Abstract:
A valve stem installation system ( 10 ) includes a conveyor ( 24 ) for moving wheel ( 14 ). A controller ( 60 ) is adaptable for segmenting the wheel ( 14 ) into a plurality of sections (S 1 -S 11 ). A detector ( 70 ) identifies and signals a general location of the aperture ( 12 ) to the controller ( 60 ) to identify a target section (S 11 ) transmitted to the controller ( 60 ) by a first signal. A robotic manipulator ( 110, 112 ) is operably connected to the controller ( 60 ) and adaptable for inserting the valve stem into the aperture ( 12 ). A sensor ( 153 ) is connected to the robotic manipulator ( 110, 112 ) and is adaptable for visually identifying the target section (S 11 ) and transmitting the general location of the aperture ( 12 ) within the target section by a second signal. The controller ( 60 ) generates a target signal transmitted to the robotic manipulator ( 110, 112 ) to increase the speed and accuracy of mating the valve stem into the aperture ( 12 ) in response to the target signal.

Description:
RELATED APPLICATIONS 
   This is a continuation in part application that claims the benefit of the non provisional patent application Ser. No. 11/095,153 for a VALVE STEM INSTALLATION SYSTEM AND METHOD OF INSTALLING VALVE STEM, filed on Mar. 31, 2005, now U.S. Pat. No. 7,578,052, and the benefit of the continuation in part application Ser. No. 10/846,823 for a VALVE STEM INSTALLATION ASSEMBLY USING RADIAL ZONE IDENTIFICATION SYSTEM, filed on May 14, 2004, now U.S. Pat. No. 7,322,089, and the benefit of the provisional patent application Ser. No. 60/606,964 for a TPM VALVE STEM INSTALLATION TOOL, filed on Sep. 3, 2004. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The subject invention relates to a wheel and tire assembly for an automotive vehicle, and more particularly to an apparatus and method for mounting a valve stem into a wheel rim. 
   2. Description of the Prior Art 
   In the assembly of automotive wheel rims and tires, the tire is mounted onto the wheel rim and then inflated. Prior to mounting the tire, a valve stem is inserted into an aperture defined in the wheel rim to permit inflation of the tire. For manufacturing wheel rims on a large production scale, machines are used to automatically insert the valve stems into the wheel rims. Because the wheel rims of different sizes require differently sized valve stems, valve stemming machines must either operate on the wheel rims of a single size or be able to accommodate the use of several sizes of the valve stems. 
   Over the last few years, snap-in valve stems have become very popular in the automotive industry due to the ease of installation method. Clamp-in tire pressure monitoring systems type of a valve stem (the TPM) are similar to the snap-in valve stems, but also include a tire pressure monitor affixed to one end of the TPM. In order to install the TPM on the wheel rim, the TPM is placed through an opening defined in the wheel rim and then secured to the wheel rim by a retention nut over the TPM. A valve cap is then screwed onto the TPM to form an airtight seal and prevent dust and dirt from entering the valve. 
   Generally, as done in the past, mounting the valve stem into the wheel rim of any kind, have been performed manually. In particular, mounting the valve stem into the wheel rim has been performed by a stem-inserting tool. Such manual processes are expensive because of the labor and time involved. In addition, operations performed manually are subject to a processing error. Several prior art patents disclose processes for mounting the valve stem into the wheel rim. U.S. Pat. No. 6,026,552, for example, teaches a spinning device to spin a wheel, an optical sensor to locate a valve stem aperture while the wheel is spinning, and a press fitting device that can slide relative to the wheel and insert a valve stem after the valve stem aperture has been located. 
   U.S. Pat. No. 5,940,960, for example, teaches and automatic valve stemming apparatus including a spinning device to spin the wheel, an optical sensor to locate the valve stem aperture, and a valve stem insertion tool to insert a valve stem after the valve stem aperture has been located. 
