Source: https://patents.google.com/patent/US4777783A/en
Timestamp: 2019-08-22 10:05:45
Document Index: 63939452

Matched Legal Cases: ['arts 30', 'arts 30', 'art 30', 'art 30', 'arts 30', 'arts 30', 'art 30', 'art 30', 'art 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 30', 'arts 60', 'art.\n14', 'arts\n1986']

US4777783A - Method for automated accumulation and loading of parts such as automotive parts and system utilizing same - Google Patents
Method for automated accumulation and loading of parts such as automotive parts and system utilizing same Download PDF
US4777783A
US4777783A US06/878,597 US87859786A US4777783A US 4777783 A US4777783 A US 4777783A US 87859786 A US87859786 A US 87859786A US 4777783 A US4777783 A US 4777783A
US06/878,597
GMF ROBOTICS Corp TROY MICHIGAN A CORP OF DE
1986-06-26 Application filed by FANUC Robotics North America Inc filed Critical FANUC Robotics North America Inc
1986-06-26 Priority to US06/878,597 priority Critical patent/US4777783A/en
1986-06-26 Assigned to GMF ROBOTICS CORPORATION, TROY, MICHIGAN A CORP. OF DE. reassignment GMF ROBOTICS CORPORATION, TROY, MICHIGAN A CORP. OF DE. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: ZALD, ROBERTA L.
1988-10-18 Publication of US4777783A publication Critical patent/US4777783A/en
A method and system are disclosed for the automated accumulation and loading of parts wherein an automated part transfer apparatus is utilized to successively pick up predetermined arrangements of spaced parts from a shuttle at a pair of unloading stations. The part transfer apparatus preferably includes a gantry robot which places the parts in predetermined positions in a container located in the work envelope of the robot. The robot continues to load the parts until the container is full. In the disclosed embodiment, the method and system are utilized for racking automotive parts after they exit a sheet metal processing machine. Preferably, the parts are vertically accumulated in spaced relationship at an accumulator station in which the shuttle aids in the stacking process. A part indexing mechanism also aids in the stacking process at the accumulator station. After the stack of spaced parts is full, the shuttle moves so that a first end of the shuttle containing the spaced parts is located at one of the unloading stations and the opposite, second end of the shuttle moves into the accumulator station. The accumulation process then continues at the second end of the shuttle while the robot is unloading the parts at the first end of the shuttle.
This invention relates to method and apparatus for automated accumulation and loading of parts, such as automotive parts, and, in particular, to method and apparatus for automated accumulation and loading of such parts into a container adapted to receive and retain such parts.
Robots are often an essential ingredient in the implementation of Flexible Manufacturing Systems (FMS) and the automated factory. The automated factory also will include a variety of material transportation devices, ranging from driver-operated forklifts to sophisticated, computer-operated, real-time reporting with car-on-track systems and color graphics tracking. These material transport systems serve to integrate workcells into FMS installations and to tie such installations and other workcells together for total factory material transport control.
The alternative gantry style is the cantilever type. The basic advantages of this type of robot include: (1) modularity of the X axis, allowing for very long travel; (2) the ability to apply a rotary wrist, making both sides of the gantry available as separate work spaces; (3) a programmable structure overhead, allowing clearance to load and unload parts from above using a crane or forklift, for example; (4) open accessibility from all directions, allowing conveyors, pallets, or part feeding from any direction; (5) design rigidity, permitting extreme accuracy and reliability for light machining tasks or routing applications; and (6) cartesian coordinates and rigid design combination, providing for application of a CNC-type controller with the inherent accuracy to permit off-line programming.
An object of the present invention is to provide an improved method and apparatus for the automated accumulation and loading of parts, such as automotive parts, in an environment which results in the production of high quality products.
Another object of the present invention is to provide an improved method and system for the automated accumulation and loading of parts, such as automotive parts, wherein the parts flow in a planned and orderly fashion while, at the same time, reducing the probability of part damage.
Yet still another object of the present invention is to provide an improved method and system for automated accumulation and loading of parts, such as automotive parts, wherein factory floor space can be utilized effectively while at the same time integrating with preexisting "islands of automation".
