Patent Description:
Robotic devices are increasingly incorporated into manufacturing facilities to perform tasks previously performed by humans. The use of robotic devices may reduce labor costs, and allow for an increase in production throughput of the manufacturing facility. Examples of manufacturing operations performed by robotic devices include machining of workpieces, inspection of workpieces, and other types of operations. Workpieces may be manually loaded onto a station next to a robotic device. When the robotic device completes an operation on the workpiece, the workpiece may be manually unloaded from the station, and replaced with another workpiece to be operated on by the robotic device.

Manufacturing facilities containing robotic devices typically include safety systems configured to stop movement of the robotic devices upon detecting the presence of a human within the work envelope of the robotic devices. In addition, when a workpiece is manually loaded or unloaded from a station at a robotic device, the movement of the robotic device may be temporarily stopped until the human moves out of the robot work envelope. As may be appreciated, the periods of time when robotic devices are non-operational reduces the production throughput of the manufacturing facility.

As can be seen, there exists a need in the art for a manufacturing system that avoids periods of non-operation of robotic devices otherwise occurring during changeout of workpieces.

<CIT>, according to its abstract, states a first holding frame of a component holding unit is allowed to hold a plurality of components composing a first assembly and a second holding frame of the component holding unit is allowed to hold a plurality of components composing a second assembly which is to be mounted on the first assembly. The first assembly held onto the first holding frame and the second assembly held onto the second holding frame are assembled by an assembly work unit. The second holding frame is allowed to reciprocate towards the first holding frame to pass the second assembly from the second holding, frame to the first holding frame. Thereafter, the first assembly and the second assembly which are held onto the first holding frame are assembled and coupled together by the assembly work unit.

A manufacturing system for processing workpieces according to claim <NUM> and a method of processing workpieces according to claim <NUM> are provided. Optional features are recited in the dependent claims.

The above-noted needs associated with manufacturing systems are specifically addressed and alleviated by the present disclosure which provides a manufacturing system for processing workpieces. The manufacturing system includes a manufacturing cell, a plurality of pallets each configured to support one or more workpieces, and at least one robotic device mounted in the manufacturing cell and configured to operate on the one or more workpieces. In addition, the manufacturing system includes at least two processing stations, including a first processing station and a second processing station, each located in the manufacturing cell and each configured to support any one of the plurality of pallets in fixed position relative to the robotic device. Furthermore, the manufacturing system includes at least one transport device configured to transport any one of the pallets to and from each of the first processing station and the second processing station. Additionally, the manufacturing system includes a controller configured to coordinate the operation of the manufacturing cell in a manner allowing the robotic device to continuously operate on a workpiece supported by one of the plurality of pallets at the first processing station while another one of the plurality of pallets is transferred to or from the second processing station.

Also disclosed is a manufacturing cell having a robotic device, a first processing station and a second processing station, and a controller. The robotic device is configured to operate on one or more workpieces each supported on a pallet. Each pallet is configured to be transported by a transport device. The first processing station and the second processing station are located within reach of the robotic device and are each configured to support a pallet in fixed position relative to the robotic device. The controller is configured to coordinate the operation of the manufacturing cell in a manner allowing the robotic device to continuously operate on a workpiece supported by a pallet at the first processing station while another pallet is transferred to or from the second processing station.

In addition, disclosed is a method of processing workpieces. The method includes supporting one or more workpieces on each of a plurality of pallets, and transporting, using a transport device, any one of the plurality of pallets onto a first processing station located in a manufacturing cell within reach of a robotic device. In addition, the method includes operating, using the robotic device, on a workpiece supported by one of the plurality of pallets at the first processing station while another one of the plurality of pallets is transferred to or from a second processing station located within reach of the robotic device.

The features, functions and advantages that have been discussed can be achieved independently in various examples of the present disclosure or may be combined in yet other examples, further details of which can be seen with reference to the following description and drawings below.

These and other features of the present disclosure will become more apparent upon reference to the drawings wherein like numbers refer to like parts throughout and wherein:.

Referring now to the drawings which illustrate preferred and various examples of the disclosure, shown in <FIG> are examples of a manufacturing system <NUM> for automated processing of workpieces <NUM>. The manufacturing system <NUM> includes a manufacturing cell <NUM>, which may be part of a manufacturing facility or factory. The manufacturing system <NUM> includes a plurality of pallets <NUM>, and at least one robotic device <NUM> mounted in the manufacturing cell <NUM>. Each one of the pallets <NUM> is configured to support one or more workpieces <NUM>. Each robotic device <NUM> is configured to operate on the workpieces <NUM>. In some examples, each robotic device <NUM> includes at least one robotic arm <NUM>.

The manufacturing system <NUM> includes a plurality of pallet stations <NUM>. The pallet stations <NUM> include at least two processing stations for each robotic device <NUM>. For example, for each one of the robotic devices <NUM>, the manufacturing system <NUM> includes a first processing station <NUM> and a second processing station <NUM> located in the manufacturing cell <NUM>. The first processing station <NUM> and the second processing station <NUM> are each configured to support any one of the pallets <NUM> in fixed position relative to the robotic device <NUM> to allow the robotic device <NUM> to operate on one or more workpieces <NUM> supported on the pallet <NUM>.

As shown in <FIG>, the manufacturing system <NUM> includes at least one transport device <NUM> configured to autonomously (i.e., without human intervention) transport any one of the pallets <NUM> to and from the first processing station <NUM> and the second processing station <NUM>. In addition, the transport devices <NUM> may transport pallets <NUM> to and from any one of the other pallet stations <NUM> in the manufacturing cell <NUM>. As shown in <FIG>, the manufacturing system <NUM> further includes a controller <NUM> (i.e., a processor) configured to coordinate the operation of the manufacturing cell <NUM> in a manner allowing the robotic device <NUM> to continuously operate on a workpiece <NUM> supported by one of the pallets <NUM> at the first processing station <NUM> while another one of the pallets <NUM> is transferred to or from the second processing station <NUM>. In this regard, the controller <NUM> may be configured to coordinate the operation of each transport device <NUM> and each robotic device <NUM> in a manner allowing each robotic device <NUM> to continuously operate on a workpiece <NUM> supported by a pallet <NUM> at a first processing station <NUM> of a robotic device <NUM>, while the transport device <NUM> transfers another pallet <NUM> to or from the second processing station <NUM> of the same robotic device <NUM>. In this regard, the robotic arms <NUM> of a robotic device <NUM> may continue to move and/or the end effector <NUM> (<FIG>) of the robotic device <NUM> may continue to operate on a workpiece <NUM> at the first processing station <NUM> while a transport device <NUM> transports a pallet <NUM> to or from the second processing station <NUM>. However, in other examples not shown, one or more of the pallet stations <NUM> may include at least one processing station for each robotic device <NUM>, and the controller <NUM> may coordinate the operation of the robotic device <NUM> and the transport device <NUM> to allow the robotic device <NUM> to operate on a workpiece <NUM> supported on a pallet <NUM> at a processing station while the transport device <NUM> is in close proximity to the same processing station.

As shown in <FIG>, the pallet stations <NUM> may include one or more feed stations <NUM> and/or one or more buffer queuing stations <NUM> or locations. Each of the feed stations <NUM> is configured to support a pallet <NUM> prior to transporting or movement by a transport device <NUM> to a processing station for being operated on by a robotic device <NUM> in accordance with predetermined processing operations defined for the workpieces <NUM> on the pallet <NUM>. After the manufacturing cell <NUM> has completed all processing operations defined for the workpiece <NUM> on the pallet <NUM>, a transport device <NUM> may return the pallet <NUM> to one of the feed stations <NUM>, after which the pallet <NUM> may be removed (e.g., manually, via forklift or crane - not shown) from the feed station <NUM> and placed into storage or transported to another manufacturing cell for further processing. The manufacturing cell <NUM> may also include one or more buffer queuing stations <NUM> or locations, as mentioned above. Each buffer queuing station <NUM> may temporarily support any one of the pallets <NUM> in between processing operations defined for the workpieces <NUM> on the pallet <NUM>. The manufacturing cell <NUM> may also include one or more operator stations <NUM> (e.g., a desk) for occupation by personnel such as a production monitor or a supervisor for monitoring the operation of the manufacturing system <NUM>.

Advantageously, the autonomous operation of the robotic devices <NUM> in coordination with the transportation of the pallets <NUM> via the transport devices <NUM> avoids periods of non-operation of the robotic devices <NUM> that would otherwise occur if the workpieces <NUM> were manually loaded and unloaded at the processing stations of each robotic device <NUM>. As a result of the continuous operation of the robotic devices <NUM>, the manufacturing system <NUM> results in an increase in the speed at which workpieces <NUM> move through the manufacturing cell <NUM>, which results in an increase in production throughput of the manufacturing cell <NUM> relative to the throughput of a conventional manufacturing system that relies on manual labor for transporting and/or processing workpieces <NUM>. In addition, the presently-disclosed manufacturing system <NUM> significantly reduces labor costs relative to the labor costs associated with conventional manufacturing systems.

Referring to <FIG>, the manufacturing cell <NUM> may include one or more subcells <NUM> for performing any one of a variety of different processes on the workpieces <NUM>. In the example shown in the figures, the manufacturing cell <NUM> includes a machining subcell <NUM>, an inspection subcell <NUM>, and a cleaning subcell <NUM>. Any one or more of the subcells <NUM> in the manufacturing cell <NUM> may include one or more robotic devices <NUM> for autonomously performing operations on workpieces <NUM>. For example, the machining subcell <NUM> may include one or more robotic devices <NUM> configured for machining, trimming, drilling, sanding, additive manufacturing (e.g., additive printing), or performing any one of a variety of other types of operations. The inspection subcell <NUM> may include one or more robotic devices <NUM> for inspecting the dimensions of a workpiece <NUM>, such as after machining and/or cleaning of the workpiece <NUM>. In one example, the end effector <NUM> on the robotic device <NUM> in the inspection subcell <NUM> may be an inspection laser scanner (not shown) for measuring the length, width, hole diameter, shape, surface contour, feature spatial position (e.g., in three-dimensional space), and/or other geometrical features of a workpiece <NUM>. Although the presently-disclosed manufacturing system <NUM> is described in the context of a machining subcell <NUM>, an inspection subcell <NUM>, and a cleaning subcell <NUM>, the manufacturing cell <NUM> may include any one of a variety of different subcells <NUM>, and is not limited to the subcells <NUM> shown in the figures.