   The art is also replete with various systems and methods, which involve a robot that installs a valve stem into a wheel rim. These systems are taught by U.S. Pat. Nos. 4,353,156; 5,940,960; 6,481,083; and 6,801,126. Other prior art devices utilize a rotatable carousel to dispense valve stems of varying sizes onto a valve stem insertion tool. The assembly line taught by the U.S. Pat. Nos. 4,353,156; 5,940,960; 6,801,126 and 6,481,083 are complex, bulky. Some of them require several separate valve stem mounting stations with the robotic manipulator moving the wheel rim to the respective valve stem mounting station. This prior art systems diminish assembly time and flexibility of assembling environment. These systems also performs numerous redundant operations, such as moving the wheel rim to different mounting stations which does not reduce time for assembly of the wheel rims and does not offer the flexibility needed in the modern manufacturing environment. Although the prior art valve stem installation systems are widely used in the automotive industry, these prior art designs have proven to be extremely complicated, and therefore non practicable, or have been inflexible in a manufacturing environment, particularly when a variety of valve stems are mated to a variety of the wheel rims. 
   One of the areas of continuous development and research is the pursuit of flexible systems operable to receive and process several differently configured rims. Another area is the pursuit of less costly valve stem insertion devices. Costliness can be defined by the capital investment required for putting the valve stem insertion system on the factory floor as well as the operating cost associated with the system. In pursuit of these goals, it would be desirable to develop a new design of the valve stem installation system adaptable for mating of at least two different valve stems into the wheel rim with high degree of accuracy and precision and at a high speed thereby eliminating the need of an extra unit, reduce space in manufacturing environment, and improving cost and efficiency of manufacturing process. 
   BRIEF SUMMARY OF INVENTION 
   An inventive valve stem installation system includes a conveyor for moving wheel rims having an aperture defined therein. A detector is cooperable with the conveyor. The detector identifies a general location of the aperture and signals the general location of the aperture to a controller via a first signal. The controller aligns the general location of the aperture with one of the sections, segmented by the controller, thereby identifying a target section. A robotic manipulator is operably connected to the controller. The robotic manipulator is adaptable for selectively engaging and inserting a valve stem and a pressure monitoring device (the TPM) into the aperture. An insertion tool is connected to the robotic manipulator. The insertion tool is adaptable for selectively engaging one of the valve stem and the TPM and interchangeably moving and inserting one of the valve stem and the TPM into the aperture as directed by the controller. 
   A sensor is connected to the robotic manipulator and is adaptable for visually identifying the target section and transmitting the general location of the aperture within the target section via a second signal. The controller integrates the first signal and the second signal through comparative software to generate a target signal. The target signal is transmitted to the robotic manipulator for adjusting movement of the robotic manipulator relative the target section thereby increasing the speed and accuracy of mating one of the TPM and the valve stem into the aperture in response to the target signal. The subject invention includes a method of engaging the valve stem and the TPM with the wheel rim having the aperture formed therein. 
   Accordingly, a valve stem installation system of the present invention is new, efficient, and provides for an effective way for selectively mounting the valve stems of various configurations into the respective wheel rim desirable to develop a new design of the valve stem installation system adaptable for mating of at least two different valve stems into the wheel rim with high degree of accuracy and precision and at a high speed thereby eliminating the need of an extra unit, reduce space in manufacturing environment, and improving cost and efficiency of manufacturing process. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
       FIG. 1  is an elevational view of an inventive valve stem installation system takes from a top; 
       FIG. 2  is a perspective view of a detection device disposed about a conveyor for moving wheel rims; 
       FIG. 3  is top view of a scanned image of the wheel rim divided into sections with an aperture disposed in one of the sections, i.e. target section; 
       FIG. 4  is a side view of a robotic manipulator having a sensor connected thereto and inserting the valve stem into the aperture; 
       FIG. 5  is a cross sectional view of an inserting tool having a first inserting device for engaging and inserting the “snap-in” type valve stem into the wheel rim and a second inserting device having clamping mechanism for engaging and inserting the TPM into the wheel rim; 
       FIG. 6  is a top view of a first alternative embodiment of the valve stem installation system; 
       FIG. 7  is a top view of a second alternative embodiment of the valve stem installation system; and 
       FIG. 8  is a flow diagram of the inventive method. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to  FIGS. 1 and 2 , a valve stem installation system (the system) is generally shown at  10 . The system  10  is adaptable to insert an individual valve stem chosen from among a plurality of differently configured valve stems into an aperture  12  defined in a wheel rim  14 . These valve stems include and are not limited to a standard rubber valve stem  16  (the valve stem) and a tire pressure monitoring device type of a valve stem  18  (the TPM), both known to those skilled in the art. Any of the aforementioned valve stems is inserted in the aperture  12  as the wheel rim  14  is moved along an assembly path, generally indicated by an arrow A. The TPM  18 , for example, includes a pressure sensor for monitoring the pressure in a tire mounted to the wheel rim  14  and transmits a signal corresponding to the sensed pressure. The TPM  18  is affixed to the wheel rim  14  by a nut (not shown) disposed upon an opposite side of the wheel rim  14  from the pressure sensor. The system  10  is adaptable to insert any types of a valve stems other than the TPM  18  and the standard valve stem and any modifications thereof. 
