Automatic tool changing machine

Abstract: The invention is a system for use in a single-anvil hydraulic press or compression system for automatically selecting and changing both the upper and lower tooling. The system is installed between the upper and lower compression anvils of a hydraulic press (21). The upper portion includes a set of holders for upper tools (27) and adjacent orientation structures or jaws. The upper tool holders and jaws are mounted on a horizontal member that may be moved such that one of the upper tools (27) is "selected" by being placed immediately below the upper anvil of the press (21). As part of this selection process, the anvil removes the tool from the selected holder, and holds it using pneumatic suction. Then the horizontal member shifts over so that the upper anvil is situated directly above the adjacent orientation structure for that tool. To switch to a different upper tool, the horizontal member again moves the (empty) holder below the upper anvil, whereupon the pneumatic suction is removed causing the tool to drop into the holder. The horizontal member then moves to the newly selected tool holder and removes the tool therefrom using the pneumatic suction. Then the horizontal structure shifts over so that the upper anvil is situated directly above the adjacent orientation structure for the newly selected tool. Available sets of tooling for the lower anvil are mounted in vertical orientation in pockets (41) on a movable belt (33) adjacent to the lower anvil. Rotation of the belt (33) moves the selected pocket (41) below a support bracket. Pneumatic pressure is used to push the lower tool (31) from the selected pocket (41) into the bracket. A slidable member on the bracket locks the lower tool (31) into place for use. To switch to a different lower tool (31), the slidable locking member is released, and the pneumatic pressure removed thereby allowing the lower tool in the bracket to fall into the waiting empty pocket (41). The belt (33) is rotated until the newly selected pocket (41) is below the support bracket. Then, the pneumatic pressure and the locking member are again used to move and lock the newly selected lower tool into place for use.

Description: The present invention relates to automatic or semiautomatic fastener insertion machines, and more particularly to a method and apparatus for automatically changing the upper and/or lower tools of a fastener insertion machine. Fastener insertion machines are sometimes referred to as presses or hydraulic presses. These machines use very high pressure to permanently attach fasteners of different sizes and shapes to workpieces. In a typical fastener insertion machine, an upper tool and a lower tool are provided in vertical alignment. A flat surface on a workpiece is placed between the upper and lower tools of the machine. The workpiece is positioned either manually or automatically so that the appropriate location (usually a precut opening) on the workpiece is placed between the machine tooling to receive the fastener. A fastener is delivered to the machine tooling, and the machine is then operated such that the upper and lower tooling are pressed firmly together causing the fastener to be attached to the workpiece. The tooling then retracts, allowing the workpiece to be moved or removed before the next insertion cycle. Fastener insertion machines typically require that both the upper and lower tooling correspond to the particular fastener to be inserted. Fasteners of different sizes and shapes generally require different upper and lower tooling; the same tooling is generally not usable for more than one type of fastener. Once the upper and lower tooling is set, the insertion machine may be operated repetitively to insert hundreds or thousands of the same kind of fasteners into workpieces. It is becoming increasingly more common for a single workpiece to require the insertion of more than one different kind of fastener. Using existing fastener insertion machines, this may be accomplished by passing a batch of workpieces through a single insertion machine several times, changing the tooling and the fastener to be inserted on each pass. This approach is inefficient, time consuming, and expensive because, among other things, the same batch of workpieces (potentially many thousands of them) must be accumulated and stored following each pass through the machine, pending the change to the next set of tooling/fastener for the next pass. Alternatively, a different fastener insertion machine could be used to insert each different fastener on the workpiece. While such an assembly line of insertion machines would be more efficient than using a single machine, it is a much more expensive proposition. A better solution would be a single machine that is capable of automatically changing tooling so that many different kinds of fasteners could be inserted on a workpiece during a single