Abstract:
A modular manufacturing system uses a universal base and power infrastructure to receive a variety of tooling plates. This is accomplished by the creation of a modular service interface for simultaneous connection of electrical and fluid power from the base to the tooling plate. In addition, a sensing system is used to automatically identify the specific tool set, and to distinguish between a single plate tool set and a double plate tool set. Individual tool sets are located with certainty through the use of physical placement guide rollers, stops, and friction fit. A PLC manages the power, tool set identification and user interface.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
     Not Applicable. 
     APPENDIX 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to manufacturing systems and, more specifically, to modular manufacturing systems where modular tool sets may be swapped for different operations. 
     Related Art 
     In the area of tooling and tool sets, the typical approach is to have a machine that is designed to perform a specific operation using a specific tool set. Depending on volumes, it is not unusual for a particular machine to be in use for anywhere between 2 and 20 hours per week. There could easily be between 5 and 15 machines used to produce a specific product, with some machines having more use than others depending on volume. For example, a machine that produces wheels for a toy car may have four times the volume as a machine that produces the car body. 
     Each machine used shares common requirements. There is a need for power—often in the form of electricity and fluids (pneumatics and hydraulics). There is a need for a user interface to provide information on the process and to allow for interruptions of mechanical processes. There is a need to apply the power correctly to a work piece. 
     This application of power is accomplished through the use of a work piece-specific tool set, and through the managed application of electrical power and fluid power through the tool set. The management of the application of electrical power and fluid is often done through the use of a programmable logic controller (PLC). In addition, the PLC will usually manage the user interface. 
     Even though there are common requirements, each machine normally has unique requirements. Some machines need 2 electrical power sources and 2 pneumatic power sources connected to the tool set at specific locations, whereas other machines could need 4 electrical power sources, and no pneumatic power sources, and still others might require only pneumatic power sources only. These differing requirements make converting a particular machine from one operation with one tool set to another operation with a second tool set very tool-set dependent, time-consuming, and impractical. Moreover, the machine has to be converted back to its original condition for the first operation. Each change in tooling takes time and labor—meanwhile, the production worker may be simply waiting for the changeover. 
     Not surprisingly, prior efforts at attempting to use fewer machines to accomplish multiple machine operations have not been commercially or widely adopted. Accordingly, the machine tool industry largely uses separate purpose built machines for each operation, as this has been generally the most efficient approach. 
     SUMMARY OF THE INVENTION 
     The invention is a modular manufacturing system that uses a universal base and power infrastructure to receive a variety of manufacturing units (hereinafter “tooling plates”). This is accomplished by the creation of a modular service interface for simultaneous connection of electrical and fluid power from the base to the tooling plate. In addition, a sensing system is used to automatically identify the specific tool set, and to distinguish between a single plate tool set and a double plate tool set. Individual tool sets are located with certainty through the use of physical placement guide rollers, stops, and friction fit. A PLC manages the power, tool set identification and user interface. 
     The sensing system senses the presence or absence of permanent flags on a tooling plate. The flags may be arranged logically to recognize up to 8 different single tool sets and up to 8 different double tool sets. Upon recognition, the PLC initiates the appropriate user interface displays and activates the appropriate electrical, fluid, and data links. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is an elevated front perspective view of the modular manufacturing system of the present invention. 
         FIG. 2  is an elevated rear perspective view of the modular manufacturing of the present invention. 
         FIG. 3  is an elevated enlarged rear view of the circle  3 - 3  of  FIG. 2 , illustrating inputs to the control panel of the present invention. 
         FIG. 4  is a bottom perspective rear view of the modular manufacturing system of the present invention. 
         FIG. 5  is an elevated rear view of the lower front control panel cabinet door of the present invention. 
         FIG. 6  is a front view of the control panel of the present invention. 
         FIG. 7  is a partial elevated perspective rear view of the modular manufacturing system of the present invention. 
         FIG. 8  is a detail view of circle  8 - 8  from  FIG. 2 . 
         FIG. 9  is a perspective view of the pneumatic valves of the modular manufacturing system of the present invention. 
         FIG. 10  is a perspective view of the left rear of control panel of the modular manufacturing system of the present invention. 
         FIG. 11A  is a partial perspective view of the rear left corner of a tool plate of the modular manufacturing system of the present invention. 
         FIG. 11B  defines an array of sensor positions. 
         FIG. 11C  is a logic chart defining tool numbers according to flag positions. 