As mentioned above, the manufacturing system <NUM> includes one or more robotic devices <NUM> configured to operate on workpieces <NUM> when mounted at pallets <NUM> installed at one of the processing stations. For example, the machining subcell <NUM> may include a pair of robotic devices <NUM>. In the present disclosure, a robotic device <NUM> may be described as any device, machine, assembly, system, subsystem, and/or any type of automated or semi-automated equipment capable of autonomously performing one or more operations on a workpiece. In this regard, a robotic device <NUM> is not limited to devices having one or more robotic arms <NUM>. In the example shown, each of the robotic devices <NUM> may optionally be mounted on a linear rail system <NUM> (e.g., <FIG>) to allow the robotic devices <NUM> to move in a longitudinal direction for expanding the work envelope of each robotic device <NUM>. In some examples, the robotic device <NUM> may have a rotatable robotic base <NUM>.

As shown in <FIG>, each robotic device <NUM> may have at least one robotic arm <NUM> having an end effector <NUM> mounted on a distal end of the robotic arm <NUM>. The end effector <NUM> may be configured as any one of a variety of different types of processing tools. For example, the end effector <NUM> may be configured as a machining spindle which holds machining tools. However, in other examples, a robotic device <NUM> may include an end effector <NUM> configured as a forming tool, an additive manufacturing head (e.g., a three-dimensional printing head), a lamination head for laminating composite material onto a layup tool, a coating applicator for applying a coating to a workpiece <NUM>, or other end effector configurations. For the inspection subcell <NUM>, the end effector <NUM> of the robotic device <NUM> may be a laser inspection device. In another example, the end effector <NUM> may be an ultrasonic device for scanning composite workpieces <NUM> for internal conditions such as voids. As may be appreciated, the end effector <NUM> of the robotic device <NUM> in the inspection subcell <NUM> may be provided in any one of a variety of configurations for inspecting a workpiece <NUM>.

The robotic devices <NUM> of the manufacturing cell <NUM> may have relatively high degrees-of-freedom to allow the robotic devices <NUM> to operate on a wide variety of workpieces <NUM> of different sizes, shapes, materials, and configurations. In addition, one or more of the robotic devices <NUM> may have an automated tool changer (not shown), providing the capability for autonomous (i.e., without human intervention) changeout of tools (not shown) used by an end effector <NUM> while one or more transport devices <NUM> are loading or unloading pallets <NUM> at the first processing station <NUM> and/or the second processing station <NUM>. In this regard, autonomous changeout of the end effector <NUM> tools may allow the robotic devices <NUM> to perform a wide variety of operations on a workpiece <NUM>. For example, a robotic device <NUM> may perform an additive manufacturing operation to add material to a workpiece <NUM>, and then autonomously change out the end effector <NUM> tool to enable the robotic device <NUM> to perform drilling operations on the same workpiece <NUM> or on a different workpiece <NUM>. Advantageously, the increased operational flexibility of the robotic devices <NUM> due to autonomous end effector <NUM> tool changeouts may reduce the amount of factory floor space required for production equipment, relative to the amount of floor space required to support a plurality of different types of production equipment (e.g., a conventional milling machine, an additive manufacturing machine) required to perform the same operations using a single robotic device <NUM>.

As mentioned above, the manufacturing system <NUM> includes at least two processing stations, including a first processing station <NUM> and a second processing station <NUM>, dedicated to each robotic device <NUM> and configured to support a pallet <NUM> within reach of the robotic device <NUM>. In the example manufacturing cell <NUM> shown in <FIG>, the machining subcell <NUM> includes two robotic devices <NUM>, each having a first processing station <NUM> and a second processing station <NUM>. The first processing station <NUM> may support a pallet <NUM> of workpieces <NUM> being operated on by the robotic device <NUM>, while the second processing station <NUM> supports a pallet <NUM> of workpieces <NUM> that have been operated on by the robotic device <NUM>, and which are awaiting a transport device <NUM> to transport the pallet <NUM> to the next pallet station <NUM>. In the machining subcell <NUM> arrangement shown in <FIG>, the two robotic devices <NUM> may be configured to work collaboratively on workpieces <NUM> that exceed the size of a single pallet <NUM>. For example, two processing stations on one side of the linear rail system <NUM> may collectively support a single workpiece <NUM> while both of the robotic devices <NUM> operate on the workpiece <NUM>. Operation of the robotic devices <NUM> in the machining subcell <NUM> may be monitored and/or at least partially controlled by a human operator located at an operator station <NUM> where the operator has a view of the robotic devices <NUM>.

Referring still to <FIG>, the machining subcell <NUM> may be enclosed by subcell walls <NUM> and a subcell roof <NUM> for controlling dust and preventing uncontrolled human entry. The machining subcell <NUM> may include at least one entrance <NUM> for passage of transport devices <NUM> into and out of the machining subcell <NUM>. As described in greater detail below, each entrance <NUM> may have at least one pass-through sensor <NUM> and an entrance barrier <NUM> (e.g., a subcell door <NUM>) that is selectively configurable (i.e., openable and closable) to allow passage (i.e., entry or exit) of the transport device <NUM> through the entrance <NUM> upon detection of the transport device <NUM> at the entrance <NUM>, without triggering an emergency stop of the robotic devices <NUM> in the machining subcell <NUM>. The machining subcell <NUM> may also include a separate man-door (not shown) to allow human access into the machining subcell <NUM>. The machining subcell <NUM> may include a dust-management system (not shown) for maintaining a clean working environment and reducing the negative impact of dust accumulation on the robotic devices <NUM> and other components and workpieces <NUM> in the machining subcell <NUM>. For example, the machining subcell <NUM> may include a dust collection booth (not shown) for collecting dust generated during machining, trimming, drilling, and/or sanding of workpieces <NUM>.

In <FIG>, the inspection subcell <NUM> is shown having a single robotic device <NUM> mounted on a linear rail system <NUM>, and having an inspection laser scanner as the end effector <NUM>. In addition, the inspection subcell <NUM> is shown having four (<NUM>) processing stations each located within reach of the robotic device <NUM>, including a first, second, third, and fourth processing station <NUM>, <NUM>, <NUM>, <NUM>. Similar to the operation of the machining subcell <NUM>, the robotic device <NUM> in the inspection subcell <NUM> may be configured to inspect one or more workpieces <NUM> mounted on a pallet <NUM> located at one processing station, while one or more pallets <NUM> are respectively transported to or from one of the other processing stations in the inspection subcell <NUM>. Similar to the machining subcell <NUM>, the operation of the inspection subcell <NUM> may be monitored and/or partially controlled by an operator at an operator station <NUM> providing a view of the robotic device <NUM>. The inspection subcell <NUM> may be at least partially enclosed by a subcell boundary <NUM> which, in the example shown, may include a safety fence <NUM> on each of opposing sides of the inspection subcell <NUM>. The opposing ends of the inspection subcell <NUM> may each be protected by an optical safety curtain (not shown) generated by one or more door laser scanners (not shown) sweeping a laser beam or curtain across the entrance <NUM> of the inspection subcell <NUM>. Similar to the above-described operation of the machining subcell <NUM>, the entrances <NUM> on the ends of the inspection subcell <NUM> may each include a pass-through sensor <NUM> that, when triggered (e.g., upon receiving a transport device signal), causes the controller <NUM> to allow a transport device <NUM> to enter the inspection subcell <NUM> without triggering an emergency stop of the robotic device <NUM>.

Referring briefly to <FIG>, any one of the subcells <NUM> may include an intracell-mounted reference system <NUM> for establishing the positions of one or more objects within the subcell <NUM>. The intracell-mounted reference system <NUM> may include a plurality of ball nests <NUM> embedded within the floor <NUM> or on the subcell walls <NUM>, ceiling, or other monuments. Each ball nest <NUM> may be configured to receive a spherical ball (not shown) to serve as a target for a laser system (not shown) for establishing or verifying the three-dimensional position of the objects (e.g., pallet stations <NUM>, station frames <NUM>, robotic devices <NUM> - <FIG>) in the subcell <NUM> (e.g., the machining subcell <NUM> and/or the inspection subcell <NUM>). The intracell-mounted reference system <NUM> may be used if there have been recent major changes to the manufacturing cell <NUM>, such as changes to the configuration of the subcell <NUM>, or following the installation of new robotic devices <NUM>, or if it is suspected that the position or orientation of the station frames <NUM> or robotic devices <NUM> may have been altered due to a recent seismic event, or due to contact of a transport device <NUM> with a station frame <NUM> or a robotic device <NUM> in the subcell <NUM>.

In addition to subcells <NUM> having robotic devices <NUM>, the manufacturing system <NUM> may include one or more subcells <NUM> that are operated by technicians (i.e., humans) instead of robotic devices <NUM>. Each subcell <NUM> staffed by a technician may include one or more processing stations for supporting a pallet <NUM>. For example, the cleaning subcell <NUM> in <FIG> has two cleaning booths <NUM> arranged side-by-side. However, in other examples, the manufacturing cell <NUM> may include cleaning booths <NUM> located in line and/or between robotic devices <NUM>. Regardless of location, each cleaning booth <NUM> may be staffed by a cleaning technician, and may include a single processing station for supporting a pallet <NUM> containing one or more workpieces <NUM> to be cleaned or washed by the cleaning technician. The cleaning subcell <NUM> may be used for cleaning workpieces <NUM>, such as after the workpieces <NUM> have been processed by the machining subcell <NUM>, and prior to inspection of the workpieces <NUM> by the inspection subcell <NUM>. The cleaning subcell <NUM> may include a dust control and collection system (not shown). In addition, each cleaning booth <NUM> may have access to a compressed air source to allow the cleaning technician to blow machining dust off of the pallets <NUM>, workpieces <NUM>, and workpiece mounting fixtures <NUM> (e.g., <FIG>) that support the workpieces <NUM> on the pallets <NUM>. The manufacturing cell <NUM> may also have subcells (not shown) to perform additional manual processes such as deburring of workpieces <NUM>, visual inspection of workpieces <NUM>, and other manual operations.

