Patent Publication Number: US-10322444-B2

Title: Apparatus, system, and method for manipulation of nested stamped parts

Description:
BACKGROUND 
     The present disclosure relates generally to devices and methods for stamping multiple parts from a single metal blank and, more specifically, for rotating at least one part relative to at least one of multiple nested parts stamped from a single metal blank as part of a manufacturing process. 
     To enhance the efficiency of energy and material utilization associated with part production, some sheet metal stamping processes may produce two or more different parts using a single press stroke. The resulting parts produced may be nested together within a single sheet of sheet metal feedstock upon completion of the single press stroke. Although these multi-part sheet metal stamping processes may enhance process efficiency, the post-stamping processes associated with each individual nested part may differ from one another. However, at least some known multi-part metal stamping processes do not provide for individualized post-stamping processes for each of the multiple nested parts, such as rotating one nested part differently relative to the other parts. As a result, damage-prone regions of one or more of the multiple nested parts, such as projecting legs or tabs, may be vulnerable to damage during post-stamping processes such as conveyor transport or sorting. 
     BRIEF SUMMARY 
     In one aspect, an apparatus for rotating an inner stamped part with respect to an outer stamped part is provided, in which the inner stamped part is nested within an aperture formed within the outer stamped part. The apparatus includes a plurality of grippers that includes at least a first gripper positioned at a first edge of the inner stamped part and a second gripper positioned at a second edge of the inner stamped part opposite to the first edge. The plurality of grippers is configured to grip the inner stamped part at the first edge and the second edge, respectively. The plurality of grippers is further configured to rotate the gripped inner stamped part about an axis of rotation. The axis of rotation intersects the first gripper and the second gripper. The plurality of grippers is also configured to open to release the inner stamped part. 
     In another aspect, a system for rotating an inner stamped part with respect to an outer stamped part is provided, in which the inner stamped part is nested within an aperture formed within the outer stamped part. The system includes a plurality of grippers. The plurality of grippers includes at least a first gripper positioned at a first edge of the inner stamped part, and a second gripper positioned at a second edge of the inner stamped part opposite to the first edge. The system further includes a base affixed to the plurality of grippers and further affixed to a station of a press line. 
     In another additional aspect, a method for rotating an inner stamped part with respect to an outer stamped part is provided in which the inner stamped part is nested within an aperture formed within the outer stamped part. The method includes receiving the inner stamped part onto a lifter in a raised position, at least a first gripper in an opened position, and a second gripper in the opened position. The method also includes closing the first and second grippers to grip the inner stamped part, lowering the lifter away from the gripped inner stamped part, and rotating the inner stamped part about an axis of rotation intersecting the first gripper and the second gripper. The method further includes raising the lifter up to the rotated inner stamped part and opening the first and second grippers to release the rotated inner stamped part. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top view of an exemplary inner stamped part nested within an outer stamped part. 
         FIG. 2  is a schematic illustration showing potential exemplary post-production related damage risks to inner stamped parts. 
         FIG. 3  is a schematic illustration of an exemplary apparatus for the selective rotation of an inner stamped part. 
         FIG. 4  is a perspective view of an exemplary apparatus for use in rotating an inner stamped part relative to an outer stamped part. 
         FIG. 5A  is an exemplary gripper in a closed position. 
         FIG. 5B  is the gripper shown in  FIG. 5A , and in an opened position. 
         FIG. 6A  is a perspective view of an apparatus for use in rotating an inner stamped part relative to an outer stamped part in which the inner stamped part is supported by a lifter and the gripper jaws are opened to receive the inner stamped part. 
         FIG. 6B  is a perspective view of the apparatus illustrated in  FIG. 6A  in which the gripper jaws have been closed to grip the inner stamped part. 
         FIG. 6C  is a perspective view of the apparatus illustrated in  FIG. 6B  in which the lifter has been lowered. 
         FIG. 6D  is a perspective view of the apparatus illustrated in  FIG. 6C  in which the inner stamped part is partially rotated. 
         FIG. 6E  is a perspective view of the apparatus illustrated in  FIG. 6D  in which the inner stamped part is fully rotated. 
         FIG. 6F  is a perspective view of the apparatus illustrated in  FIG. 6E  in which a second lifter is raised to support the inner stamped part. 
         FIG. 6G  is a perspective view of the apparatus illustrated in  FIG. 6F  in which the gripper jaws are opened to release the inner stamped part. 