         FIG. 12  is an elevated side view of a proximity switch and a cutaway view of a flag of the present invention. 
         FIG. 13  is a schematic of the lower plate modular connectors of the present invention. 
         FIG. 14  is a schematic of the upper plate modular connectors of the present invention. 
         FIG. 15  is a front perspective view of the tool plate holding table of the present invention. 
         FIG. 16  is a perspective view of the roller assembly of the present invention. 
         FIG. 17  is a bottom perspective view of a tool plate of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     As best seen in  FIGS. 1, 2, and 4 , a modular machining system is shown generally at  30 . Modular machining system comprises a base  32 , first, second, third, and fourth supports,  34 ,  36 ,  28 , and  40 , respectively, main deck  42 , upper deck  44 , control panel shown generally at  46 , user interface  48 , first main deck tool plate holder  50 , second main deck tool plate holder  52 , main deck modular service interface  54 , upper deck modular service interface  56 , first upper deck tool plate holder  58 , and second upper deck tool plate holder  60 . 
     Now the power feed to modular manufacturing system  30  will be described. Modular manufacturing system  30  has a power input  70  which connects at one end to an exterior electrical grid network (not shown). The power input  70  is extends from the top left corner, as best seen in  FIG. 2 , down the inside (not shown) of second support  36 , to the inside of control panel  46  (see  FIGS. 1 and 2 ) in area  3 - 3  (see  FIG. 2 ). 
     It should be noted that various components in area  3 - 3  of  FIG. 2  have been omitted for clarity.  FIG. 3  shows a portion of the inside of control panel  46  in which the components of area  3 - 3  have not been omitted for clarity. In  FIG. 3 , it is seen that the power input  70  terminates via plug  74  through control panel  46 . To be clear, this termination is on the physical supporting panel of control panel  46 , and is not an operative power connection to any components of control panel  46 . From this termination on control panel  46 , as best seen in  FIG. 5 , power is then communicated to the inside of front door  72  at safety power stop  76 . While located on the inside of front door  72 , Safety power stop  76  is further connected to emergency stop switch  78  (see  FIG. 1 ) located on the outside of front door  72  which, if actuated, creates an open circuit. Safety power stop  76 , which is normally closed, operatively delivers power to control panel  46 . In this way, if the emergency stop switch  78  is actuated, power is prevented from reaching any operative component of control panel  46 . 
     Now the pneumatic input to modular manufacturing system will be explained. As best seen in  FIGS. 2 and 7 , at the right rear corner of modular manufacturing system  30 , ambient air is drawn through filters  80  by pump unit  82 . From pump unit  82 , air is delivered into pressure accumulator tank  86 . From pressure accumulator tank  86 , pressurized air is output to area  8 - 8  shown in  FIG. 2 . 
     Area  8 - 8  of  FIG. 2  has various component details that have been omitted for clarity. However, as better seen in  FIG. 8 , the area  8 - 8  shows hose  88  extending from pressure accumulator tank  86  and terminating at manifold  90 . Manifold  90  is connected to a plurality of valves,  92  (as best seen in  FIGS. 2, 8, and 9 ). 
     The service interface will now be discussed. The configuration of main deck modular service interface  54  is best shown in  FIG. 13 . The configuration of upper deck modular service interface  56  is best shown in  FIG. 14 . The output of valves  92  have 20 terminations (10 valve and 10 non-valved pressure) at main deck modular service interface  54  and twenty terminations (10 valve and 10 non-valve pressure) at upper deck modular service interface  56 . 
     It should be noted that the inputs  1 - 16  (on main deck modular service interface  54  in  FIG. 13  and on upper deck modular service interface in  FIG. 14 ) are actually both data inputs (preferably input nos.  1 - 8 ) and data outputs (preferably input nos.  9 - 16 ). 
     The programmable logic controller is now described. As best seen in  FIG. 6 , control panel  46  has a general purpose programmable controller in the form of a programmable logic controller (PLC)  100  located at the bottom rack. PLC  100  is operatively connected to power from safety power stop  76 , air pump  82 , manifold  90 , valves  92 , data inputs  104  and data outputs  106  (best seen in  FIG. 10 ), to main deck modular service interface  54 , to upper deck modular service interface  56 , to user interface  48 , and to tool plate sensing area shown generally at  110  (which includes first tool plate sensor  112 , second tool plate sensor  114 , third tool plate sensor  116 , single plate tool set sensor  118 , and double plate tool set sensor  120 ). 