Referring to <FIG>, the manufacturing system <NUM> may include any number of transport devices <NUM>. As mentioned above, each transport device <NUM> is configured to transport pallets <NUM> between processing stations. The transport devices <NUM> may be provided in any one of a variety of different configurations. For example, in <FIG>, the transport devices <NUM> may be provided as vehicles. In other examples not shown, the transport devices <NUM> may be provided as overhead equipment such as cranes or gantries (not shown), or as drones (not shown). In a still further example shown in <FIG>, <FIG> and <FIG>, the transport devices <NUM> may be provided as a plurality of floor-mounted conveyor sections <NUM> of a conveyor system <NUM>, as described below. In one example, a transport device <NUM> may be described as a robotic vehicle programmed to autonomously navigate the manufacturing cell <NUM>. A robotic vehicle (e.g., <FIG>) may have a guidance system for navigating along predetermined transport device routes <NUM> between pallet stations <NUM>.

In <FIG>, the conveyor system <NUM> (e.g., <FIG>) may have multiple conveyor sections <NUM> defining the transport devices routes <NUM> between the pallet stations <NUM>. Each conveyor section <NUM> may includes a conveyor belt <NUM> (<FIG>) supported by a series of rollers (not shown). The rollers may be supported by a series of support posts (not shown) extending from the floor <NUM> on opposite sides of the conveyor belt <NUM>. The conveyor system <NUM> may include a rotatable conveyor section <NUM> at each intersection of two conveyor sections <NUM> oriented in different directions. When a pallet <NUM> being transported along one conveyor section <NUM> arrives at a rotatable conveyor section <NUM>, the rotatable conveyor section <NUM> rotates the pallet <NUM> to thereby orient the pallet <NUM> into alignment with the intersecting conveyor section <NUM> to allow the pallet <NUM> to move along the intersecting conveyor section <NUM>. Alternatively or additionally, the conveyor system <NUM> may include a mechanical push mechanism (not shown) at each intersection, to push the pallets <NUM> from one conveyor section <NUM> onto an intersecting conveyor section <NUM>.

The transport device routes <NUM> may be made up of a plurality of route segments <NUM>. The scheduling of the timing and order of movement of the transport devices <NUM> and/or the pallets <NUM> between pallet stations <NUM> may be controlled by the controller <NUM> of the manufacturing system <NUM>, and may be based on a time simulation of the flow of workpieces <NUM> through the manufacturing cell <NUM>. The movement of individual transport devices <NUM> (e.g., <FIG>) along the transport device routes <NUM>, and/or the transportation of the pallets <NUM> along the transport device routes <NUM> via the conveyor system <NUM> (e.g., <FIG>), may be controlled by a transport device software module.

In the example of <FIG>, the movement of the pallets <NUM> via the transport devices <NUM> may be programmed or controlled to travel along certain a known path or route segments <NUM> in a common (i.e., one-way) direction to avoid conflicts with the movement of other pallets <NUM> and/or other transport devices <NUM>. The guidance system of the transport devices <NUM> configured as vehicles may be a laser guidance system (not shown) having a laser device for tracking laser reflectors (not shown) mounted to the floor <NUM> and/or to other structures (e.g., subcell walls <NUM>, manufacturing facility walls, etc.) of the manufacturing cell <NUM>. In another example, the guidance system of the transport devices <NUM> may be a magnetic guidance system or a linear scale guidance system comprising sensors (not shown) on each transport device <NUM> for sensing magnetic elements or scale elements (e.g., magnetic tape, linear scale - not shown) mounted on or in the floor <NUM> of the manufacturing facility.

The transport devices <NUM> and/or the manufacturing cell <NUM> may include one or more safety systems configured to automatically halt the movement of a transport device <NUM> upon determining the potential for contact between the transport device <NUM> and an obstruction along a transport device <NUM> route. In some examples, each transport device <NUM>, such as each robotic vehicle, may include a light imaging and ranging system (e.g., LIDAR) to avoid colliding with unexpected objects. The manufacturing cell <NUM> may include one or more idle stations (not shown) for temporarily parking a transport device <NUM> (i.e., vehicle) during the production of workpieces <NUM>. The idle stations may be strategically positioned within the manufacturing cell <NUM> to decrease the average time required for a transport device <NUM> to reach any pallet station <NUM>. The idle stations may be located off of the transport device routes <NUM> to avoid interfering with the movement of other transport devices <NUM>. The idle stations may each include a charging system for recharging the batteries of the transport device <NUM> while parked at the idle station.

Referring to <FIG>, <FIG>, <FIG> and <FIG>, the manufacturing system <NUM>, may include a station frame <NUM> at each pallet station <NUM>. Each station frame <NUM> may be removably mounted to the floor <NUM> of the manufacturing cell <NUM>. As shown in <FIG> and <FIG> and described in greater detail below, each station frame <NUM> may be precisely and repeatably located and oriented at a pallet station <NUM> via a mechanical locating system <NUM> (<FIG>) having multiple locating points <NUM> (<FIG>) configured to precisely and repeatably locate the station frame <NUM> to the floor <NUM> of the manufacturing cell <NUM>. Similarly, each pallet <NUM> may be located and oriented on a station frame <NUM> via a mechanical locating system <NUM> (<FIG>) having multiple locating points <NUM> (<FIG>) configured to precisely and repeatably locate the pallet <NUM> to the station frame <NUM>. In the example shown, each locating system <NUM> may be a three-point locating system <NUM> having exactly three locating points <NUM>. However, in other examples not shown, the locating system <NUM> may be a four-point locating system having four locating points <NUM> arranged in an orthogonal pattern, such as a rectangular pattern or a square pattern. Regardless of the number of locating points <NUM>, the locating system <NUM>, such as the three-point locating system <NUM> shown in <FIG>, is configured such that when a pallet <NUM> is loaded onto a station frame <NUM> at a processing station <NUM>, <NUM>, the one or more workpieces <NUM> (<FIG>) on the pallet <NUM> (<FIG>) are within the reach envelope of the end effector <NUM> (<FIG>) of the robotic device <NUM> (<FIG>) that the processing station <NUM>, <NUM> is associated with.

For the manufacturing system <NUM> example of <FIG> in which the transport device <NUM> comprises a conveyor system <NUM>, the pallet <NUM> at each processing station <NUM>, <NUM> may be located and oriented via a mechanical locating system <NUM>. The mechanical locating system <NUM> at each processing station <NUM>, <NUM> includes a plurality of locating points <NUM><NUM> for supporting the pallet <NUM>. Once the conveyor system <NUM> transports a pallet <NUM> into one of the processing stations <NUM>, <NUM> proximate a robotic device <NUM>, the locating points <NUM> at the processing station <NUM>, <NUM> are configured to lift the pallet <NUM> off of the conveyor belt <NUM>, and non-movably support the pallet <NUM> a relatively short distance (e.g., up to <NUM> inches) above the conveyor belt <NUM> in a precise location and orientation relative to the robotic device <NUM>, as described below.

As shown in <FIG>, the locating points <NUM> at each processing station <NUM>, <NUM> may include a cone system <NUM>, comprised of locating cones for lifting and supporting the pallet <NUM>. For example, the locating system <NUM> at each processing station <NUM>, <NUM> may be a three-point locating system <NUM> having a primary locating cone <NUM> and a secondary locating cone <NUM>, both of which may be located on one side of the conveyor section <NUM>. The primary locating cone <NUM> and the secondary locating cone <NUM> are tapered. The three-point locating system <NUM> also includes a tertiary locating element <NUM> (e.g., a planar plate) located on an opposite side of the conveyor section <NUM> from the locating cones. The locating cones may be configured similar to the locating cones described below and shown in <FIG>, <FIG>, <FIG>, and <FIG>, and are also shaped complementary to the below-described locating cups of the cup system <NUM> included with the pallet <NUM>. The primary locating cone <NUM>, the secondary locating cone <NUM>, and the tertiary locating element <NUM> may each be mounted on a locating point post <NUM> extending upwardly from the floor <NUM>. Each locating point post <NUM> has a locating point actuator <NUM> (e.g., an electromechanical actuator, a pneumatic actuator, a hydraulic actuator, etc.), for vertically moving the primary locating cone <NUM>, the secondary locating cone <NUM>, and the tertiary locating element <NUM>.

Referring to <FIG>, each pallet <NUM> may be positioned on the conveyor system <NUM> such that when a pallet <NUM> arrives at one of the processing stations <NUM>, <NUM> (e.g., <FIG>), the vertical centerlines (not shown) of the locating cups of the pallet <NUM> are generally aligned with the vertical centerlines (not shown) of the locating cones at the processing station <NUM>, <NUM>. For example, the vertical centerlines of the locating cups of the pallet <NUM> may be within a relatively small distance (e.g., <NUM> inch) of the vertical centerlines of the locating cones.

Referring to <FIG>, with the pallet <NUM> stationary on the conveyor section <NUM> at the processing station <NUM>, <NUM>, the locating point actuators <NUM> are activated to move the primary locating cone <NUM>, the secondary locating cone <NUM>, and the tertiary locating element <NUM> upwardly into engagement respectively with the primary locating cup <NUM>, the secondary locating cup <NUM>, and the tertiary locating feature <NUM> (e.g., a planar underside) of the pallet <NUM>. The engagement of the tapered shape of the locating cone with the tapered shape of the locating cups results in self-positioning of the pallet <NUM> (and workpiece <NUM>) into a repeatable and precise location relative to the robotic device <NUM>. The locating point actuators <NUM> may lift the pallet <NUM> off of the conveyor belt <NUM>, and non-movably support the pallet <NUM> (and workpiece <NUM>) in a precise and repeatable location and orientation relative to the robotic device <NUM>.

In <FIG>, the upward movement of the cone system <NUM> at the processing station <NUM>, <NUM> into engagement with the cup system <NUM> of the pallet <NUM> may also result in the engagement of a station vacuum connector <NUM> of the processing station <NUM>, <NUM> with a pallet vacuum connector <NUM> of the pallet <NUM>. The station vacuum connector <NUM> is fluidly coupled to a factory vacuum pressure source <NUM>, such as a factory vacuum pump. When the station vacuum connector <NUM> is sealingly engaged with the pallet vacuum connector <NUM>, the factory vacuum pressure source <NUM> may provide vacuum pressure at the apertures <NUM> (<FIG>) of the mounting surface <NUM> of the workpiece mounting fixture <NUM> for vacuum coupling of the workpiece <NUM> to the workpiece mounting fixture <NUM> for when the workpiece <NUM> is operated on by the robotic device <NUM>, as described below with regard to <FIG>.