In carrying out the above objects and other objects of the present invention, a method is provided for the automated loading of parts into a container adapted to receive and retain the parts therein, the container being located in the work envelope of an automatic part transfer apparatus. A predetermined number of parts are first accumulated in a predetermined spaced arrangement at an accumulator station. All of the accumulated parts are then shuttled from the accumulator station to one of a pair of unloading stations in the work envelope. The apparatus is controlled so that the apparatus picks up the parts from the one unloading station and places the parts in predetermined positions in the container. The predetermined spaced arrangement of parts is maintained during the steps of shuttling and controlling. The above steps are repeated until the container is substantially full.
Further in carrying out the above objects and other objects of the present invention, a system for loading parts into the container is provided. The system comprises an automated part transfer apparatus adapted to receive and retain at least two of the parts in a predetermined spaced arrangement and capable of working within a work envelope. The system further comprises accumulating means for accumulating the parts in the predetermined spaced arrangement at an accumulator station. The accumulating means includes shuttle means for receiving and retaining the parts in the predetermined spaced arrangement. A shuttle drive means is provided for driving the shuttle means so that the shuttle means moves the parts from the accumulator station to one of a pair of unloading stations in the work envelope. A controller controls the part transfer apparatus so that the apparatus picks up the parts from the unloading station and places the parts in predetermined positions in the container, the container being positioned within the work envelope.
Preferably the part transfer apparatus includes a robot which successively picks up the parts from the unloading stations and places the parts into the container without disturbing the predetermined spaced arrangement.
Also, preferably, the parts may be successively accumulated in stacks at opposite ends of the shuttle means to minimize the time required to fully load the container with parts. In this way, while some parts are accumulated at the accumulator station, other parts are being loaded into the container.
In the preferred embodiment, the robot comprises a gantry robot having a specially designed end effector connected to the distal end of its robot arm.
The advantages accruing to the use of such a method and system are numerous. For example, parts can be quickly moved and loaded into a part container without having to store the parts. In this way inventory levels can be kept small. Also, the frequency of part movement is minimized and the parts are kept apart during the process thereby rendering it less likely that the parts to be loaded will be damaged.
FIG. 1 is a top plan, partially schematic view, partially broken away, illustrating the method and system in accordance with the present invention for the automated accumulation and loading of parts, such as automotive parts, which are illustrated in phantom;
FIG. 2 is a side elevational, partially schematic view, partially broken away, of the system including a robot illustrated in two operative positions in phantom;
FIG. 3 is a side elevational detailed view, partially broken away, of a part lift mechanism of the system with a part to be lifted indicated in phantom;
FIG. 4 is a side elevational view, partially broken away, of a part load mechanism of the system;
FIG. 5 is a top plan view, partially broken away, of the part load mechanism of FIG. 4;
FIG. 6 is a sectional view of a drive for the part load mechanism taken along lines 6--6 of FIG. 5;
FIG. 7 is a side elevational view of a shuttle mechanism of the system;
FIG. 8 is a top plan view of the shuttle mechanism; and
FIG. 9 is a side elevational view, partially broken away, of a portion of the system illustrating the different loading movements of a gantry robot of the system.
Referring to the drawings, there is illustrated in FIGS. 1 and 2, a method and system for automated accumulation and loading of material, such as automotive parts, in containers 10. Such parts may include sheet metal parts such as roof panels, outer lids, panel compartments, outer lift windows, hatchbacks and the like which have been stamped by a sheet metal press or stamping machine. The method and system have particular utility in racking such automotive parts in specially designed baskets or the containers 10.
The containers 10 are indexed to a part loading station 12. Many different methods and apparatus can be utilized to move or index the containers 10 to the part loading station 12, such as by conveyor or monorail, or even manually, without departing from the spirit of the present invention.