         FIG. 6H  is a perspective view of the apparatus illustrated in  FIG. 6G  in which the gripper jaws are rotating to the initial rotation illustrated in  FIG. 6A . 
         FIG. 6I  is a perspective view of the apparatus illustrated in  FIG. 6H  in which the gripper jaws have rotated back to the initial rotation illustrated in  FIG. 6A . 
         FIG. 7  is a perspective view of an exemplary base. 
         FIG. 8  is a perspective view of the base illustrated in  FIG. 7  installed within an exemplary station of a press line. 
         FIG. 9  is a perspective view of an inner stamped part nested within an aperture formed within an outer stamped part mounted on an exemplary apparatus. 
         FIG. 10  is a top view of an inner stamped part showing two exemplary axes of rotation. 
         FIG. 11  is a schematic illustration of a first phase of performing an exemplary method of rotating an inner stamped part relative to an outer stamped part. 
         FIG. 12  is a schematic illustration of a second phase of performing the method illustrated in  FIG. 11 . 
         FIG. 13  is a schematic illustration of the third phase of performing the method illustrated in  FIG. 11 . 
     
    
    
     DETAILED DESCRIPTION 
     The apparatus, systems and methods described herein relate generally to the manufacturing processes of stamped metal parts, and more specifically, to production and post-production handling of stamped metal parts fabricated using a part-in-part (PIP) manufacturing process, in which one or more inner stamped parts nested within an aperture formed within an outer stamped part are formed using a single press stroke. In various aspects, the PIP process may enhance the efficiency of utilizing materials, such as metal stock, by producing one or more additional parts from material that would typically be discarded or reused after completion of the pressing of a single part. Further, because two or more parts are formed in a single press stroke, the PIP manufacturing process may further enhance energy efficiency and production time relative to other manufacturing processes that may use separate press strokes, separate dies, and/or separate presses to produce individual presses parts. 
       FIG. 1  is a top view showing an inner stamped part  102  nested within an aperture  106  formed within an outer stamped part. In various aspects, PIP production method produces at least one inner stamped part  102  positioned within the aperture  106  by providing additional die features to form the metal stock positioned within the aperture  106 . Typically, in known processes, said metal stock may be trimmed and removed using non-PIP production methods, into one or more additional inner stamped parts  102 . However, additional post-production processes may be needed to manipulate one or more of the multiple nested parts. 
     A PIP manufacturing process including, but not limited to the inner stamped parts  102  and outer stamped parts  104  may produce an inner stamped part  102  that may include tabs, legs, or other deformable projections in which the deformable projections may be positioned in an orientation that may result in an increased risk of damage to the deformable projections during post-production processes.  FIG. 2  is a schematic side view of inner part  102  with deformable legs  108  progressing through post-production handling processes. As illustrated in  FIG. 2 , if legs  108  are oriented downward, the legs  108  may be vulnerable to damage after an impact  204  of the dropped part  102  on a conveyer  202 . In addition, the legs  108  may get caught within irregularities in the surface of the conveyor  202  such as gaps  206 , further exposing the legs  108  to possible damage. 
       FIG. 3  is a schematic overview of an apparatus  300  for the rotation  302  of an inner stamped part  102  in a PIP manufacturing process. As illustrated in  FIG. 3 , the inner stamped part  102  may be selectively inverted relative to the outer stamped part  104  (not shown) prior to post-production processes, such as transport on a conveyer belt  202 . By inverting the inner stamped part  102 , the legs  108  of the part  102  may project upward and away from potentially damaging equipment features such as gaps  206  within the conveyor belt  202 . 
     In various aspects, the rotation of the inner stamped part  102  relative to the outer stamped part  104  may be enabled by an apparatus  300 , shown illustrated in  FIG. 4 . Although the description of the apparatus  300 , system, and method of rotating the inner stamped part  102  disclosed herein below is presented in the context of a single rotation or flip of the inner stamped part  102 , it is to be understood that the apparatus  300  may enable any combination of translations and/or rotations without limitation. In particular, the apparatus  300  may enable any amount of rotation as needed to enhance an aspect of the post-production handling including, but not limited to, dropping or otherwise transferring the inner stamped part  102  from the apparatus  300  to a conveyor belt or other part sorting or transport device. In one non-limiting example, the inner stamped part  102  may be rotated about 180° (i.e. flip the inner stamped part) relative to the outer stamped part  104 . 