For the conveyor system <NUM> of <FIG>, <FIG> and <FIG>, the locating system <NUM> may be omitted from processing stations <NUM>, <NUM> that do not require precise location and/or precise orientation of the pallet <NUM> (and workpiece <NUM>). For example, the locating system <NUM> may be omitted from processing stations <NUM>, <NUM> that involve manual processes such as washing (e.g., at a cleaning subcell <NUM>), deburring, visual inspection, and other workpiece operations. In addition, the locating system <NUM> may be omitted from pallet stations <NUM> such as feed stations <NUM> and buffer queuing stations <NUM> or locations. The pallets <NUM> at feed stations <NUM> and buffer queuing stations <NUM> may instead by supported on a conveyor section <NUM> dedicated to that pallet station <NUM>.

Referring to <FIG>, shown is an example of a manufacturing system <NUM> wherein each pallet <NUM> is mounted on a station frame <NUM> at a processing station <NUM>, <NUM> near a robotic device <NUM>. As mentioned above, in any of the manufacturing system <NUM> examples disclosed herein, the pallet <NUM> may have one or more workpiece mounting fixtures <NUM>. Each workpiece mounting fixture <NUM> may be configured to support one or more workpieces <NUM>. Each workpiece mounting fixture <NUM> may have a mounting surface <NUM>. The contour of the mounting surface <NUM> may be complementary to the contour of the workpiece <NUM> to be supported by the workpiece mounting fixture <NUM>. The workpiece mounting fixture <NUM> may be permanently mounted to the pallet <NUM>. For example, each workpiece mounting fixture <NUM> may be coupled to a pallet <NUM> via mechanical fasteners extending through one or more of a plurality of fastener holes (e.g., circular holes and/or slots - not shown) formed in a pallet base panel <NUM>.

The mounting surface <NUM> of the workpiece mounting fixture <NUM> may contain a plurality of apertures <NUM>. The apertures <NUM> of the workpiece mounting fixture <NUM> may be fluidly coupled to a vacuum pressure source <NUM> (<FIG>) via internal passages (not shown) in the workpiece mounting fixture <NUM>. Vacuum pressure at the apertures <NUM> may result in vacuum coupling of the workpiece <NUM> to the mounting surface <NUM>, and may prevent movement of the workpiece <NUM> relative to the pallet <NUM> when the workpiece <NUM> is being operated on by the robotic device <NUM>. In addition, vacuum coupling of the workpiece <NUM> to the mounting surface <NUM> may prevent movement of the workpiece <NUM> relative to the pallet <NUM> when the pallet <NUM> is being transported by the transport device <NUM>, as described below.

Referring to <FIG>, shown are examples of pallets <NUM> supporting different configurations of workpieces <NUM>, with each workpiece <NUM> mounted on a workpiece mounting fixture <NUM> securely coupled to the pallet <NUM>. The pallets <NUM> may be provided in one or more lengths based on the size and/or quantity of workpieces <NUM> to be supported by the pallet <NUM>. For example, <FIG> illustrate a pallet <NUM> having a standard size of <NUM> inches wide by <NUM> inches long. <FIG> shows the pallet <NUM> supporting a single workpiece <NUM>. <FIG> shows the pallet <NUM> of the same size as in <FIG>, and showing the pallet <NUM> supporting four workpieces <NUM> of relatively small size, with two of the workpieces <NUM> having a different configuration than the other two workpieces <NUM> on the pallet <NUM>. <FIG> illustrates a pallet <NUM> having the same width as the pallets <NUM> of <FIG>, but having an extended length of <NUM> inches, and is shown supporting two workpieces <NUM> each having a relatively long length. As may be appreciated, the pallets may be provided in any one a variety of different sizes, shapes and configurations, and is not limited to the sizes and shapes disclosed herein.

As mentioned above, the manufacturing cell <NUM> may be configured to process workpieces <NUM> of any size, shape, configuration, and material composition, including metallic workpieces <NUM> and/or non-metallic workpieces <NUM>. For example, the workpieces <NUM> may be comprised of aluminum, steel, or any one of a variety of other metallic compositions. In another example, the workpieces <NUM> may be composite workpieces <NUM> comprised of fiber-reinforced polymer matrix material.

Referring to <FIG>, shown is an example of a transport device <NUM> configured as a vehicle for transporting pallets <NUM> between the pallet stations <NUM> of the manufacturing cell <NUM>. The transport device <NUM> may have a vehicle chassis <NUM> and vehicle wheels <NUM>. In the example shown, the transport device <NUM> has a pair of vertically movable vehicle forks <NUM>. The vehicle forks <NUM> may be configurable for engagement with a corresponding pair of fork tubes <NUM> (<FIG>) of each pallet <NUM> for raising and lowering the pallet <NUM> onto the pallet stations <NUM> of the manufacturing cell <NUM>. The vehicle forks <NUM> may be inserted into the fork tubes <NUM> of a pallet <NUM> while the pallet <NUM> is mounted on a station frame <NUM> at one of the pallet stations <NUM>. The vehicle forks <NUM> may be vertically movable for raising and lowering pallets <NUM> off of pallet stations <NUM>. In an alternative example not shown, the transport device <NUM> may be configured as a non-forked transport device having a relatively low profile, and may be configurable into a height that is shorter than the height of the station frame panel <NUM> above the floor <NUM> (<FIG>). In such an arrangement, the station frame <NUM> may be open at one end to allow the transport device <NUM> to move underneath the station frame panel <NUM> and underneath the pallet <NUM>. Once the transport device <NUM> is underneath the pallet <NUM>, the transport device <NUM> may raise upwardly into engagement with the bottom of the pallet <NUM> to lift the pallet <NUM> off the station frame <NUM>. The transport device <NUM> may then translate the pallet <NUM> away from the station frame <NUM> and transport the pallet <NUM> to another pallet station <NUM>.

As mentioned above, any transport device <NUM> vehicle disclosed herein may have a laser guidance system (not shown) having at least one vehicle signaling device <NUM> (e.g., a laser beacon) for emitting a laser beam for reflecting off of laser reflectors (not shown) mounted at different locations in the manufacturing cell <NUM>. In addition, the laser beam emitted by the vehicle signaling device <NUM> may be sensed by a pass-through sensor <NUM> (<FIG>) located proximate an entrance <NUM> (<FIG>) to a subcell <NUM> (<FIG>) to trigger activation of the entrance barrier <NUM> (e.g., a subcell door <NUM> - <FIG>), thereby allowing the transport device <NUM> to pass through the entrance <NUM>. In another example, the vehicle signaling device <NUM> may be a wireless transmitting device configured to transmit a wireless signal over a dedicated wifi network of the manufacturing cell <NUM>. The wireless signal may include a request for opening the entrance <NUM>. While the transport device <NUM> waits near the entrance <NUM>, the controller <NUM> (<FIG>), in response to the pass-through sensor <NUM> sensing or receiving the transport device signal, may determine whether or not to allow the transport device <NUM> to pass through the entrance <NUM>, as described below. In addition to a vehicle signaling device <NUM>, any one of the transport device <NUM> examples disclosed herein may also include a transport device vacuum source <NUM> (e.g., a vacuum pump) for generating vacuum pressure at the apertures <NUM> of the mounting surface <NUM> (<FIG>) of the workpiece mounting fixture <NUM> (<FIG>) for maintaining vacuum coupling of the workpiece <NUM> to the workpiece mounting fixture <NUM> when the pallet <NUM> is transported between pallet stations <NUM> by the transport device <NUM>.

Referring to <FIG>, shown in <FIG> is an exploded view of example of a cone system <NUM> that is mountable to the floor <NUM> of the manufacturing cell <NUM>. The cone system <NUM> is part of a locating system <NUM> that contains exactly three locating points <NUM>, including two locating cones <NUM>, <NUM> and a tertiary locating element <NUM>, arranged in a triangular pattern. However, the locating system <NUM> may includes more than three locating points <NUM>. The locating cones of the cone system <NUM> include a primary locating cone <NUM>, and a secondary locating cone <NUM>. The tertiary locating element <NUM> may be configured as a rest button <NUM> as shown. The primary locating cone <NUM>, the secondary locating cone <NUM>, and the tertiary locating element <NUM> (e.g., the rest button <NUM>) may each be removably couplable to an embedded plate <NUM> (<FIG>) that may be bonded within a cored hole <NUM> (<FIG>) formed in the floor <NUM> of the manufacturing cell <NUM>. The primary locating cone <NUM> and the secondary locating cone <NUM> may each have a generally conical outer surface (e.g., a simple cone shape, an ogive shape, or other rounded conical shape - <FIG>), and the rest button <NUM> may have at least a partial spherical outer surface (e.g., <FIG>). The cone system <NUM> is part of a three-point locating system <NUM> for accurately and repeatably locating and orienting a station frame <NUM> on the floor <NUM> of the manufacturing system <NUM> at one of the pallet stations <NUM>.

<FIG> shows the primary locating cone <NUM>, the secondary locating cone <NUM>, and the rest button <NUM> threadably engaged respectively to the embedded plates <NUM> in the floor <NUM>. Also shown in <FIG> is a utilities pit <NUM> through which the pallet station <NUM> and/or the station frame <NUM> may have access to various utilities, such as a factory vacuum pressure source <NUM>, a factory compressed air source <NUM>, controller input/output lines, and/or electrical power. In some examples of the manufacturing cell <NUM>, each one of the pallet stations <NUM>, including the first and second processing stations <NUM>, <NUM> (<FIG>), the feed stations <NUM> (<FIG>, and the buffer queuing stations <NUM> (<FIG>, may include a cone system <NUM> to engage with the cup system <NUM> of any one of the pallets <NUM>, to thereby enable any pallet <NUM> to be precisely located relative to the floor <NUM> the manufacturing cell <NUM>. In other examples of the manufacturing cell <NUM>, only the processing stations <NUM>, <NUM> near robotic devices <NUM> may have a cone system <NUM>, and the remaining pallet stations <NUM> may be devoid of a cone system <NUM>.

