper and lower 
electrical connectors 26 and 42 and the upper and lower thermocouple 
connectors 30 and 44 to move in cooperation with each other to permit 
alignment of the connectors with mating connectors 54 mounted on the 
pre-heat station 21. The opposite interior sides 63 of recess 58 may be 
beveled and the opposite end corners 64 of top edge 62 may be chamfered to 
facility guiding the top edge 62 into the recess 58 to interlock the upper 
and lower mounting plates 28 and 46 when the upper die half 12 is lowered 
to the second or operating position for docking with pre-heat station 21. 
Referring to FIGS. 2 and 4, lower mounting plate 46 has a pair of guide 
holes 65 formed therein and a pair of guide bushings 66 disposed in each 
guide hole 65 for receipt of tapered alignment or guide pins 68 mounted on 
the pre-heat station 21. Referring now to FIG. 6, in accordance with the 
present invention, the centerlines 70 of tapered guide pins 68 are 
preferably offset above the centerlines 72 of guide bushings 66 to cause 
the lower mounting plate 46 and the upper mounting plate 28 to move 
upwardly and laterally, if necessary, such that the mounting shoulder 
bolts 50 will be substantially in the center of the mounting holes 52 of 
the lower mounting plate 46 before the connectors 26 and 42 interconnect 
with the mating connectors 54 mounted on docking station 21. Guide pins 68 
have a predetermined length such that they are received by guide bushings 
66 to cause movement of the upper and lower mounting plates 28 and 46 to 
cause alignment of the electrical connectors 26 and 42 and the 
thermocouple connectors 30 and 44 with the mating receiving connectors 54 
before the respective connectors come into contact with one another during 
docking of the die mold 10 to the station 21. Pre-heat station 21 
preferably includes a bumper or stop 73 to prevent hard impact of the die 
mold 10 with the station 21 which could potentially damage the connectors 
and other components. 
Referring back to FIG. 5, in accordance with the present invention, 
elongated vertical slots 32 have a predetermined length to permit some 
compression of the workpiece during a molding operation. When a charge or 
unmolded workpiece is initially placed within the die mold 10 and the 
upper die half 12 is lowered to its operating position, the upper and 
lower die mold halves 12 and 16 may still be at a spacing from one another 
relative to their spacing after the completion of a molding process. The 
additional length 74 of elongated slots 32 permits the upper die mold half 
12 to move downwardly and compress the workpiece being molded between the 
die mold halves 12 and 16. This compression during a molding operation may 
be as much as 1" or more. 
It should, therefore, be apparent from the foregoing that the electrical 
connectors 26 and 42 and the thermocouple connectors 30 and 44 are capable 
of independent movement from the upper and lower adapter plates 11 and 14 
and the die halves 12 and 16 to permit alignment and docking with the 
mating connectors 54 on the pre-heat station 21, when the die mold 10 is 
advanced toward the pre-heat station 21, and the upper die mold half 12 
and the upper adapter plate 11 can move independently of the upper 
mounting plate 28 and the connectors 26 and 30 mounted thereon to permit 
compression of the mold 10 during a molding operation. 
The pre-heat station 21 preferably includes a conveyor arrangement 76, such 
as a plurality 78 of bearing mounted rollers. The roller bearing conveyor 
assembly 76 permits movement of the die mold 10 into a docking position 
with pre-heat station 21 as shown in FIGS. 3 and 7 when upper mold half 12 
is lowered into its operating position for performing a molding operation. 
The die mold 10 may be moved into the docked position with pre-heat 
station 21 by a mechanical ram 80 or a similar type mechanical arrangement 
for moving the die mold 10 in and out of the docked position with station 
21. After preheating, the die mold is preferably moved to a press station 
(not shown) where the adapter plates 11 and 14 and mold halves 12 and 16 
are forced together to form the workpiece. 
While the present invention has been described with respect to the 
automatic, self-aligning electrical connection of a die mold manufacturing 
device to a preheat station, those skilled in the art will recognize that 
the features illustrated and described herein may be applied to other 
types of automated manufacturing devices or systems where automatic 
coupling of a workpiece receptacle to an external source or process 
inputs, such as pneumatics, hydraulics or the like, and automatic 
connection to the control mechanisms for these inputs are desired. 
It will be readily understood by those skilled in the art that the present 
invention is not limited to the specific embodiments described and 
illustrated herein. Different embodiments and adaptations besides those 
shown herein and described, as well as many variations, modifications and 
equivalent arrangements will now be apparent or will be reasonably 
suggested by the foregoing specification and drawings, without departing 
from the substance or scope of the invention. While the present invention 
has been described herein in detail in relation to its preferred 
embodiments, it will be understood that this disclosure is only 
illustrative and exemplary of the present invention and is made merely for 
purposes of providing a full and enabling disclosure of the invention. 
Accordingly, it is intended that the invention be limited only by the 
spirit and scope of the claims appended hereto.