     In another aspect, the inner stamped part  102  may be rotated about any axis of rotation without limitation using the apparatus  300 . In one aspect, the inner stamped part  102  may be rotated about an axis of rotation  404  that is parallel with one of the coordinate axes of the coordinate system  402  as defined in  FIG. 4  including, but not limited to an x-axis defined parallel to the direction of movement of the pressed parts from station to station within the press line used to produce the inner pressed part  102  and outer pressed part  104 , a y-axis defined perpendicular to the direction of movement of the pressed parts as well as within a horizontal plane parallel to the plane of the sheet metal feedstock within the press line prior to exposure to any of the press cycles, and a z-axis defined in an upward direction that is also mutually perpendicular to the x-axis and the y-axis. By way of non-limiting example, the axis of rotation  402  may be oriented parallel to the y-axis of coordinate system  402 , as illustrated in  FIG. 4 . In other aspects, the axis of rotation  404  may be oriented at any arbitrary direction within the coordinate system  402  as defined in  FIG. 4 . 
     In an additional aspect, the inner stamped part  102  may be rotated two or more times about two or more different axes of rotation  404  without limitation. In one aspect, each rotation of the two or more rotations of the inner stamped part  102  may be enabled by a single pair of grippers similar to the pair of grippers  301  illustrated in  FIG. 4 . By way of non-limiting example (not illustrated) the support platform on which a single pair of grippers is mounted may itself be mounted to a turntable or other means of enabling a rotation of the inner stamped part  102  about a second axis of rotation. In another aspect, the two or more rotations of the inner stamped part  102  may be enabled by a first pair of grippers corresponding to the rotation about a first axis of rotation, a second pair of grippers corresponding to the rotation about a second axis of rotation, and so on. By way of non-limiting example (not illustrated) the apparatus  300  may incorporate an additional pair of grippers (not shown) aligned with a second axis of rotation in addition to the first pair of grippers  301  aligned with the first axis of rotation  404  as illustrated in  FIG. 4 . In this other aspect, each rotation of the inner stamped part  102  may be enabled sequentially by successive pairs of grippers that each grip the inner stamped part  102  one at a time in series. 
     Referring again to  FIG. 4 , the apparatus  300  may include at least one pair of grippers  301  configured to enable several aspects of the method of rotating the inner stamped part relative to the outer stamped part as disclosed herein. In one aspect, the pair of grippers  301  may be configured to receive an inner stamped part  102  from a preceding station of a press line used to produce the nested inner and outer stamped parts produced using a PIP manufacturing process. In another aspect, the pair of grippers  301  may be configured to grasp and rotate the inner stamped part  102  about an axis of rotation  404 . In another additional aspect, the pair of grippers  301  may be configured to release the rotated inner stamped part  102  prior to transfer to a subsequent station of a press line. 
     Referring again to  FIG. 4 , the pair of grippers  301  may include a first gripper  302  and a second gripper  304  aligned along the axis of rotation  404  as illustrated in  FIG. 4 . In various aspects, any gripper device suitable for use in systems and methods of automated manufacturing of pressed metal parts may be incorporated into the apparatus  300  without limitation.  FIG. 5A  and  FIG. 5B  are perspective views of a gripper  500  in one aspect in a closed configuration (see  FIG. 5A ) and an opened configuration (see  FIG. 5B ). Referring again to  FIG. 5A  and  FIG. 5B , each gripper  500  includes a first articulated appendage  502  and second articulated appendage  504  attached to a rotatable cylinder  506  using a first hinge joint  508  and a second hinge joint  510 , respectively. 
     In various aspects, the gripper  500  may be operatively coupled to one or more actuators (not shown) to enable the movements of the first articulated appendage  502  and the second articulated appendage  504  between the opened and closed configurations. Any actuators suitable for generating the opening and closing forces used to open and close the gripper&#39;s articulated appendages  502 / 504  include, but are not limited to: pneumatic actuators, hydraulic actuators, and/or electromechanical actuators such as screwjacks. 
     In the closed position as illustrated in  FIG. 5A , the gripper  500  may grasp or clamp an edge  512  of a sheet metal feedstock  514  between the first and second articulated appendages  502 / 504 . In these various aspects, the first articulated appendage  502  and the second articulated appendage  504  may include first contact surface  516  and second contact surface  518 , respectively. In one aspect, the first and second contact surfaces  516 / 518  may be coated with a compliant material including, but not limited to, a polymer such as nylon to inhibit slipping of the inner stamped part  102  when the gripper  500  is in a closed position, in particular while rotating the inner stamped part  102 . In another aspect, the first and second contact surfaces  516 / 518  may be coated with a hard and/or wear-resistant material including, but not limited to, Kevlar, metal oxides, and/or metal carbides. In one aspect, the first and second contact surfaces  516 / 518  may be coated with Kevlar-impregnated nylon material to enhance the wear-resistance of the first and second contact surfaces  516 / 518 . 