pass of the workpiece through the machine. There are a number of tool changing devices that have been developed for punch presses in the prior art. (E.g. U.S. Patent Nos 4,205,427; 4,719,691; 5,699,866). Such devices generally include a magazine of alternative upper tools which can be swapped out using one of a variety of grippers. However, since these machines have been developed for punch presses which generally cut holes into workpieces, they generally deal with changing only the upper cutting tool. Other tool changing devices such as those described in U.S. Patent Nos 3,811,179; 4,696,091 and 5,762,594 describe similar devices which are also designed to only change the upper tools using a magazine of available tools. U.S. Patent No. 5,326,201 describes a complicated mechanism for changing upper tools in a blind broaching machine. However, neither this nor any of the above listed inventions make any provision for changing the lower tooling. US Patent No. 4,269,739 describes a tool changing device for a turret punch press which includes changing the lower tooling; however, the turret operation of this device is highly specific, and differs greatly from the present invention. None of the above inventions make any provision for supplying fasteners to the tooling, holding the different fasteners associated with different tooling, or changing to a different fastener supply with the change in tooling. US 5,669,866 discloses a tool changing apparatus for a numerically controlled punch press wherein an upper tool is attached below a vertically operable lamb in a tool head. An array of tool cartridges can be moved beneath the tool head in the X direction by a first actuator and the tool head can be moved in the Y direction by a second actuator. Tool exchange is accomplished by Y positioning of the tool head and X positioning of the tool cartridges without the need to alter the Y position of the workpiece. The present invention provides a fastener insertion machine with an apparatus for changing the upper tooling comprising an upper tool attached below a vertically operable ram; a movable plate member adjacent to said upper tool, said member supporting a plurality of dispensers, each dispenser including an upper tool extension tray, movable fastener support jaws and a tube for feeding fasteners to said dispenser, a first actuator for moving said plate member to align said dispensers with said upper tool; a second actuator for delivering fasteners to said support jaws; suction means for establishing a first vacuum in said upper tool for holding tool extensions against said upper tool; and suction means for establishing a second vacuum for holding fasteners against a selected tool extension. In a preferred embodiment the upper tool is provided with two separate vacuum ports. The first vacuum is used to secure a small removable tool extension or tool tip to the flat end of the upper tool. The second vacuum pulls through both the upper tool and the tool tip, and is used to hold fasteners in place against the tip during fastener installation. A movable plate member is provided in the vicinity of the upper tool. The plate member carries a set of alternative tool dispensers. Each dispenser includes a tray for holding a removable tool tip, a fastener feed tube, and a corresponding set of movable fastener orientation structures or holding jaws. The jaws may be slidable, pivotally mounted and spring loaded, and/or mechanically, electrically or pneumatically operated; or without a pivot, horizontally and/or vertically movable. The plate member is designed to be moved on a horizontal plane (in both the X and Y directions), and to also be tilted or moved vertically upwards for transferring tool tips from the various trays. In operation of the above embodiment, the plate member is moved in the X and Y directions until the tool tray of one of the dispensers is located directly below the upper tool. The plate is then tilted or moved vertically upward and the first vacuum of the upper tool is activated, causing the tool tip to be removed from the tray and attached to the bottom of the upper tool. This vacuum remains activated for the entire time the selected tool tip is in use. The plate member is brought back down, and then moved in the X and Y directions until the extended fastener holding jaws are brought directly below the upper tool. The jaws are retracted (without retracting the entire plate member) to receive a fastener from the feed tube, and then extended forward again into position below the upper tool, now holding a fastener for insertion. The hydraulic ram then moves the upper tool (with tip) in a downward direction. As the tip comes into contact with the fastener, the second suction holds the fastener against the tip as it continues downward. The spring loaded jaws are forced open as the ram pushes the tooling through, eventually to be pressed against a workpiece above