As best shown in FIG. 2, a conveyor, generally indicated at 14, receives and retains the containers 10 as they move thereon by means of locating on support rollers 16 which are rotatably supported between pairs of upwardly extending supports 18. The rollers 16 are provided to permit conveyance of the containers 10 within the part loading station 12. The rollers 16 are driven by drive motors (not shown) to move the containers 10. The containers 10 may be located by locating pins (not shown) or any other locating device at any of the particular locations within the part loading station 12, so that the containers 10 do not strike one another.
At the station 12, the containers 10 are located within the work envelope of a gantry robot, generally indicated at 20. The gantry robot 20 is supported by a superstructure, the vertical beams of which are indicated at 22 in FIG. 1. The gantry robot 20 includes a carriage (not shown) which is slidably mounted within its runway defined by horizontal beams (also not shown). The gantry robot 20 also includes a telescoping tube or mast 24 which comprise the vertical or Z axis of the robot 20. An end effector, generally indicated at 43 in FIG. 9, includes a gripper 44 mounted on a wrist 45' of the robot 20.
In general, at an accumulator station 26, one end portion of a tray shuttle mechanism, generally indicated at 28, is filled with automotive parts 30. The opposite end portion of the shuttle mechanism is located in one of a pair of unloading stations 45 and 47. The parts 30 are moved into the station 26 by being lifted up by a part lift mechanism, generally indicated at 32, from a conveying means or mechanism, generally indicated at 34 in FIGS. 1 and 2. The conveying mechanism 34 preferably comprises a plurality of part support fixtures or transfer beds 36 which include support fixtures 37. The beds 36 are connected in spaced relationship to an indexing conveyor or transfer rail 38. The transfer rail 38 is driven by a transfer drive 39. The upper surface of each of the support fixtures 37 is preferably formed to be complementary with the lower surface of each part 30 so that each part 30 is not only positioned properly, but also has a proper orientation for transfer to the part lift mechanism 32 by transfer bars 40 shown in a pair of positions by phantom lines in FIG. 3. The bars 40 are moved vertically by a lift drive 42. In this way, the parts 30 are transferred through a combination of indexing horizontal and vertical steps, as is well known in the art.
The system also preferably includes a reject-part removal mechanism 50, as shown in FIG. 2, which removes defective parts 30 which have been inspected at an inspection station 51 upstream the mechanism 50. The mechanism 50 places the rejected part onto another conveyor 52 parallel to the transfer rail 38.
Referring to FIG. 3, the part lift mechanism 32 includes a plurality of spaced apart support members 54 which are mounted on a support stand 56. In turn, the support stand 56 is supported for vertical movement on a nut mechanism 58 which is threadedly mounted on a screw 60 for vertical movement upon rotation of the screw 60. In turn, the screw 60 is rotatably coupled to a stepper motor 62 having an output shaft 64. The opposite end of the screw 60 is rotatably mounted by a bearing 65. Upon rotation of the output shaft 64 the screw 60 will turn, thereby causing the nut mechanism 58 to move either upwardly or downwardly thereby causing the supported part 30 to follow this movement.
The shuttle mechanism 28 is movably supported on a bridge structure, generally indicated at 76, which includes a plurality of interconnecting vertical and horizontal beams and plates 78 and 80, respectively. The shuttle mechanism 28 also includes a plurality of interconnecting vertical and horizontal beams and plates 65 and 67 to support the other parts of the shuttle mechanism 28. Since the two end portions of the shuttle mechanism 28 are substantially identical only one end portion will be described in detail.
After the part lift mechanism 32 lifts a part 30 into the accumulator station 36, a first set of lowermost fingers 66, mounted on the shuttle mechanism 28, receive and retain the part 30 by moving inwardly from a retracted position. The first set of fingers 66 are removably mounted on the ends of shafts 68 which, in turn, are controlled to move between extended and retracted positions by cylinders 70 mounted on the shuttle mechanism 28. The fingers 66 may be replaced by fingers having a different configuration if the system is to accumulate parts having a different configuration.