   The system  10  includes a conveyance device, generally indicated at  24 , for moving the wheel rims  14  of different sizes. The conveyance device  24  includes first  26  and second  28  ends and side walls  30 ,  32 . A plurality of modules  36 ,  38 ,  40 ,  42  are aligned with respect to one another along the assembly path A of the conveyance device  24 . The conveyance device  24  is lengthened or shortened by increasing or decreasing, respectively, the number of modules  36 ,  38 ,  40 ,  42 . 
   Alternatively, the conveyance device  24  is formed from a single module, such as an endless conveyor loop (not shown). As best shown in  FIG. 1 , each module  36 ,  38 ,  40 ,  42  includes a plurality of rollers  44  rotatable about the axis. Those skilled in the mechanical art will appreciate that other conveyance devices may be used for moving the wheel rims  14  between the first end  26  and the second end  28 . The rollers  44  support the wheel rims  14  during movement along the assembly path A. Each of the modules  36 ,  38 ,  40 ,  42  also includes a motor  46 , respectively, mechanically engaged with the rollers  44  to rotate the rollers  44  around the axis. The rollers  44  and the respective motors  46  are operably associated with respect to one another by appropriate gearing, sprockets and chains, or pulleys and belts, generally indicated at  48 . Those skilled in the mechanical art will appreciate that other mechanical engagements are used to associate each of the motors  46  with respective rollers  44 . Each of the separate modules  36 ,  38 ,  40 ,  42  is disposed at a separate work station disposed along the conveyance device  24 . The invention includes various associations of the modules  36 ,  38 ,  40 ,  42  in relation to the conveyance device  24 . 
   A controller system, generally shown at  60 , will be discussed in greater detail as the description of the system  10  proceeds. The controller system  60  is operably connected with the conveyance device  24  and an identification station or detector, generally shown at  50  and discussed in great details as the description of the system  10  proceeds. As best shown in  FIG. 2 , the identification station  50  of the present invention includes a frame, generally indicated at  62  extending upwardly from a floor. The frame  62  is further defined by a plurality of vertical posts  64 ,  66  interconnected by vertical beams or beam  68  at the respective tops, as shown in  FIGS. 1 and 2 , respectively. A camera  70  is supported by the vertical beam  68  and is positioned centrally between the vertical posts  64 ,  66  to scan the wheel rim  14  to determine a size, angle, and location of aperture  12  defined within an edge of the wheel rim  14 . The information about the size, angle, and location of the aperture  12  is further transmitted to the controller  60 . The wheel rim  14  is scanned by the camera  70  and the scanned image of the wheel rim  14  is communicated to the controller  60  via a first signal. The first signal includes and is not limited to structural features of the wheel rim  14  including the then-current location of the aperture  12 . The identification station  50  also includes one or more lights  71  and  73  to enhance the quality of the scanned image. 
   The identification station  50  of the exemplary embodiment of the invention also includes a positioning device, generally shown at  80 , disposed below the rollers  44  associated with the module  36 . The positioning device  80  engages the wheel rim  14  at the identification station  50  and raises the wheel rim  14  from the rollers  44 , toward the camera  70 . The positioning device  80  rotates the wheel rim  14  after the location of the aperture  12  has been identified to a preferred position. For example, the positioning device  80  positions the aperture  12  to reduce the complexity of moving operations of a robotic device, generally shown at  90 , disposed at a valve stem inserting station (to be described in greater detail below) downstream of the identification station  50 . 
   Alternatively, the identification station  50  also includes a light curtain, generally shown at  94  including a beam emitting array  96  and a beam receiving array  98 . The beam emitting array includes a plurality of individual beam emitters axially spaced along a first support structure and the beam receiving array includes a plurality of individual beam receivers axially spaced along a second support structure (both not shown). Corresponding emitters and receivers communicate with one another to sense the height of the wheel rim  14  disposed at one of the module  36 . The light curtain  94  enhances the identification of the wheel rim  14  from among a plurality of differently configured wheel rims  14  by cooperating with the positioning device  80 . For example, the positioning device  80  engages a surface of the wheel rim  14  when the positioning device  80  lifts the wheel rim  14  toward the camera  70 . Alternatively, the positioning device  80  includes a sensor (not shown) to sense the amount of extension of the positioning device  80 . Concurrently, the beam emitting array  96  and the beam receiving array  98  communicate with one another to sense a top surface and a bottom surface of the wheel rim  14 . 