the lower tool. In order to change to another upper tool tip, the hydraulic ram is withdrawn, and the plate member is moved until the empty tray on the tool dispenser is positioned immediately below the upper tool. The tool tray is tilted or moved vertically upward, and the first vacuum is removed allowing the tip to fall into the tray. The plate member is then brought down and moved until a different tool tip is positioned below the upper tool. The plate member is again tilted or raised, and the first vacuum is re-activated in order to pick up the new tool tip. Then, as previously described, the plate is brought back down, the fastener holding jaws associated with the new tip are moved into position, and fasteners are delivered for insertion. In a second embodiment, on a C-frame support below the lower tooling, a movable continuous belt is provided which includes a plurality of pockets, each pocket designed to hold a lower tool piece. The top of each pocket is open, and the bottom of each pocket has an opening therein. The belt may be indexed forward or backward in order to line up a pocket holding a tool with the lower tool holder in the C-frame. A lift is located below the belt along the vertical axis defined by the tooling centerline. Once the pocket is in position, the lift is activated in order to raise the tool piece out of the pocket and bring it up to the lower tool holder. A clamp is then activated to hold the tool piece in position. This clamp also supports the lower tool piece, and must therefore be able to withstand the force exerted by the hydraulic cylinder during the insertion process. The lift is then withdrawn, allowing the operation of the hydraulic to commence. In operation of the second embodiment, to change the lower tool piece, the lift is raised to support the tool piece in the lower tool holder. The clamp is then removed, allowing the lift to bring the tool piece back down into its pocket. The belt is then indexed to line up another pocket containing a different tool piece below the lower tool holder. The lift then raises the new tool piece up to the lower tool holder where it is clamped in place. In most cases, when the upper tooling is changed, it is also necessary to change the lower tooling in order to correspond. However, in some applications the same lower tool may be used with more than one (very similar) upper tool; likewise, in some applications, the same upper tool may be used with more than one (very similar) lower tool. Of course, where a given fastener (e.g. a threaded washer) is replaced by a dissimilar fastener (e.g. a threaded stud) both the upper and lower tooling must be changed. A preferred embodiment is described below by way of example only with reference to Figures 1 to 15 of the accompanying drawings, wherein: Fig. 1 is a perspective view of a typical C-frame fastener insertion machine; Fig. 1A is a cross sectional view of the lower tool changing assembly of the present invention; Fig. 2 is a perspective view of the lower tool changing apparatus of the present invention showing the clamp in a closed position; Fig. 3 is the perspective view of Fig. 2 showing the clamp in an open position; Fig. 4 is the perspective view of Fig. 3 showing the lower tool piece being lowered into a pocket. Fig. 5 is the perspective view of Fig. 4 showing the lower tool piece fully lowered into a pocket. Fig. 6 is the perspective view of Fig. 5 after the belt has indexed one pitch bringing a new pocked under the lower tool holder. Fig. 7 is a perspective view of an alternative embodiment of a lower tool changing mechanism. Fig. 8 is a perspective view of the upper tooling changing apparatus of the present invention. Fig. 9 is an enlarged perspective view showing the plate member in a tilted position for attachment of a tool tip to the upper tool. Fig. 10 is the perspective view of Fig. 9 after the tool tip has been attached and the plate member has been retracted back to horizontal. Fig. 11 is the perspective view of Fig. 10 showing the shuttle jaws retracted to receive a fastener. Fig. 12 is the perspective view of Fig. 11 showing the shuttle jaws extended and holding a fastener. Fig. 13 is the perspective view of Fig. 12 showing the fastener aligned below the upper tool. Fig. 14 is the perspective view of Fig. 13 showing the upper tool pushing through the shuttle jaws and moving the fastener down. Fig. 15 is a perspective view of an alternative embodiment of the upper tooling changing device of the present invention. Like reference characters designate like or corresponding parts throughout the several views. Fig. 1 depicts a typical manually operated fastener insertion machine. This machine is a C-frame press 21 with a vertical hydraulic ram 23. In use, an operator uses a foot pedal 25 to activate the ram 23 to drive an upper tool 27 down until it makes contact with a lower tool 31. At the tooling interface, fasteners may be