<FIG> shows an example of a station frame <NUM> mounted to the floor <NUM> of the manufacturing cell <NUM> via a cup system <NUM> (<FIG>). In the example, shown, the station frame <NUM> includes three station frame legs <NUM> extending downwardly from a station frame panel <NUM>. The cup system <NUM> of the station frame <NUM> is similar to the cup system <NUM> of the pallet <NUM>. The cup system <NUM> includes two locating cups <NUM>, <NUM> (<FIG>) and a tertiary locating feature <NUM> (<FIG>) arranged in a triangular pattern that is complementary to the triangular pattern of the cone system <NUM>. The tertiary locating feature <NUM> may be configured as flat pad <NUM>. The locating cups <NUM>, <NUM> and the tertiary locating feature <NUM> (e.g., the flat pad <NUM>) may be mounted on the bottom of the station frame legs <NUM> of the station frame <NUM>. The primary locating cup <NUM>, the secondary locating cup <NUM>, and the flat pad <NUM> may be configured to engage respectively with the primary locating cone <NUM>, the secondary locating home, and the rest button <NUM> of the cone system <NUM>. To secure the station frame <NUM> to the floor <NUM>, a threaded insert <NUM> may be embedded in the floor <NUM> at the location of each cored hole <NUM>. Each one of the station frame legs <NUM> may include a 1eg tab <NUM> protruding laterally from the lower end of each station frame leg <NUM>. Each leg tab <NUM> may include a hole for receiving a mechanical fastener (e.g., a bolt) for threadably engaging the threaded insert <NUM> for securing the station frame <NUM> to the floor <NUM> when the cup system <NUM> of the station frame is mounted to the cone system <NUM> of the floor <NUM>.

<FIG> shows an example of a pallet <NUM> mounted to the station frame <NUM> of <FIG> via the three-point locating system <NUM>, and which is configured similar to the above-described three-point locating system <NUM> for coupling the station frame <NUM> to the floor <NUM> of the manufacturing cell <NUM>. In this regard, the station frame <NUM> may include a cone system <NUM> as shown in <FIG> and described above, and which protrudes upwardly from the station frame panel <NUM>. The pallet <NUM> may include a cup system <NUM> as described above. The cup system <NUM> of the pallet <NUM> may be mounted to an underside of the pallet <NUM>, and may engage with the cone system <NUM> protruding upwardly from the station frame panel <NUM>. Advantageously, the three-point locating system <NUM> is configured to precisely and repeatably position each pallet <NUM> relative to the robotic device <NUM> (<FIG>) within a relatively tight tolerance (e.g., within <NUM> inch) of a nominal position of the pallet <NUM> at the pallet station <NUM>.

Although the cone system <NUM> is described as including two cones and one rest button, in an alternative example (not shown) the cone system <NUM> may include exactly three spheres configured to engage respectively with the primary locating cup <NUM>, the secondary locating cup <NUM>, and the flat pad <NUM> of the cup system <NUM>. In a still further alternative example, instead of a cone system <NUM> being mounted to the floor <NUM> the manufacturing cell <NUM> and a cup system <NUM> being mounted to the bottom of the station frame legs <NUM>, a cone system <NUM> may be mounted to the bottom of the station frame legs <NUM>, and a cup system <NUM> may be mounted to the floor <NUM> the manufacturing cell <NUM>. Likewise, instead of a cone system <NUM> protruding upwardly from the station frame panel <NUM> and a cup system <NUM> mounted to an underside of the pallet <NUM>, the cone system <NUM> may be mounted to an underside of pallet <NUM>, and the cup system <NUM> may be mounted to the station frame panel <NUM>.

Referring to <FIG>, shown in <FIG> is an example of a station frame <NUM> configured to be mounted to the floor <NUM> (<FIG>) of the manufacturing cell <NUM> via the above-described three-point locating system <NUM>. As mentioned above, at each pallet station <NUM> (<FIG>) including at the first and second processing station <NUM>, <NUM> (<FIG>) of a robotic device <NUM> (<FIG>), a station frame <NUM> may be engaged to the floor <NUM> of the manufacturing cell <NUM> via a three-point locating system <NUM> as shown in <FIG>. In addition, any one of the pallets <NUM> may be configured to be mounted to the station frame <NUM> at any pallet station <NUM>, including at the first and second processing stations <NUM>, <NUM>, via a three-point locating system <NUM> as shown in <FIG>.

In <FIG>, the station frame <NUM> may be constructed of a rigid material such as metallic material (e.g., steel), and may include a station frame panel <NUM> supported on the station frame legs <NUM>. The station frame panel <NUM> may be conspicuously marked and/or painted in bright colors to promote human awareness. A set of four tooling features <NUM> may be permanently mounted on the top side of the station frame <NUM>. In the example shown, the tooling features <NUM> are configured as balls or spheres. However, the tooling features <NUM> may be provided in any one of a variety of alternative shapes, sizes, and configurations. The tooling features <NUM> may protrude upwardly from the station frame panel <NUM>, and may be used to verify, via a laser scanning system (not shown) or mechanical probing system (not shown), that the station frame <NUM> is located and oriented within a predetermined tolerance (e.g., within <NUM> inch) of a nominal position of the stations frame <NUM>, relative to a world coordinate system (not shown) of the manufacturing cell <NUM>.

Referring to <FIG>, any one of the pallet stations <NUM> (including the processing stations <NUM>, <NUM> in <FIG>) disclosed herein may include an RFID read/write head <NUM> coupled to an electrical connector <NUM>, and powered by an electrical power cable (not shown) extending upwardly from the utilities pit <NUM> (<FIG>) in the floor <NUM> of the manufacturing cell <NUM>. The RFID read/write head <NUM> may be configured to receive data from an RFID tag <NUM> (<FIG>) mounted to the underside of each pallet <NUM>, as a means for positively identifying each pallet <NUM>, and for storing information about workpieces <NUM> that are mounted on the pallet <NUM> that is placed or located at the pallet station <NUM>. Any one of the pallet stations <NUM> (including the processing stations <NUM>, <NUM> in <FIG>) and/or any one of the station frames <NUM> disclosed herein may include a pallet presence switch <NUM> for detecting when a pallet <NUM> is placed or located at a pallet station <NUM>, such as when a pallet <NUM> is loaded on the station frame <NUM>.

In addition, in <FIG>, any one of the pallet stations <NUM> and/or the station frames <NUM> disclosed herein may include a station vacuum connector <NUM>, such as a station vacuum cone <NUM>, for vacuum coupling with a pallet vacuum connector <NUM>, such as a pallet vacuum cup <NUM> (<FIG>), that may be included with each pallet <NUM> for maintaining vacuum coupling of the workpiece <NUM> (<FIG>) to the workpiece mounting fixture <NUM> (<FIG>), as described in greater detail below. In this regard, the pallet station <NUM> and/or the station frame <NUM> may also include a mechanical vacuum valve <NUM> for actuating the factory vacuum pressure source <NUM> when the pallet vacuum connector <NUM> (<FIG>) engages with the station vacuum connector <NUM> after the cup system <NUM> (<FIG>) of the pallet <NUM> engages with the cone system <NUM> (<FIG>) of the station frame <NUM> as the pallet <NUM> placed at the station frame <NUM>, as mentioned above and described in greater detail below.

Also shown in <FIG> is a compressed air conduit <NUM> (<FIG>) extending upwardly out of the utilities pit <NUM> (<FIG>) in the floor <NUM>. The compressed air conduit <NUM> may be fluidly coupled to a factory compressed air source <NUM>, and may have a terminal end that is directed toward the station vacuum cone <NUM>. During the process of locating a pallet <NUM> at a pallet station <NUM>, such as by lowering a pallet <NUM> onto a station frame <NUM> via a transport device <NUM>, the factory compressed air source <NUM> may be commanded (e.g., by the controller <NUM> of the manufacturing cell <NUM>) to direct a burst of compressed air from the compressed air conduit <NUM> onto the station vacuum cone <NUM> as a means to blow debris (e.g., carbon dust, metallic dust, etc.) off of the station vacuum cone <NUM> prior to the pallet vacuum cup <NUM> (<FIG>) being lowered into engagement with the station vacuum cone <NUM>, thereby ensuring a tight seal between the station vacuum cone <NUM> and the pallet vacuum cup <NUM>.

Referring to <FIG>, shown is an underside of an example of a pallet <NUM>. In any one of the manufacturing system <NUM> examples disclosed herein, the pallet <NUM> may be constructed of a rigid material such as steel, and may include a pallet base panel <NUM> having a plurality of slotted holes (not shown) and/or tapered holes (not shown) to attach any one of a variety of different configurations of workpiece mounting fixtures <NUM> (<FIG>). The pallet base panel <NUM> may be supported by a pallet framework <NUM> (e.g., ribs, webs) to provide a high-stiffness and high-strength structure to which one or more workpiece mounting fixtures <NUM> may be fastened. In the example of <FIG>, the pallet <NUM> may include a pair of fork tubes <NUM> configured to received a pair of vehicle forks <NUM> (<FIG>). However, in an alternative example (e.g., <FIG>), the pallet <NUM> may be provided without fork tubes <NUM>, and the transport device <NUM> may be provided without vehicle forks <NUM>. In one such example, the transport device <NUM> may be configured to move underneath the pallet <NUM> at a station frame <NUM>, and vertically move the pallet <NUM> onto and off of the station frame <NUM>. In another example, the transport device <NUM> (e.g., a drone, an overhead crane, etc.) may be configured to attach to the pallet <NUM> from above, and may vertically move the pallet <NUM> onto and off of the pallet stations <NUM>.