   Alluding to the above, the controller system  60  is adapted to receive signals from the sensor associated with the positioning device  80  and with the light curtain  94  and sense when the wheel rim  14  is moved by the positioning device  80 . Specifically, the controller system  60  identifies the amount of extension of the positioning device  80  that corresponds to movement of the wheel rim  14 , movement of the wheel rim  14  sensed by the light curtain  92 . This axial distance may further enhance the identification of the wheel rim  14  from the plurality of differently configured wheel rims  14 . 
   Preferably, the controller system  60  includes a controller device, i.e. computer, operably and electronically communicated with the identification station  50  and the robotic device  90 . The computer has an input/output interface, a central processor unit, a random access memory, i.e. RAM, and a read only memory, i.e. ROM. The input interface is electrically connected with the robotic device  90  and the identification station  50 . The controller is pre-programmed with the various tire wheel rim  14  size and types of the valve stem  16  or the TPM  18  to be engaged in the aperture  12 . The ROM stores a program, i.e. comparative software that determines proper mating order and mating engagement between the particular wheel rim  14  and the valve stem  16  or the TPM  18 . The comparative software integrated the first signal and a second signal (to be discussed as the description of the present invention proceeds) to generate a target signal. 
   The controller engages the motor  46  to rotate the rollers  44  associated with the modules  36 ,  38 ,  40 ,  42  and concurrently disengage the motor  56 . The controller system  60  compares the image received from the camera  70  with a plurality of images stored in memory and identifies the particular configuration of the wheel rim  14 . The scanned images stored in the memory of the controller correspond to all of the differently configured wheel rims  14  that pass through the identification station  50 . Each of the images stored in memory is associated with structural characteristics and physical dimensions of a corresponding wheel rim  14  including the orientation of the aperture  12 . 
   As will be set forth more fully below, the controller system  60  controls processing steps performed downstream of the identification station  50  based, at least in part, on the physical dimensions of the wheel rim  14  identified from the scanned image received from the camera  70  via the aforementioned first signal. As best shown in  FIG. 3 , the controller system  60  divides the scanned image into a plurality of sections S 1  through S 11  and locates the aperture  12  with respect to the particular section S 1  through S 11  that defines the aperture  12 . For example, the aperture  12  is defined by the section S 11 , wherein the section S 11  is identified as a target section. Preferably, the controller system  60  divides or segments the wheel rim  14  with as many boundary lines as possible to define as many sections as possible. The greater the number of sections, the more accurate the initial locating of the aperture  12  will be. The controller system  60  moves pairs of the wheel rims  14  concurrently along the assembly path A between the identification station  50  and the valve stem insertion station defined by the robotic device. For example, a first wheel rim  14  is moved to the module  36  from the identification station  50  and maintained at the module  36  until a second wheel rim  14  is received by the identification station  50  and the aperture  12  defined by the second wheel rim  14  has been identified with respect to location and orientation. 
   After the wheel rim  14  at the identification station  50  has been processed, both of the wheel rims  14  individually disposed at the module  36  and at the module  38  are moved concurrently along the assembly path A. The wheel rim  14  formerly at the module  36  is moved to the module  38  and the wheel rim  14  formerly at the identification station  50  is moved to the module  36 . 
   Referring again to  FIG. 1 , two stem feeders, generally indicated at  100  and  102 , respectively, are included to deliver different sizes and shapes of the valve stems  16  and the TPM  18 . The stem feeders  100  and  102  are positioned adjacent the conveyance device  24 . Each stem feeder  100  and  102  stores one of the TPM  18  or the regular rubber valve stem  16 . Each stem feeder  100  and  102  includes a hopper  104  that receives the valve stems  16  or the TPM  18 . A bowl  106  receives the valve stem  16  or the TPM  18  from the hopper  104 . The bowl  106  is rotated about its axis thereby by creating a centrifugal force that aligns and orients each of the valve stems  16  or the TPM  18  in to a single track escapement. The valve stems  16  or the TPM  18  are delivered by the centrifugal force into a stem pick-up port to be accessible by the robotic device  90 . The bowl  106  stops rotating automatically when the stem pick-up port is full with the valve stems  16  or the TPM  18 , and is turned on automatically, when the valve stems  16  or the TPM  18  in the stem pick-up port are required thereby preventing unnecessary damage to the valve stems  16  or the TPM  18  and loose valve stems  16  or the TPM  18 . At least one nut feeder  108  is positioned adjacent one of the stem feeder  100  or  102  that contains the TPM  18 . 