squeezed into workpieces. This is accomplished by placing a workpiece having a prepared opening therein on the lower tool 31. A fastener may be inserted manually into the prepared opening before the workpiece is placed on the lower tool, or the fastener may be delivered automatically after the workpiece is in position on the lower tool. The squeezing or pressing action (often several hundred pounds, or even several tons per square inch) which occurs when upper tool 27 makes contact with the fastener, workpiece and lower tool 31 is sufficient to create a permanent joint between the fastener and the workpiece. The workpiece is then moved or removed to allow the machine to perform another operation. Some machines are capable of running automatically and typically include a workpiece positioning apparatus. The present invention can be used on all types of fastener insertion machines. Referring to Figs. 2-6 it is seen that the lower tool changing apparatus of the present includes a lower tool holder 29 attached to and supported by the lower half of C-frame 21. A movable belt 33 is provided along C-frame 21 below tool holder 29 such that it passes below the lower tool holder at one end and around a pulley 35 at the other end. A motor 37 and gear mechanism 39 are illustrated for imparting motion to belt 33 by rotating pulley 35; however, any appropriate indexing mechanism could be used to advance or retract belt 33. A plurality of pockets 41 are provided along belt 33 for holding different lower tool pieces 31. Although only three pockets are depicted in Figs. 2-6, any number of pockets could be made available on belt 33, space providing. Each pocket is open at the top, and has a floor at the bottom for supporting the different lower tool pieces 31. An opening is provided in the floor of each pocket 41 in order to receive movable rod 43 operated by lift 45. Lift 45 may be any suitable device such as a piston, a pneumatic cylinder, electric motor, or hydraulic. A slidable clamp 47 operated by piston mechanism 49 is provided in lower tool holder 29 to hold a lower tool 31 in place. Mechanism 49 may be operated pneumatically, hydraulically or electrically. Clamp 47 also provides support for tool piece 31 at 48 sufficient to withstand the pressure exerted by the hydraulic ram 23 during operation. (See Fig. 1A). Figs. 2 shows a lower tool piece 31 held in place by clamp 47 on holder 29. To change lower tool pieces, rod 43 is extended upward by lift 45. Piston 49 is then operated to slide clamp 47 back in order to release the lower tool piece 31 as shown in Fig. 3. Lower tool piece 31 is now supported only by rod 43 which is then lowered by lift 45 as shown in Fig. 4. When rod 43 is fully retracted, piece 31 drops into pocket 41 as shown in Fig. 5. Belt 33 is then indexed to bring a different desired pocket with corresponding lower tool piece into position below tool holder 29 and above rod 43. Any of the pockets 41 of belt 33 may be moved into position for use in any order. In Fig. 6, the next pocket 41a on belt 33 has been moved into position. Lift 45 then raises rod 43 thereby moving lower tool piece 31a up into the lower tool holder 29. Once piece 31a is in position, piston 49 moves clamp 47 into place locking piece 31a into lower tool holder 29 for use. Rod 43 is then retracted until needed for the next tool change. The upper tool changing mechanism is illustrated in Figs. 8-14. A slidable plate member or tooling plate 51 is provided which supports a plurality of upper tool dispensers 53 slidably deployed on a shuttle tooling plate 56 beneath plate 51. Although four such dispensers are illustrated, any number may be provided depending on space limitations. Each dispenser includes a tool tip holder 57 for holding removable tool extensions or tool tips 55. Each dispenser also includes a pair of slidable orientation structures or shuttle jaws 61 for holding fasteners. Jaws 61 may be pivotally mounted and spring loaded, and/or mechanically, electrically or pneumatically operated; or without a pivot, jaws 61 may be horizontally and/or vertically movable. A plurality of fastener feed tubes 59 are attached to plate 51, each adjacent to a tool dispenser 53. A linear actuator 50 is used to index tooling plate 51 in the direction depicted by arrows X of Fig. 8. A horizontal slide table 52 is used to move dispensers 53 in the direction depicted by arrows Y of Fig. 8. A tilt cylinder 63 is used to raise and lower plate 51 and attached dispensers 53 toward and away from the flat lower face of upper tool 27, pivoting at 65. Alternatively, any suitable mechanism may be used in place of cylinder 63 to move plate 51 and the attached dispensers 53 in a vertical direction. Once an upper tool extension 55 is selected, linear actuator 50 moves plate 51 so that the holder 57 of the dispenser 53 containing the selected tip 55 is beneath the upper tool 27. Slide table 52 moves shuttle