     Tool plate identification is now explained. As best seen in  FIG. 4 , tool plate sensing area  110  consists of five sensors: first tool plate sensing  112 , second tool plate sensor  114 , third tool plate sensor  116 , single plate tool set sensor  118 , and double plate tool set sensor  120 . The sensors,  112 - 120 , are arranged one row of three sensors,  112 ,  114 , and  116 , and a second row of two sensors,  118 ,  120 . This arrangement is best seen in  FIG. 11B . Preferably, each sensor,  112 ,  114 ,  116 ,  118 ,  120  is a inductive proximity sensor. 
     As seen in  FIGS. 11A and 17 , tool plate  142  is provided with a first tool plate flag sensor  112 F, second tool plate sensor flag  114 F, and third tool plate sensor flag  116 F. For a particular tool plate, each tool plate flag sensor  112 F,  114 F,  116 F, is fixed in an “on” or “off” position. In addition, a notch N in an edge of a tool plate  142  may or may not be placed above single plate tool set sensor  118  and double plate tool set sensor  120 . The presence of a notch N above single plate tool set sensor  118  (not shown) signifies a single plate tool set; similarly, the presence of a notch N above a double plate tool set sensor  120  (as shown in  FIG. 11A ) signifies a double plate tool set. 
     Thus, according to whether a particular tool set is a single plate or double plate, and according to the first row of three flags,  112 F,  114 F,  116 F, the chart in  FIG. 11C  shows that up to eight separate, unique single tool plate sets may be separately distinguished (numbered  9 - 11 ). For example, if notch N is over the single tool set sensor  118 , flag  112 F is “off”, flag  114 F is “on”, and flag  116 F is “off”, then PLC  100  will recognize that tool number  11  is ready for operation. PLC  100  will accordingly initiate the software associated with tool number  11 , including the appropriate user interface. Similarly, up to eight separate, unique double tool plate sets may be separately distinguished. For example, with respect to  FIG. 11A , double tool set tool number  4  is shown; namely notch N signifies a double tool set, flag  112 F is “off”, flag  114 F is “off”, and flag  116 F is “on”. Upon recognition of this unique tool set, PLC  100  automatically can bring up the correct user interface, energize specific power feeds, energize specific pneumatic feeds, open specific data links, and adjust the vertical height of decks  42 ,  44 . 
     With reference to  FIG. 12 , each flag,  112 F,  114 F,  116 F comprises a cap  172  which works in tandem with the proximity switch sensors  112 ,  113 , and  116 . Each cap  172  has an exterior shoulder  174 , and identically dimensioned exterior threads  176  on each side of exterior shoulder  174 . Each cap  172  defines an interior space  178  having a height sufficient to avoid proximity detection by proximity sensors  112 ,  114  or  116 . Each cap  172  is further provided with a metallic end face  180  which may be a separate piece or integral. As best seen in  FIG. 11A , the exterior surface of metallic end face  180  is preferably stamped or engraved with the word “OFF”. The distance between the exterior shoulder  174  and the exterior surface of metallic end face  180  is less than the thickness of tool plate  142 . In other words, cap  172  is an externally threaded tube with a solid end face  180  and a concentric exterior shoulder  174  having a wider diameter than the tube and located a precise distance from the solid end face  180 . 
     In use, a cap  172  is reversibly threaded into each of the three flag locations to serve as flags  112 F,  114 F, and  116 F. For example, if a cap is inserted (threaded into tool plate  142 ) with the “OFF” lettering up in each of the three flag locations, when the tool plate  142  is in position over the sensors  112 ,  114 ,  116 , then the interior space  178  is presented to each of sensors  112 ,  114 , and  116 . Accordingly, sensors  112 ,  114 , and  116  will each indicate a lack of proximity and will not be engaged. According to  FIG. 11C , depending on whether a single tool set or a double tool set is indicated, this configuration will be recognized as either tool number  8  or tool number  16 . 