   As best shown in  FIG. 4 , the robotic device  90  includes at least two robots  110  and  112  adjacent one another and adaptable for multi-axial movement relative to the wheel rim  14  and the conveyance device  24 . Each of the robots  110  or  112  is controlled by the controller system  60  to insert valve stems  16  or the TPM  18  in the wheel rims  14  disposed at the modules  36 ,  38 ,  40 ,  42 , respectively. The robots  110  and  112  are structured similarly and function similarly with respect to one and the other. The robot  110  includes an insertion tool, generally shown at  114  in  FIG. 4 , and a robot arm  116  pivotably engaged within a base support portion  118  defining an elbow joint therebetween. The robot arm  116  moves the insertion tool  114  into position to insert any of the valve stems  16  or the TPM  18  in the aperture  12  defined by the wheel rim  14 . 
   Referring to  FIG. 5 , the insertion tool  114  includes first and second insertion devices, generally shown at  120  and  122 , respectively. The first  120  and second  122  insertion devices are configured to insert a differently configured valve stem, such as the valve stem  16  and the TPM  18 . Preferably, the first insertion device  120  supports the standard valve stems  16  for insertion in the aperture  12  and the second insertion device  122  supports the TPM  18  for insertion in the aperture  12 . The first and second insertion devices  120  and  122  and its functional and mechanical aspects are fully described in the patent application Ser. No. 11/095,153 assigned to the assignee of the present invention and is incorporated herewith by reference in its entirety. 
   As best shown in  FIGS. 4 and 5 , a sensor  124  is operably connected to the insertion tool  114 . Depending on modification of the insertion tool  114 , the sensor  124  is attached to the insertion tool  114  adaptable for engaging and inserting single type of the valve stem, as illustrated in  FIG. 4  or several types of the valve stem, as shown in  FIG. 5 . The sensor  124  includes an optical sensor and the like, adaptable to scan an image of the wheel  14  at the target section S 11  to determine precise location of the aperture  12  within the target section S 11  thereby creating the second signal and transmitting the second signal to the controller  60  as the insertion tool  114  moves to the wheel  14  at the target section S 11 . The controller  60  adjusts movement of the insertion tool  114  to the wheel  14  in response to the target signal transmitted by the controller to the robot  110  or  112  as the comparative software of the controller integrates the first and second signals to create the aforementioned target signal. The sensor  124  supplements the camera  70  to enhance the speed and efficiency of the valve stem insertion process. 
   Alluding to the above, the inventive system  10  may include several alternative embodiments adaptable to be used at various manufacturing environments. As shown in  FIG. 6 , a first alternative embodiment of the system  10  is generally shown at  200 . The wheel  14  is first moved to the locating station  202  and a scanned image of the wheel  14  is taken by a camera  204 . The scanned image of the wheel  14  is communicated  206  to a controller  212  that divides the scanned image into a plurality of sections. The valve stem aperture  12  is located with respect to one of the sections. The wheel  14  is then moved to a stemming station, generally shown at  214  for insertion of a valve stem in the valve stem aperture  12 . The valve stem is inserted with a robotic device, i.e. robot generally shown at  216 . The robot  216  is operably communicated  218  with the controller  212  and moves an insertion tool  220  connected to the section that defines the valve stem aperture  12 . As a result, the robot  216  is not required to move the insertion tool  220  around the periphery of the wheel  14  to locate the valve stem aperture  12 . 
   Referring now to  FIG. 7 , a second alternative embodiment of the system  10  is generally shown at  300 . The system  300  includes a stemming station generally shown at  302  having includes a single robotic device or robot  304  and a plurality of valve stem sorters  306  and  308 . Each of the valve stem sorters  306  and  308  sort and position differently configured valve stems. The robot  304  can move to one of the valve stem sorters  306  and  308  to retrieve the valve stem for insertion in the valve stem aperture  12  defined in the wheel  14 . 
   While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.