As described above, the pallet <NUM> includes the above-mentioned cup system <NUM> for engaging the cone system <NUM> (<FIG>) of a station frame <NUM>, or engaging the cone system <NUM> associated with the above-described conveyor system <NUM> (e.g., <FIG>, <FIG>, and 5A). In <FIG>, the cup system <NUM> includes the primary locating cup <NUM>, the secondary locating cup <NUM>, and the tertiary locating feature <NUM>, such as a flat pad <NUM>. The primary locating cup <NUM> may be centered on the pallet proximal end of the pallet <NUM>. The pallet proximal end may be described as the end into which vehicle forks <NUM> are inserted into the fork tubes <NUM>. The secondary locating cup <NUM> and the flat pad <NUM> may each be respectively located at the pallet distal end opposite the pallet proximal end. However, to match the arrangement of the primary locating cone <NUM>, secondary locating cone <NUM>, and tertiary locating element <NUM> of the locating system <NUM> in <FIG>, the primary locating cup <NUM> and the secondary locating cup <NUM> may be located on opposite ends of the pallet <NUM> and on one side of the pallet <NUM>, and the tertiary locating feature <NUM> may be located at an approximate mid-point of the opposite side of the pallet <NUM>.

As shown in <FIG>, the primary locating cup <NUM> of any of the pallet <NUM> configurations disclosed herein may be configured as a circular tapered hole <NUM>. The secondary locating cup <NUM> of any of the pallet <NUM> configurations disclosed herein may be configured as a slotted tapered hole <NUM>. The slotted tapered hole <NUM> may have a slot axis (not shown) that is oriented perpendicular to an axis passing through the center of the slotted tapered hole <NUM> and the center of the tertiary locating feature <NUM> (e.g., the flat pad <NUM>). The tertiary locating feature <NUM> or flat pad <NUM> may have a planar outer surface (e.g., <FIG>). In any of the manufacturing system <NUM> examples disclosed herein, the engagement of the primary locating cone <NUM> (<FIG>) with the circular tapered hole <NUM> of the primary locating cup <NUM> may constrain the pallet <NUM> from moving laterally at the primary locating cone <NUM>. In addition, in any of the manufacturing system <NUM> examples disclosed herein, the engagement of the secondary locating cone <NUM> (<FIG>) with the slotted tapered hole <NUM> of the secondary locating cup <NUM> may constrain the pallet <NUM> from pivoting about the primary locating cone <NUM>, while accommodating slight differences in the distance between the primary locating cone <NUM> and the secondary locating cone <NUM> on different pallets <NUM>. Furthermore, in any of the manufacturing system <NUM> examples disclosed herein, the engagement of the tertiary locating element <NUM> (e.g., the rest button <NUM>) with the tertiary locating feature <NUM> (e.g., the planar outer surface of the flat pad <NUM>) may constrain the orientation of the pallet <NUM>, such as maintaining the pallet <NUM> in a horizontal orientation.

Referring still to <FIG>, as mentioned above, each pallet <NUM> may include one or more pallet vacuum connectors <NUM>, such as pallet vacuum cups <NUM>, <NUM> , each of which may be fluidly coupled to a vacuum manifold <NUM> via vacuum conduits <NUM>. The transport devices <NUM> (<FIG>) and the pallet stations <NUM> (<FIG>), including the first and second processing stations <NUM>, <NUM> (<FIG>), may each have a vacuum pressure source <NUM> (<FIG>) fluidly couplable to the apertures <NUM> (<FIG>) of the workpiece mounting fixture <NUM> (<FIG>) for generating vacuum pressure at the apertures <NUM> to thereby vacuum couple the workpiece <NUM> to the mounting surface <NUM> (<FIG>). The pallet <NUM> may also include a vacuum reserve tank <NUM> fluidly coupled to the vacuum manifold <NUM> via a vacuum conduit <NUM>. As described in greater detail below, a pallet vacuum connector <NUM> (e.g., pallet vacuum cup <NUM>) is configured to mate with the transport device vacuum connector <NUM> (e.g., transport device vacuum cone <NUM> - <FIG> and <FIG>) when the pallet <NUM> is transported by a transport device <NUM>. The pallet vacuum connector <NUM> (e.g., pallet vacuum cup <NUM>) is configured to mate with the station vacuum connector <NUM> (e.g., station vacuum cone <NUM> - <FIG>) when the pallet <NUM> is mounted on a station frame <NUM> (e.g., <FIG>), or when a pallet <NUM> is placed at a processing station <NUM>, <NUM> (e.g., <FIG>). In the event of a loss of vacuum pressure from the factory vacuum pressure source <NUM> (<FIG>) and/or from the transport device vacuum source <NUM> (<FIG>), the vacuum reserve tank <NUM> may provide backup vacuum pressure to the apertures <NUM> to maintain vacuum coupling of the workpiece <NUM> to the workpiece mounting fixture <NUM>.

Referring to <FIG>, shown in <FIG> is a sectional view of an example of the primary or secondary locating cup <NUM>, <NUM> of the station frame <NUM> respectively mounted on the primary or secondary locating cone <NUM>, <NUM> on the floor <NUM> of the manufacturing cell <NUM>. The primary and secondary locating cups <NUM>, <NUM> of the station frame <NUM> may each be coupled to a bottom of a station frame leg <NUM>. As mentioned above, the primary and secondary locating cones <NUM>, <NUM> may be threadably engaged respectively to embedded plates <NUM> that are adhesively bonded within a cored hole <NUM> in the floor <NUM>. Also shown in <FIG> is the primary or secondary locating cup <NUM>, <NUM> of the pallet <NUM> respectively mounted on the primary or secondary locating cone <NUM>, <NUM> of the station frame <NUM>. The primary and secondary locating cups <NUM>, <NUM> of the pallet <NUM> may be coupled to the pallet framework <NUM> on the underside of the pallet <NUM>. The primary and secondary locating cones <NUM>, <NUM> of the station frame <NUM> may protrude upwardly from the station frame panel <NUM>.

<FIG> is a sectional showing an example of the flat pad <NUM> of the station frame <NUM> resting on the rest button <NUM> on the floor <NUM> of the manufacturing cell <NUM> via an embedded plate <NUM>. The flat pad <NUM> of the station frame <NUM> may be coupled to the bottom of a station frame leg <NUM>. The rest button <NUM> may be threadably engaged to an embedded plate <NUM> bonded within a cored hole <NUM> in the floor <NUM>. Also shown is the flat pad <NUM> of the pallet <NUM> mounted on the rest button <NUM> of the pallet station <NUM>. The flat pad <NUM> of the pallet <NUM> may be coupled to the pallet framework <NUM> on the underside of the pallet <NUM>. The rest button <NUM> of the station frame <NUM> may protrude upwardly from the station frame panel <NUM>.

Referring to <FIG>, shown in <FIG> are sectional views of a portion of a pallet <NUM> and a station frame <NUM> as the pallet <NUM> is lowered onto the station frame <NUM>, and illustrating the process of the primary or secondary locating cup <NUM>, <NUM> of the pallet <NUM> respectively engaging the primary or secondary locating cone <NUM>, <NUM> of the station frame <NUM>, and also illustrating the engagement of the pallet vacuum cup <NUM> of the pallet <NUM> with a station vacuum cone <NUM> of the station frame <NUM>. <FIG> are magnified views showing the engagement of the pallet vacuum cup <NUM> with the station vacuum cone <NUM>. As described above, each of the pallets <NUM> in <FIG> has a pallet vacuum cup <NUM> which may be mounted to the underside of the pallet <NUM> (<FIG>). The pallet stations <NUM> in <FIG>, including the first and second processing stations <NUM>, <NUM> (<FIG>), may each include a station vacuum cone <NUM>. The station vacuum cone <NUM> may be fluidly coupled to a vacuum conduit <NUM> extending out of the utilities pit <NUM> (<FIG>) at each pallet station <NUM>. The vacuum conduit <NUM> may be fluidly coupled to a factory vacuum pressure source <NUM> (e.g., a factory vacuum pump).

As shown in <FIG>, the station vacuum cone <NUM> is configured to sealingly engage with the pallet vacuum cup <NUM> when the transport device <NUM> places the pallet <NUM> at the first or second processing station <NUM>, <NUM>, thereby providing vacuum pressure at the apertures <NUM> (<FIG>) of the mounting surface <NUM> (<FIG>) of the workpiece mounting fixture <NUM> for holding the workpiece <NUM> and fixed position when the workpiece <NUM> is operated on by the robotic device <NUM>. The station vacuum cone <NUM> may be supported on a cone spring <NUM> mounted on a mounting bracket <NUM>, which is mounted to the station frame <NUM>. The pallet vacuum cup <NUM> may include a circumferential seal <NUM> (e.g., a wiper seal) located at the base of the pallet vacuum cup <NUM>. The circumferential seal <NUM> may facilitate sealing engagement of the pallet vacuum cup <NUM> to the station vacuum cone <NUM> when the pallet <NUM> is lowered onto the station frame <NUM> at the first or second processing station <NUM>, <NUM>. The cone spring <NUM> is configured to urge the station vacuum cone <NUM> upwardly toward the pallet vacuum cup <NUM>, to thereby maintain sealing engagement of the outer surface of the station vacuum cone <NUM> with the circumferential seal <NUM>. In addition, the cone spring <NUM> may allow the station vacuum cone <NUM> to laterally move into alignment with the pallet vacuum cup <NUM> to facilitate sealing engagement therebetween.

As shown in <FIG>, when the transport device <NUM> transports a pallet <NUM> to a new pallet station <NUM>, the pallet <NUM> may initially be slightly laterally offset from the station frame <NUM>. More specifically, the cup system <NUM> (<FIG>) of the pallet <NUM> may initially be laterally offset from the cone system <NUM> (<FIG>) of the station frame <NUM>. As a result, the pallet vacuum cup <NUM> may also be laterally offset from the station vacuum cone <NUM>. The height of the primary and secondary locating cones <NUM>, <NUM> may be greater than the height of the station vacuum cone <NUM>, thereby causing the primary and secondary locating cones <NUM>, <NUM> to respectively engage with the primary and secondary locating cups <NUM>, <NUM> prior to engagement of the station vacuum cone <NUM> with the pallet vacuum cup <NUM>.