     In a separate example, if cap  172  is inserted (threaded into tool plate  142 ) upside down (relative to the previous example), then the interior space  178  is open to the upper surface of tool plate  142 . In this case, the metallic end face  180  is not visible to the upper surface of tool plate  142 . Because the distance between the exterior shoulder  174  and the exterior surface of metallic end face  180  is less than the thickness of tool plate  142 , the surface of metallic end face  180  is not planar with the bottom surface of tool plate  142 . Instead, there is a short distance (height) and space between main deck  42  and the surface of metallic end face  180 . However, this short distance is adapted to be within the inductive sensing range of proximity sensors  112 ,  114 , and  116 . Accordingly, each proximity sensor  112 ,  114 , and  116  will indicate proximity and will be engaged—providing an “ON” indication. According to  FIG. 11C , depending on whether a single tool set or a double tool set is indicated, this configuration will be recognized as either tool number  1  or tool number  9 . 
     Once the flags,  112 F,  114 F, and  116 F are set, they are intended to remain unchanged with the tool plate. 
     Physical placement of tool plate  142  into modular manufacturing systems is now explained. As best seen in  FIGS. 4, 11 and 12 , tool plate sensing area  110  is located on the left side towards the rear of main deck  42 . When a single tool plate  142  is placed on main deck  42 , the travel of tool plate is assisted via first roller  126 , second roller  128 , and third roller  130 . Each roller  126 ,  128 ,  130  is assembled in the manner shown in  FIG. 16 . For example, first roller  126  comprises a roller block  132 , a rolling bearing  134  held in place to roller block  132  by a pin  136 , with the roller block  132  being fixed to main deck  42  preferably by bolts  140 . Preferably, the height of roller block  132  is less than the thickness of main deck  42  to enable bolts  142  to engage main deck  42 . Rolling bearing  134  will thus extend higher than the level of the main deck  42 . 
     As seen in  FIG. 17 , the bottom of single tool plate  142  defines a first groove  144 , a second groove  146 , and a third groove  148 . None of the grooves,  144 ,  146 ,  148  are in vertical or horizontal registration with respect to each other. Each groove,  144 ,  146 , and  148  has a gradually increasing depth, and is shallower at the initial entry point of each roller. Each groove,  144 ,  146 ,  148  increases in depth such that at the end of each groove, the depth exceeds the height that rolling bearing  134  extends from main deck  42 . 
     As a result, as the leading edge of single tool plate  142  is placed on main deck  42  and translated towards the rear, single tool plate  142  encounters first roller  126 , second roller  128 , and third roller  130 . More specifically, first roller  126  eventually finds first groove  144 ; second roller  128  eventually finds second groove  146 , and third roller eventually finds third groove  148 . When the depth of each groove of single tool plate  142  exceeds the extension height of rolling bearing  134  of each roller ( 126 ,  128 ,  130 ), single tool plate  142  will cease to roll on first, second and third rollers,  126 ,  128 ,  130 , respectively, and will instead be disposed surface-to-surface (flat) on main deck  42 . Preferably, the end edge of each groove ( 144 ,  146 ,  148 ) is in contact with a surface of rolling bearing  134  such that the tool plate is in a known position mechanically. While only three grooves ( 144 ,  146 ,  148 ) are discussed, it should be appreciated that in  FIG. 1 , there are actually shown six grooves, with three grooves on each side of main deck  42 . However, for simplicity and brevity, only three grooves ( 144 ,  146 ,  148 ) are discussed in detail. 
     In addition to a known position mechanically, there is also electronic verification of position. Specifically, as discussed previously, as the leading edge of single tool plate  142  travels over tool plate sensing area  110 , the flags ( 112 F,  114 F,  116 F) and presence of notch N is noted. 
     Upon verification of position and unique identification of tool set, PLC  100  further mechanically locks the position of tool plate  142 . Specifically, first pin  152  (not shown) is raised above the surface of main deck  42  and extended into first tool plate aperture  152 A; at the same time, second pin  154  ( FIGS. 4 and 15 ) is raised above the surface of main deck  42  and extended into second tool plate aperture  154 A. 
     As a separate mechanical guarantee of position, first tool set plate  142  is provided, on the top surface, at its right and left sides with a strip of thick wear resistant plastic. First clamp block  160  is actuated (preferably pneumatically) to extend first clamp shafts  162 . First clamp shafts  162  are slightly lower than the surface of the plastic strip. Accordingly, first clamp shafts  162  encounter, and then slide over the strip of plastic, compressing the plastic strip and ensuring a friction fit. This applies clamping pressure to maintain the lower surface of tool set plate  142  against the surface of main deck  42 . Similarly, as seen in  FIG. 4 , the right side, second clamp block  164  is actuated to extend second clamp shafts  166  (seen in  FIG. 15  in the extended position) over the strip of plastic on the right side of tool plate  142 , thereby applying clamping pressure on both right and left sides of tool plate  142 . 