plate 56 forward so that tip holder 57 is directly below upper tool 27. Then, cylinder 63 (or a suitable alternative vertical actuator) is activated to raise plates 51 and 56 upward raising tip holder 57 and bringing tip 55 directly into contact with tool 27 as shown in Fig. 9. A vacuum is then activated providing suction at the end of tool 27 which removes tip 55 from holder 57 and holds it against the flat bottom of upper tool 27. Cylinder 63 is then retracted, lowering plates 51 and 56, with tip 55 remaining attached to the end of tool 27 as shown in Fig. 10. Once a tip has been attached to upper tool 27, linear actuator 50 may move plate 51 (in the X direction of Fig. 8) in order to align jaws 61 directly beneath upper tool 27 as shown in Fig. 13. Either before or after this alignment of the jaws, shuttle tooling plate 56 may be retracted and then extended in order for the jaws 61 to pick up a fastener as shown in Figs. 11 and 12. In order to pick up a fastener, slide table 52 is pulled in the direction of the Y arrow of Fig. 8 away from the tooling interface. This causes all of the dispensers 53 and their associated tool holders 57 and jaws 61 to be pulled beneath tooling plate 51 as shown in Fig. 11. A fastener 67 is then blown down tube 59 into the opening between the semi-circular edges of jaws 61. Slide table 52 is then extended out toward the tooling interface which pushes all of the dispensers 53, holders 57 and jaws 61 back out from under plate 51. Jaws 61 now hold fastener 67 as shown in Fig. 12. For efficiency, since all of the jaws of all of the dispensers shuttle back and forth each time the shuttle tooling plate 56 is moved, it is often desirable for each set of jaws 61 to pick up a fastener simultaneously. In that way, as soon as tool tip 55 is changed, linear actuator 50 may move plate 51 to align the upper tool 27 with the new set of jaws which already hold a fastener 67 ready for insertion as shown in Fig. 13. Once the jaws 61 are positioned below the upper tool 27, repetitive shuttle operations by slide table 52 can be used to deliver multiple additional fasteners to the tooling interface. Each fastener is inserted by the downward motion of ram 23 which pushes upper tool 27 and tip 55 against fastener 67 held by jaws 61. A second suction pulling through tool 27 and tip 55 holds fastener 67 against tip 55 as it continues downward for insertion. The pivotally mounted spring loaded jaws 61 bend as the upper tool 27 continues downward for insertion. After the fastener insertion is completed, ram 23 retracts upward, bringing upper tool 27 and tip 55 with it. Meanwhile, jaws 61 may be shuttled by the back and forth operation of slide table 52 to pick up another fastener for insertion. To change upper tool extensions, before another fastener is picked up, linear actuator 50 moves tooling plate 51 such that the upper tool 27 is positioned above an empty tool tip tray 57. Tooling plate 51 is moved up, the suction at the end of upper tool 27 is released, and tool tip 55 drops into tray 57. Plate 51 is then moved down, and actuator 50 them moves plate 51 such that a different tray 57 is positioned below upper tool 27. Tooling plate 51 is again moved up, vacuum suction is activated at the end of upper tool 27, and the newly selected tool tip 55 is attached to the end of the upper tool. An appropriate computerized control mechanism should be used to coordinate the various functions of the upper and lower tool changing devices of the present invention. The control should not allow the upper tool to perform a press operation unless a lower tool has been placed in the lower tool holder and clamp 47 and support 48 activated. The control should also prevent more than one tool tip 55 from being placed in the same tray 57, or more than one lower tool 31 from being placed in the same pocket 41. A plurality of appropriate orientation and singulation devices (such as that disclosed in U.S. Patent No. 5,191,960) should be employed to deliver properly oriented fasteners 67 through tubes 59 using pneumatic pressure. In use, as an example, a given workpiece may require insertion of nine identical fasteners of variety A, six of variety B, and three of variety C at wide ranging locations on the workpiece. For efficiency, the controls for the upper and lower tooling could be set so that the upper and lower tooling is changed for variety A, followed by nine shuttles of plate 56 so that nine fasteners are delivered in succession, the workpiece being moved to the appropriate location for each insertion. Following the ninth insertion, the control would change both the upper and lower tooling to the next variety B, followed by six shuttles and insertions. Finally the control would change the upper and lower tooling to variety C and complete the final three insertions. At this point, the next workpiece would be introduced, the upper and lower tooling changed back to variety