<FIG> shows the pallet <NUM> further lowered onto the station frame <NUM>, and illustrating the further engagement of the primary locating cup <NUM> (or secondary locating cup <NUM>) of the pallet <NUM> with the primary locating cone <NUM> (or secondary locating cone <NUM>) of the station frame <NUM>. <FIG> is a magnified view showing the pallet vacuum cup <NUM> initially laterally offset from the station vacuum cone <NUM> during the process of lowering the pallet <NUM> onto the station frame <NUM>. As a result of the conical shape of the primary and secondary locating cones <NUM>, <NUM>, the lowering of the pallet <NUM> onto the station frame <NUM> causes the side surfaces of the primary or secondary locating cones <NUM>, <NUM> to engage the side surfaces respectively of the primary and secondary locating cups <NUM>, <NUM>, thereby laterally shifting the pallet <NUM> causing the pallet vacuum cup <NUM> to move toward axial alignment with the station vacuum cone <NUM>, similar to the above-described self-alignment process associated with the conveyor system <NUM> arrangement illustrated in <FIG>.

<FIG> shows the pallet <NUM> lowered onto the station frame <NUM>, and illustrating the full engagement of the primary locating cup <NUM> (or secondary locating cup <NUM>) of the pallet <NUM> with the primary locating cone <NUM> (or secondary locating cone <NUM>) of the station frame <NUM>, and allowing the pallet vacuum cup <NUM> to engage with the station vacuum cone <NUM>. <FIG> is a magnified view showing the pallet <NUM> completely lowered onto the station frame <NUM>, and the pallet vacuum cup <NUM> sealed to the station vacuum cone <NUM> via the circumferential seal <NUM>. As mentioned above, when a pallet <NUM> is lowered onto a station frame <NUM>, the mechanical vacuum valve <NUM> (<FIG>) may be activated to thereby fluidly couple the pallet vacuum cup <NUM> to the factory vacuum pressure source <NUM> (<FIG>), and resulting in vacuum pressure at the apertures <NUM> (<FIG>) of the workpiece mounting fixture <NUM>.

Referring to <FIG>, shown in <FIG> is an example of a transport device <NUM> transporting a pallet <NUM> supporting a workpiece <NUM> mounted on a workpiece mounting fixture <NUM>. As mentioned above, the transport device <NUM> may include one or more transport device vacuum sources <NUM> (e.g., vacuum pumps). The transport device <NUM> may also include a transport device vacuum cone <NUM> (<FIG>) which may be fluidly coupled to the one or more transport device vacuum sources <NUM> via a vacuum conduit <NUM>. In the example of <FIG>, the transport device vacuum cone <NUM> may be mounted to the transport device <NUM>. For example, the transport device vacuum cone <NUM> may be mounted to one of the vehicle forks <NUM> via a mounting bracket <NUM>. The transport device vacuum cone <NUM> may be supported by a cone spring <NUM> similar to the mounting arrangement of the station vacuum cone <NUM>. As described above, each of the pallets <NUM> may have a pallet vacuum connector <NUM>. In <FIG>, the pallet vacuum connector <NUM> is a pallet vacuum cup <NUM> opening downwardly and located on an underside of the pallet base panel <NUM>.

<FIG> shows a pallet <NUM> during the initial stage of being lowered by a transport device <NUM> onto a station frame <NUM>. The pallet vacuum cup <NUM> of the pallet <NUM> is initially engaged to the transport device vacuum cone <NUM> of the transport device <NUM>, while the pallet vacuum cup <NUM> of the pallet <NUM> is vertically separated from the station vacuum cone <NUM> of the station frame <NUM>, similar to the above-described arrangement shown in <FIG>. <FIG> shows the pallet <NUM> further lowered onto the station frame <NUM>, and illustrating the pallet vacuum cup <NUM> of the pallet <NUM> still engaged to the transport device vacuum cone <NUM> of the transport device <NUM>, and also showing the pallet vacuum cup <NUM> of the pallet <NUM> engaged to the station vacuum cone <NUM> of the station frame <NUM> similar to the arrangement shown in <FIG>. <FIG> shows the pallet <NUM> completely lowered onto the station frame <NUM>. The vehicle forks <NUM> are further lowered, causing the pallet vacuum cup <NUM> of the pallet <NUM> to disengage from the transport device vacuum cone <NUM> of the transport device <NUM>, while the pallet vacuum cup <NUM> of the pallet <NUM> remains engaged to the station vacuum cone <NUM>. Advantageously, the arrangement of the vacuum cups <NUM>, <NUM> and vacuum cones <NUM>, <NUM> allows for uninterrupted vacuum pressure at the mounting surface <NUM> of the workpiece mounting fixture <NUM> during the transfer of the pallet <NUM> onto and off of the station frame <NUM>.

When it is time for the pallet <NUM> to be removed the station frame <NUM>, a transport device <NUM> (<FIG>) may approach the pallet <NUM> to cause the vehicle forks <NUM> to be inserted into the fork tubes <NUM> of the pallet <NUM>. As shown in <FIG>, each of the fork tubes <NUM> has opposing side walls <NUM> that are narrower at the top of the fork tubes <NUM> than at the bottom of the fork tubes <NUM>, and causing the pallet <NUM> to self-center on the vehicle forks <NUM> when the vehicle forks <NUM> are inserted into the fork tubes <NUM> and vertically raised into engagement with the pallet <NUM> to lift the pallet <NUM> off of the pallet station <NUM>. As the vehicle forks <NUM> are raised, the transport device vacuum cone <NUM> is configured to sealingly engage with the pallet vacuum cup <NUM>, after which the pallet vacuum cup <NUM> disengages from the station vacuum cone <NUM>. The engagement of the transport device vacuum cone <NUM> to the pallet vacuum cup <NUM> fluidly couples the transport device vacuum cone <NUM> to the transport device vacuum pump <NUM>. The transport device vacuum pump <NUM> (<FIG>) provides vacuum pressure at the apertures <NUM> of the workpiece mounting fixture <NUM> for maintaining vacuum coupling of the workpiece <NUM> to the mounting surface <NUM> (<FIG>) of the workpiece mounting fixture <NUM> when the pallet <NUM> is transported by the transport device <NUM>.

Referring to <FIG>, shown is an example of a transport device <NUM> approaching an entrance <NUM> to the machining subcell <NUM>. As mentioned above, a manufacturing cell <NUM> may include any number of subcells <NUM>, each having a subcell boundary <NUM> at least partially enclosing the subcell <NUM>. The subcell boundary <NUM> may separate the subcell <NUM> from the remainder of the manufacturing cell <NUM>, and may prevent human access into the subcell <NUM> for safety reasons, and may also prevent the escape of debris such as machining dust (e.g., carbon dust) that may be generated during manufacturing operations (e.g., trimming, sanding, etc.) By the one or more robotic devices <NUM> in the machining subcell <NUM>.

In any one of the manufacturing system <NUM> examples disclosed herein, the subcell boundary <NUM> has at least one entrance <NUM> for passage of a transport device <NUM> into and out of the subcell <NUM>. At least one of the entrances <NUM> may have a pass-through sensor <NUM> In addition, at least one of the entrances <NUM> may have an entrance barrier <NUM> (e.g., a subcell door <NUM>) that is selectively configurable to either prevent or allow passage of the transport device <NUM> through the entrance <NUM> for either entering or exiting the subcell <NUM>. The pass-through sensor <NUM> may be a laser scanner or a curtain on an exterior side and/or an interior side of the subcell boundary <NUM> proximate the entrance <NUM>. The subcell boundary <NUM> may comprise physical subcell walls <NUM>, physical fencing, a physical curtain, or other physical boundary structure. As mentioned above, the entrance barrier <NUM> may be a physical subcell door <NUM> (e.g., a roll-up door, a side-hinged door, a gate, etc.). Alternatively or additionally, the entrance barrier <NUM> may be a non-physical barrier. For example, each entrance barrier <NUM> may include an optical safety curtain (not shown) generated by one or more door laser scanners (not shown) configured to scan in a two-dimensional plane across the entrance <NUM>. The transport devices <NUM> may each have physical features (not shown) that penetrate the optical safety curtain at specific locations and in specific order as the transport device <NUM> passes through the entrance, as a means to confirm that a transport device <NUM> is entering the subcell, and not a person.

As mentioned above, for transport devices <NUM> configured as a vehicle, the transport device <NUM> may have at least one vehicle signaling device <NUM> (e.g., a laser beacon, a wireless transmitting device, etc.) configured to emit or transmit a transport device signal (e.g., a laser beam, a wireless signal, etc.). The pass-through sensor <NUM> at the entrance <NUM> to the subcell <NUM> may be configured to sense or receive the transport device signal when the transport device <NUM> approaches or is near the entrance <NUM> to the subcell <NUM>, and/or is within a predetermined distance (e.g., <NUM> feet) of the entrance <NUM>. For examples where the pass-through sensor <NUM> is a wireless receiver configured to receive a wireless signal transmitted by a transport device-mounted wireless transmitting device, the wireless signal may be transmitted over a dedicated wifi network. The wireless signal may include a request for opening the entrance <NUM>.

The controller <NUM> (<FIG>), in response to the pass-through sensor <NUM> sensing or receiving a transport device signal, may determine whether or not to allow the transport device <NUM> to pass through the entrance <NUM>. If allowed to pass, the controller <NUM> may command the entrance barrier <NUM> to allow passage of the transport device <NUM> through the entrance <NUM>. For example, in the case of the machining subcell <NUM>, when the pass-through sensor <NUM> senses the transport device signal of an approaching transport device <NUM>, the controller <NUM> determine whether to allow the transport device <NUM> to pass through the entrance <NUM>, and may open the subcell door <NUM> to allow the transport device <NUM> to either enter or exit the machining subcell <NUM>, depending on whether the transport device <NUM> is inside or outside of the machining subcell <NUM>. In the case of the inspection subcell <NUM>, the controller <NUM> may allow a transport device <NUM> to pass through the entrance <NUM> when the pass-through sensor <NUM> of the inspection subcell <NUM> receives the transport device signal of an approaching transport device <NUM>. After the transport device <NUM> has passed through the entrance <NUM> and is moving away from the entrance <NUM>, the controller <NUM> may reactivate the entrance barrier <NUM> (e.g., close the subcell door <NUM>) to prevent passage through the entrance <NUM>. The entrance <NUM> may remain closed at all other times, unless manually commanded to open by an operator.