     Connection of services (such as electrical, pneumatic, and data) is now discussed. Once the position of tool plate  142  has been verified electronically, and mechanically fixed, it should be appreciated that main deck modular service interface  54  is in vertical registry and spaced below tool plate modular service interface  54 T. Tool plate modular service interface  54 T mirrors (not specifically shown) the layout connections of main deck modular service interface  54 . At this point, PLC  100  raises main deck modular service interface  54  up past the surface of main deck  42 . The means for raising and lowering main deck modular service interface  54  is disposed underneath main deck  42 , and is shown in  FIG. 4 . When main deck modular service interface  54  is raised, it engages tool plate modular service interface  54 T such that power, pneumatic and data connections from both interfaces  54 ,  54 T are connected simultaneously. Even though physically connected, for a specific tool plate, not all power sources, pneumatic sources, and data links are necessarily activated—rather only the ones which are necessary for that specific tool plate. 
     Upper deck  44  is now discussed. While it may be obvious, a single tool set comprises a single tool plate where manufacturing operations originate from the single tool plate. A double tool set indicates two tool plates—a lower plate and an upper plate. While much of the previous description has been directed to the operation of the lower tool plate, the modular manufacturing system  30  of the present invention has an upper deck  44  in registry with main deck  42 . Upper deck  44  is configured in mirror image to main deck  42  with respect to upper deck modular service interface  56 . In addition, upper deck  44  is configured in mirror image to main deck  42  with respect to fixation of an upper tool plate through the use of identical fixation means: first upper deck tool plate holder  58 , second upper deck tool plate holder  60 , and extendable pins (not shown) similar to first pin  152  and second pin  154 . Understandably, upper deck  44  does not include any tool plate identification (as performed by tool plate sensing area  110  on main deck  42 ), and does not include rollers such as first roller  126 , second roller  128 , and third roller  130 . 
     Movement of decks is now described. Main deck  42  may be vertically adjusted by translating along first translation guide  184 , second translation guide  186 , third translation guide  188 , and fourth translation guide  190 . Similarly, upper deck  44  may be vertically adjusted by translating along first translation rod  194 , second translation rod  196 , third translation rod  198 , and fourth translation guide  200 . 
     The normal operation of the invention is now discussed. In a commercial manufacturing environment, the present invention would be utilized in the following manner. Tooling is created and fixed to a tool plate having a notch N appropriate for whether the tool involves a single plate or double plate. The tool plate also has main deck tool plate modular service interface  54 T, and the tooling is appropriately connected to the necessary inputs and outputs. The tool plate is assigned a tool number, and the flags  112 F,  114 F, and  116 F are set. PLC  100  is programmed to recognize the assigned tool number, to activate and control various functions of the tool, to mechanically lock the tool plate in place, to adjust the height of the decks ( 42 ,  44 ), and to provide a user interface that provides information and control over the manufacturing process. The tool plate is loaded, and manufacturing commences. After the manufacturing run has concluded (for example wheels for a toy car have been made), the tool plate is removed. A different second tool plate is loaded. The PLC  100  recognizes the tool number, activates the mechanical locks, activates the appropriate services from main deck modular service interface  54 , adjusts the height of the decks ( 42 ,  44 ), and manufacturing commences. After the manufacturing run has concluded (for example the top body for a toy car), the second tool plate is removed. A different third tool plate is loaded. The PLC  100  recognizes the tool number, activates the mechanical locks, activates the appropriate services from main deck modular service interface  54 , adjusts the height of the decks ( 42 ,  44 ), and manufacturing commences. After the manufacturing run has concluded (for example the bottom body for a toy car), the third tool plate is removed. In the present example, a single modular manufacturing system  30  is used to perform three separate manufacturing operations, instead of using three separate machines to perform three separate manufacturing steps. 
     As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, the present invention is adapted to allow multiple modular manufacturing units  30  to be bolted together to increase the operational area. So, it is possible to bolt three modular manufacturing units  30  to form an “L” shape, or to form one long area operational area. Because each modular manufacturing unit  30  employs standard components in volume, bolting multiple units  30  may be more economical than making a single, larger custom machine. As a separate example, while the present invention prefers the use of pneumatic power, it is entirely possible to use a different kind of fluid power—hydraulic power—in lieu of a pneumatic system. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.