A, and the process would repeat. An alternative embodiment of a lower tool is illustrated in Fig. 7. Here, instead of using belt 33 with pockets 41, a rotatable cylinder 32 is provided below the support for the lower tool holder 29. Cylinder 32 includes a plurality of slots 34 for holding lower tools 31. A lift 45 is provided below the cylinder along the vertical axis defined by the tooling centerline. By rotating the cylinder 32, a slot 34 containing a lower tool 31 may be placed in position below the lower tool holder. The lift 45 is activated in order to raise the tool piece out of the slot and bring it up to the lower tool holder 29, as shown in Fig. 7. Clamp 47 is then activated to hold and support the tool piece in position. To change the lower tool piece using this embodiment, the lift 45 is raised to support the tool piece in the lower tool holder. The clamp 47 is then retracted, allowing the lift to bring the tool piece back down into its slot 34. Cylinder 32 is then indexed using motor mechanism 36 to line up another slot containing a different tool piece below the lower tool holder. Lift 45 then raises the new tool piece up to the lower tool holder 29 where it is clamped in place. An alternative embodiment of the upper tool changer is illustrated in Fig. 15. Here, the tilt cylinder 63 is replaced with a slide table 62 that is similar to slide table 52 which is used to move shuttle plate 56. The illustration shows a pneumatic unit, but it could be equally otherwise powered. Instead of tilting, in this embodiment the tip trays 57 are raised and lowered vertically when transferring tool tips 55. It is to be understood that variations and modifications of the present invention may be made without departing from the scope of the appended claims. It is also to be understood that the present invention is not to be limited by the specific embodiments disclosed herein, but only in accordance with the appended claims when read in light of the foregoing specification.

Claims: Fastener insertion machine with an apparatus for changing the upper tooling comprising an upper tool (27) attached below a vertically operable ram (23); a movable plate member (51) adjacent to said upper tool, said member supporting a plurality of dispensers (53), each dispenser including an upper tool extension (55) tray (57), movable fastener support jaws (61) and a tube (59) for feeding fasteners to said dispenser; a first actuator (50) for moving said plate member to align said dispensers with said upper tool; a second actuator (52) for delivering fasteners to said support jaws; suction means for establishing a first vacuum in said upper tool for holding tool extensions (55) against said upper tool; and suction means for establishing a second vacuum for holding fasteners against a selected tool extension (55). Fastener insertion machine with an apparatus according to claim 1 for further changing the lower tooling, further comprising a lower tool support (29) in a vertical alignment with said upper tool (27); a movable belt (33) having a plurality of pockets (41) attached thereto located below said lower tool support for holding lower tool pieces (31); an opening in said lower tool support in vertical alignment with said upper tool; a mechanism (37, 39) for indexing said belt to position a selected pocket below said opening; a vertical lift (45) below said opening for raising and lowering lower tool pieces (31) between said pockets (41) and said opening; and a clamp (47) for holding and supporting lower tool pieces positioned in said opening. Fastener insertion machine with an apparatus according to claim 1 or claim 2 wherein a third actuator (63) is provided for raising and lowering said plate member (51) to facilitate delivery and removal of upper tool extensions (55) to said upper tool (27). Fastener insertion machine with an apparatus according to claim 1 for further changing the lower tooling, further comprising a lower tool support (29) in vertical alignment with said upper tool (27); a rotatable cylinder (32) having a plurality of slots (34) located thereon for holding lower tool pieces (31); an opening in said lower tool support in vertical alignment with said upper tool; said slots being movable into alignment with said lower tool support opening; a vertical lift (45) below said opening for raising and lowering lower tool pieces (31) between said pockets (41) and said opening; and a clamp (47) for holding and supporting lower tool pieces positioned in said opening, each slot (34) having a small aperture therein for receiving said vertical lift (45) for raising and lowering lower tool pieces (31) between said slots and said lower tool support opening.

Inventors: KELLY RORY T, LANE BRIAN E, MCDANIEL DENNIS W, KELLY, RORY T., LANE, BRIAN E., MCDANIEL, DENNIS W.
Applicants: HAEGER INC, HAEGER, INC.
Application year: 1999
Main classification: B21J15
IPC codes: B23Q3, B21J15