     In another additional aspect, illustrated in  FIG. 5B , the first and second contact surfaces  516 / 518  may include interlocking surface features to inhibit slippage of the inner stamped part  102  within the gripper  500  during use. Any known interlocking surface features may be incorporated into the first and second contact surfaces  516 / 518  including, but not limited to: interlocking ridges and furrows, interlocking bumps and depressions, and any other known interlocking surface features. In one aspect, the first contact surface  516  may include a raised ridge  520  dimensioned to interlock within a corresponding furrow  522  formed within the second contact surface  518 . 
     Referring again to  FIG. 5A  and  FIG. 5B , the first articulated appendage  502  and the second articulated appendage  504  of the gripper  500  are operatively coupled to a rotatable cylinder  506  to form the first hinge joint  508  and the second hinge joint  510 . In various aspects, the rotatable cylinder  506  is operatively coupled to an actuator (not illustrated) configured to rotate the gripper  500 . In one aspect, the actuator rotates the inner part  102  as illustrated in  FIG. 3  via the pair of grippers  301 . In another aspect (not illustrated) the actuator may rotate the pair of grippers  101  after the inner stamped part  102  has been transferred to a subsequent station of the press line in order to reposition the pair of grippers  101  back to an initial position suitable for receiving the next inner stamped part  102  from the preceding station of the press line. 
     In various aspects, any one or more actuators suitable for generating the torque used to rotate each gripper  500  may be incorporated into the apparatus  300  including, but not limited to: pneumatic actuators, hydraulic actuators, and/or electromechanical actuators. In one aspect, each gripper  500  may be operatively coupled to a separate dedicated actuator, and the actuators associated with a pair of grippers  101  (see  FIG. 4 ) are operated in a coordinated manner to rotate the inner stamped part  102 . In another aspect, the first gripper  302  and second gripper  304  may be operatively coupled to a shared actuator to enable the coordinated movements of the pair of grippers  301 . 
     By way of non-limiting example, the first gripper  302  and second gripper  304  may both be operatively coupled to a shared actuator  318 , such as a rack and pinion rotary actuator  318 , as illustrated in  FIG. 4 . Referring again to  FIG. 4 , the actuator  318  may be operatively coupled to a driveshaft  332 . Each end of the driveshaft is retained in place by a first bearing  314  and a second bearing  316 . One end of the driveshaft  332  is operatively coupled to the first gripper  302  via a first belt  328  and first series of pulleys  324 . The opposite end of the driveshaft  332  is operatively coupled to the second gripper  304  via a second belt  330  and second series of pulleys  326 . 
     In various aspects, the apparatus  300  is configured to rotate the inner stamped part  102  with respect to the outer stamped part  104  within any automated stamped metal production systems and devices without limitation. In one aspect, the apparatus may be positioned within a station of a press line of a stamped part manufacturing system. Non-limiting examples of stamped part manufacturing system suitable for use with the apparatus  300  include: tandem press systems, transfer press systems, and any other suitable stamped part manufacturing system known in the art. 
     In various aspects, the apparatus  300  may further include at least one lifter configured to support the inner stamped part  102  as it is received from a preceding station in the press line, and as the rotated inner stamped part  102  is transferred to a subsequent station in the press line. The number of lifters included in the apparatus  300  may depend on any one or more of at least several factors including, but not limited to, the axis of rotation of the inner stamped part  102  as it is rotated by the apparatus  300 . As illustrated in  FIG. 10 , if the selected axis of rotation  1002  passes through the center of gravity  1004  of the inner stamped part  102 , the position of the center of gravity  1004  relative to the apparatus  300  does not vary before and after rotation of the inner stamped part  102 . In this aspect, a single lifter may be used to support the inner stamped part  102  before and after rotation without risk of the inner stamped part  102  falling off of the single lifter. 
     In another aspect, also illustrated in  FIG. 10 , if the selected axis of rotation  1006  passes through the dimensional center  1008  of the inner stamped part  102 , the position of the dimensional center  1008  relative to the apparatus  300  may be offset relative to the apparatus  300  if the dimensional center  1008  is offset from the center of gravity  1004  of the inner stamped part  102 . In this aspect, a single lifter may be not be sufficient to support the inner stamped part  102  before and after rotation without risk of the inner stamped part  102  falling off of a single lifter due to the shift of the center of gravity  1004  due to rotation by the apparatus  300 . In this other aspect, the apparatus may include a first lifter  306  and a second lifter  308  to support the inner stamped part  102  before and after rotation by the apparatus  300 , respectively, as illustrated in  FIG. 4 . 