Referring to FIGS. 4 and 5, a part loading mechanism, generally indicated at 74, includes a second set of movable fingers 72 which receive and retain the stack of parts 30 when the first set of fingers 66 are retracted. The parts 30 are moved upwardly by the second set of fingers 72 which are vertically driven by a pair of stepper motors 82 mounted on opposite sides of the bridge structure 76. The output shaft of each of the stepper motors 82 is mechanically coupled to a screw 84 on which a nut structure 86 is mounted for vertical movement upon rotation of the screw 84. The fingers 72 are supported on the nut structures 86. The opposite end of each of the screws 84 is rotatably mounted by a bearing 88 at the top surface of one of the horizontally extending plates 80.
Referring to FIG. 4, the second set of fingers 72 are also removable to accommodate different parts. The fingers 72 are mounted on the ends of shafts 90 of cylinders 92 which, in turn, are supported on their respective nut structures 86. The shafts 90 and, consequently, their respective fingers 72, are controlled to move between extended and retracted positions by their respective cylinders 92. The fingers 72 are movable upwardly or downwardly according to the direction of movement of the nut structures 86 along their respective screws 84.
After the parts 30 within the shuttle mechanism 28 have been moved vertically upward by the part load mechanism 74, the first set of fingers 66 mounted on the shuttle mechanism 28 are again moved inwardly to receive and retain the parts 30 in the tray shuttle mechanism 28. Then the second set of fingers 72 mounted on the part loader mechanism 74 are moved outwardly or retracted.
When the shuttle mechanism 28 is full of parts, the shuttle mechanism 28 is shuttled so that the stack of parts 30 are positioned in one of the pair of unloading stations 45 and 47. As illustrated in FIG. 4 by phantom lines, the shuttle mechanism 28 is slidably mounted on a pair of spaced, parallel shuttle rails 94 of the bridge structure 76. The length of the shuttle mechanism 28 and the length of the bridge structure 76 is such that the length of the shuttle stroke is held constant and is equal to the distance between the accumulator station 26 and either one of the unloading stations 47 and 45.
The shuttle mechanism 28 includes a plurality of rollers 96 and slides 97 which respectively rollingly and slidably engage the shuttle rails 94 to permit shuttle movement of the shuttle mechanism 28. A shuttle drive, indicated at 98 in FIGS. 1 and 2, drives the shuttle mechanism 28.
Referring to FIG. 9, there is illustrated some of the various movements taken by the gantry robot 20 and its associated gripper 44 in picking up a stack of parts 30 from one of the unloading stations 47 and 45 and placing the parts 30 in the container 10. The gripper 44 preferably includes a plurality of extensible and retractable, spaced fingers 95 complimentarily shaped to the shape of the parts 30 to maintain the spacing between the parts 30 during the movements illustrated in FIG. 9. Also, quick change tooling 99 and a compliance mechanism 100 are interposed between the robot wrist 45' and the gripper 44. The tooling 99 allows a different gripper to be used when handling parts of a different configuration. The compliance mechanism 100 adjusts for small misalignments, as is well known in the art.
Initially, after the gripper 44 has been positioned above the parts 30 to be picked up at the first unloading station 45, the robot 20 is controlled in a conventional fashion by its robot controller 46 to move downwardly along its Z axis to a position immediately adjacent the parts 30. Then the robot 20 is controlled so that the fingers 95 of the gripper 44 are extended to receive and retain the parts 30. The gripper 44 then lifts the parts 30 from the shuttle mechanism 28. The robot 20 and its gripper 44 are controlled to rotate the parts 30 90° about a pair of axes of the wrist 45' while moving the parts 30 longitudinally towards the container 10 and through a loading downstroke. The parts 30 are then released by the fingers 95 of the gripper 44 by retracting the fingers 95. The fingers 95 are retracted as well as extended by cylinders (not shown).
The robot 20 then reverses its prior movements to move to a position above a second set of parts 30 at the second unloading station 47 into which the opposite end of the shuttle mechanism 28 has moved after accumulating a second set of parts 30.
After the containers 10 are fully loaded by the gantry robot 20, the containers 10 are moved out of the loading station 12 and, consequently, out of the work envelope of the robot 20.