     Referring again to  FIG. 4 , the first lifter  306  and the second lifter  308  may be operatively coupled to a first piston  310  and a second piston  312 , respectively, to raise and lower to support the inner stamped part  102  as needed during as the apparatus  300  is performing the method of rotating the inner stamped part  102  as described herein below. The first and second pistons  310 / 312  may each be coupled to a precision linear actuator configured to provide the necessary forces to move the lifters  306 / 308  between the raised and lowered positions. In various aspects, the apparatus  300  may further include a first piston guide  320  and a second piston guide  322  to define the respective paths travelled by the first and second lifters  306 / 308  between their respective raised and lowered positions. 
     In one aspect, the apparatus  300  may further include a base configured to be affixed to a station of a press line, and further configured to be affixed to the apparatus.  FIG. 7  is a perspective view of a base  700  in one aspect. As illustrated in  FIG. 7 , the base  700  may be a slab-like structure with an apparatus contact face  702  that is configured to be affixed to the apparatus  300  (not shown). In an aspect, the apparatus contact face  702  may be provided with a plurality of fastener fittings  708  configured to receive a plurality of corresponding fasteners to affix the apparatus  300  to the base  700 . In another aspect, the base may further include a press contact face  704  situated opposite to the apparatus contact face  702 . In this other aspect, the press contact face  704  may include a plurality of fastener fittings  706  configured to receive a plurality of corresponding fasteners to affix the base  700  to a station of a press line (not shown). 
       FIG. 8  is a perspective view of the base  700  affixed to a station  802  of a press line  800 . Referring to  FIG. 8 , fasteners are inserted through each fastener fitting  706  to affix the base  700  to the press line  800 . Fasteners are also inserted into each fastener fitting  708  to affix the apparatus  300  to the base  700 . In this perspective, the apparatus  300  and press line  800  together form a system for rotating the inner stamped part  102  relative to the outer stamped part  104 . 
     In various aspects, the press contact face  704  may be customized to render the base  700  compatible with a particular press line. In these various aspects, a single design of an apparatus  300  may be rendered compatible with a wide variety of press lines by providing a variety of bases  700  with identical apparatus contact faces  702 , in which each press contact face  704  of each base  700  corresponds to a different press line. 
     In various aspects, the apparatus  300  may be used to perform a method of rotating the inner stamped part relative to the outer stamped part within a press line used to produce the stamped parts  102 / 104 .  FIGS. 6A-6I  illustrated the arrangement of the apparatus and inner stamped part at various steps of the method. Referring to  FIG. 6A , the gripper jaws are configured to an open position and the first lifter is configured to a raised position to receive and support the inner stamped from a previous station from the press line. As illustrated in  FIG. 6B , the gripper jaws are then configured to a closed position to grip the inner stamped part. The first lifter is then lowered to provide a clear path within which the inner stamped part may be rotated. The pair of grippers of the apparatus is then rotated, causing the corresponding rotation of the inner stamped part, as illustrated in  FIG. 6D . Upon completion of the rotation of the inner stamped part (see  FIG. 6E ), the second lifter is configured in a raised position to support the inner stamped part when the jaws of the grippers are opened, as illustrated in  FIG. 6G . Once the gripper jaws are opened, the rotated inner stamped party may then be removed and/or transferred to a subsequent station of the press line. Referring to  FIG. 6H , the opened gripped jaws may then be rotated back to their initial starting position, shown illustrated in  FIG. 6I . The second lifter may then be lowered and the first lifter raised to prepare the apparatus for receiving another inner stamped part from the previous station of the press line. 
     In various aspects, in order to enhance the compatibility of the apparatus with the press line, the elapsed time taken to rotate the inner stamped part may be configured to fit within a characteristic cycle time of the press line. In various aspects, this cycle time typically varies from about 2 seconds to about 10 seconds. By way of non-limiting example, the apparatus may perform all steps of the method of rotating the inner stamped part within 3-second cycle time representative of a cycle time of a press line. As illustrated in  FIGS. 11-13 , the inner stamped part may be received and gripped in the first second (see  FIG. 11 ), rotated in the next second (see  FIG. 12 ), and released to the next station of the press line in the third second. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.