A control means or a programmed host computer is preferably electrically coupled to the robot controller 46 and the other part and container handling mechanisms in order to synchronize motion of the containers 10, the parts 60 and the robot 20.
Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
1. A method for the loading of shaped parts into a stacking container adapted to receive and retain the parts therein, the method utilizing a program controlled robot having an end effector movable with respect to at least two control axes, the method comprising the steps of:
(a) stacking a predetermined number of parts in a predetermined spaced, non-contact stack at an accumulator station;
(b) shuttling the stacked parts from the accumulator station to at least one unloading station;
(c) moving the end effector with respect to the two control axes to pick up the stack of parts from the at least one unloading station and place the stack of parts in predetermined positions in the container;
(d) maintaining the predetermined spaced, non-contact stack of parts during the steps of shuttling and moving;
(e) conveying the parts from an upstream position to a downstream position adjacent the accumulator station;
(f) loading the parts from the downstream position to the accumulator station; and
(g) iterating steps (a) through (f) until the container is substantially full.
2. The method of claim 1 wherein steps (a) and (c) are performed substantially simultaneously on different sets of parts.
(f) conveying the parts from an upstream position to a downstream position adjacent the accumulator station; and
(g) vertically moving the parts from the downstream position to the accumulator station.
4. The method of claim 3 wherein steps (f) and (c) are performed substantially simultaneously.
5. The method of claim 1 wherein said step of accumulating includes the steps of:
(h) receiving and retaining the parts at the accumulator station; and
(i) vertically indexing the parts at the accumulator station in preparation for receiving and retaining another part at the accumulator station.
6. The method of claim 5 wherein said steps (i) and (c) are performed substantially simultaneously.
7. The method of claim 1 wherein the end effector is adapted to receive and retain the plurality of parts in the predetermined, spaced, non-contact arrangement.
8. The method of claim 1 wherein a predetermined number of parts are successively shuttled to two unloading stations.
9. A system for loading shaped parts into a stacking container, the system comprising:
a program controlled robot having an arm provided with an end effector movable with respect to at least two control axes, and adapted to receive and retain at least two of the parts in a predetermined spaced, non-contact arrangement;
accumulator means for accumulating the parts in the predetermined spaced, non-contact stack at an accumulator station, said accumulating means including shuttle means for receiving and retaining said parts in the predetermined spaced, noncontact stack;
shuttle drive means for driving said shuttle means, said shuttle means moving the stack of parts from the accumulator station to at least one unloading station; and
a controller for causing the robot to move the end effector with respect to the at least two control axes to successively pick up the stack of parts from the unloading station and place the stack of parts in predetermined positions in the container.
10. The system as claimed in claim 9 wherein said robot comprises a gantry robot.
11. The system as claimed in claim 10 wherein said robot comprises a gantry robot having an arm, said end effector being mounted at the free end of the arm.
12. The system as claimed in claim 9 further comprising conveyor means for conveying the parts from an upstream position to a downstream position adjacent the accumulator station and a part lift mechanism for lifting the parts from the downstream position to the accumulator station, said shuttle means receiving and retaining each part lifted by said mechanism into the accumulator station.
13. The system as claimed in claim 12 wherein said accumulator means includes part indexing means for vertically indexing the accumulated parts at the accumulator station in preparation for said shuttle means receiving and retaining another part.
14. The system as claimed in claim 9 wherein said shuttle means is adapted to receive and retain first and second sets of spaced parts at opposite ends thereof.
US06/878,597 1986-06-26 1986-06-26 Method for automated accumulation and loading of parts such as automotive parts and system utilizing same Expired - Fee Related US4777783A (en)
US06/878,597 US4777783A (en) 1986-06-26 1986-06-26 Method for automated accumulation and loading of parts such as automotive parts and system utilizing same
US4777783A true US4777783A (en) 1988-10-18
ID=25372362
US06/878,597 Expired - Fee Related US4777783A (en) 1986-06-26 1986-06-26 Method for automated accumulation and loading of parts such as automotive parts and system utilizing same
US (1) US4777783A (en)
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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:ZALD, ROBERTA L.;REEL/FRAME:004571/0640