Referring to <FIG>, shown is a flowchart of steps of a method <NUM> of processing workpieces <NUM> using any one of the manufacturing cell <NUM> examples described above. Step <NUM> of the method <NUM> includes supporting one or more workpieces <NUM> on each of a plurality of pallets <NUM>. As mentioned above, each pallet <NUM> may include one or more workpiece mounting fixtures <NUM> which are each pallet <NUM> is configured to support one or more workpieces <NUM>. Each of the workpieces <NUM> may be loaded (e.g., by a technician) onto the workpiece mounting fixture <NUM> of a pallet <NUM> prior to the pallet <NUM> being loaded (e.g., via a manually-operated forklift or crane) onto a feed station <NUM>.

Step <NUM> of the method <NUM> includes transporting, using a transport device <NUM>, any one of the pallets <NUM> to a first processing station <NUM>, which may be located within reach of a robotic device <NUM>. As described above, the manufacturing cell <NUM> includes one or more transport devices <NUM> configured to transport pallets <NUM> between different pallet stations <NUM>. As described above, the one or more transport devices <NUM> may comprise overhead equipment such as cranes or gantries (not shown), or drones (not shown). In another example, the transport devices <NUM> may comprise the above-described floor-mounted conveyor system <NUM> (<FIG>, <FIG>, and <FIG>), and step <NUM> may comprise transporting the pallets <NUM> using a plurality of conveyor sections <NUM> extending along transport device routes between the plurality of pallet stations <NUM>.

In an example where the transport devices <NUM> are vehicles, the process of transporting a pallet <NUM> may include inserting a pair of vertically movable vehicle forks <NUM> of a transport device <NUM> into a pair of fork tubes <NUM> of the pallet <NUM>. The pallet <NUM> may be supported on a station frame <NUM> at the feed station <NUM>. The method may include transporting any one of the plurality of pallets <NUM> to and/or from a feed station <NUM>, which is configured to support any one of the pallets <NUM> prior to pickup or engagement by a transport device <NUM> for transporting the pallet <NUM> to one or more processing stations <NUM>, <NUM>. The method may also include transporting any one of the pallets <NUM> to and/or from a buffer queuing station <NUM> configured to temporarily support any one of the pallets <NUM> in between processing operations at one of the processing stations <NUM>, <NUM>.

As mentioned above, the opposing side walls <NUM> of each fork tube <NUM> may be narrower at the top of the fork tube <NUM> than at the bottom. The method may include raising the vehicle forks <NUM> while inside the fork tubes <NUM> to thereby lift the pallet <NUM>, and causing each vehicle fork <NUM> to engage with one of the side walls <NUM> of the fork tubes <NUM>. As a result, the method includes self-centering the pallet <NUM> on the pair of vehicle forks <NUM> due to engagement of the vehicle forks <NUM> with the side walls <NUM> of the fork tubes <NUM> when raising the vehicle forks <NUM> inside the fork tubes <NUM> to lift the pallet <NUM>. Upon arriving at another pallet station <NUM> such as a first processing station <NUM>, the method may include lowering the vehicle forks <NUM> to place the pallet <NUM> on the station frame <NUM> at the first processing station <NUM>.

Step <NUM> of the method <NUM> includes operating, using the robotic device <NUM>, on a workpiece <NUM> supported by the pallet <NUM> at the first processing station <NUM> while transporting, using a transport device <NUM>, another pallet <NUM> to or from a second processing station <NUM>, which may be located within reach of the robotic device <NUM>. The method may include controlling, using a controller <NUM> of the manufacturing cell <NUM>, the movement of the transport devices <NUM> and the robotic device <NUM> in a manner allowing the robotic device <NUM> to continuously operate on workpieces <NUM> during the movement of the pallets <NUM> by a transport device <NUM> to and from a second processing station <NUM>. In this manner, the manufacturing system <NUM> significantly reduces or eliminates human intervention in workpiece transporting, handling, and processing (e.g., machining, inspection, cleaning, etc.), which advantageously increases the consistency of workpiece processing, and also reduces operational time and labor cost.

The method <NUM> may include coupling, using at least one locating system <NUM> (e.g., a three-point locating system <NUM>), the pallet <NUM> to the first and/or second processing station <NUM>, <NUM> in a precise and repeatable location and orientation relative to the robotic device <NUM>. In this regard, the method may include coupling any pallet <NUM> to any one of the pallet stations <NUM> using the above-described three-point locating system <NUM>. As indicated above, each one of the pallet stations <NUM>, including the feed stations <NUM> and the buffer queuing locations <NUM>, may utilize a three-point locating system <NUM> for accurately locating pallets <NUM> at the pallet stations <NUM>. The step of coupling any one of the pallets <NUM> to either the first or second processing station <NUM>, <NUM> may include coupling a cup system <NUM> of a pallet <NUM> to a cone system <NUM> included with the first and/or the second processing station <NUM>, <NUM>. As described above, the cone system <NUM> in one example has a primary locating cone <NUM>, a secondary locating cone <NUM>, and a tertiary locating element <NUM> (e.g., a rest button <NUM>) arranged in a triangular pattern. The cup system <NUM> has a primary locating cup <NUM>, a secondary locating cup <NUM>, and a tertiary locating feature <NUM> (e.g., a flat pad <NUM>) also arranged in a triangular pattern, and configured to engage respectively with the primary locating cone <NUM>, the secondary locating cone <NUM>, and the tertiary locating element <NUM> of the cone system <NUM>.

As mentioned above, in the example of <FIG>, <FIG>, <FIG>, and <FIG>, each one of the pallet stations <NUM> has a station frame <NUM> that may be mounted to the floor <NUM> of the manufacturing cell <NUM>. In such an arrangement, the method may include mounting, via a three-point locating system <NUM>, a station frame <NUM> to a floor <NUM> of the manufacturing cell <NUM> at each of the first and second processing stations <NUM>, <NUM>, and mounting, via another three-point locating system <NUM>, any one of the pallets <NUM> to the station frame <NUM> at each of the first and second processing stations <NUM>, <NUM>. To facilitate the mounting of the station frame <NUM> to the floor <NUM> of the manufacturing cell <NUM>, the method may include mounting each of a primary locating cone <NUM>, a secondary locating cone <NUM>, and a rest button <NUM> to an embedded plate <NUM> contained with a cored hole <NUM> formed in the floor <NUM> of the manufacturing cell <NUM>. The method may further include engaging the primary locating cone <NUM>, the secondary locating cone <NUM>, and the rest button <NUM> respectively to the primary locating cup <NUM>, the secondary locating cup <NUM>, and the flat pad <NUM> respectively included with three station frame legs <NUM> extending downwardly from the station frame <NUM>.

In the example of <FIG> which has a conveyor system <NUM> as the transport device <NUM>, the process of coupling a pallet <NUM> to either the first processing station <NUM> or the second processing station <NUM> includes transporting the pallet <NUM> into one of the processing stations <NUM>, <NUM> proximate a robotic device <NUM>. The process further includes moving, via locating point actuators <NUM>, the locating points <NUM> (e.g., the primary locating cone <NUM>, the second locating cone <NUM>, and the tertiary locating element <NUM> upwardly into engagement respectively with the primary locating cup <NUM>, the secondary locating cup <NUM>, and the tertiary locating feature <NUM> (e.g., a planar underside) of the pallet <NUM>, and lifting the pallet <NUM> off of the conveyor belt <NUM>. The locating points <NUM> may non-movably support the pallet <NUM> above the conveyor belt <NUM> in a precise location and orientation relative to the robotic device <NUM> while the robotic device <NUM> operates on the workpiece <NUM>.

When loading a pallet <NUM> onto a station frame <NUM> or placing a pallet <NUM> at a pallet station <NUM> (e.g., at a first or second processing station <NUM>, <NUM>), the method may include, reading, via an RFID read/write head <NUM> on the station frame <NUM>, an RFID tag <NUM> included with each pallet <NUM> to allow the controller <NUM> to positively identify the pallet <NUM> that is loaded onto the station frame <NUM> or placed at the pallet station <NUM>. In addition, the method may include detecting, via a pallet presence switch <NUM>, the presence of the pallet <NUM> when loading a pallet <NUM> onto a station frame <NUM> or placing a pallet <NUM> at a pallet station <NUM>. Occasionally, the method may include verifying, using a set of tooling features <NUM> mounted at the pallet station <NUM> and/or on the station frame <NUM>, the location of the pallet station <NUM> or station frame <NUM> relative to a world coordinate system of the manufacturing cell <NUM>.

Step <NUM> of supporting one or more workpieces <NUM> on each of the pallets <NUM> may comprise supporting one or more workpiece mounting fixtures <NUM> on at least one of the pallets <NUM>. As described above, at least one of the workpiece mounting fixtures <NUM> may have a mounting surface <NUM> containing a plurality of apertures <NUM>. The method may include mounting a workpiece <NUM> on the mounting surface <NUM> of the workpiece mounting fixture <NUM>. In addition, the method may include vacuum coupling the workpiece <NUM> to the mounting surface <NUM> when transporting the pallet <NUM> (e.g., via a transport device <NUM>) using the vacuum pressure source <NUM> of the transport device <NUM> (e.g., a transport device vacuum source <NUM>, such as a vacuum pump), and vacuum coupling the workpiece <NUM> to the mounting surface <NUM> when supporting the pallet <NUM> at the first and/or second processing station <NUM>, <NUM> using the vacuum pressure source <NUM> respectively at the first and/or second processing stations <NUM>, <NUM> (e.g., the factory vacuum pressure source <NUM>).

Vacuum coupling of the workpiece <NUM> to the mounting surface <NUM> when transporting the pallet <NUM> via the transport device <NUM> may include raising the transport device <NUM> into engagement with the pallet <NUM> for lifting the pallet <NUM> off of the pallet station <NUM>. For example, as mentioned above, the transport device <NUM> may have a pair of vehicle forks <NUM> that may be inserted into a pair of fork tubes <NUM> that may be included with the pallet <NUM>. The transport device <NUM> also includes a transport device vacuum cone <NUM> mounted to the transport device <NUM>. The transport device vacuum cone <NUM> may be mounted on a cone spring <NUM>. The cone spring <NUM> may urge the transport device vacuum cone <NUM> upwardly into engagement with the pallet vacuum cup <NUM> of the pallet <NUM>.

The transport device vacuum cone <NUM> may be fluidly coupled to the transport device vacuum source <NUM> (e.g., vacuum pump). The method may include sealingly engaging the transport device vacuum cone <NUM> with the pallet vacuum cup <NUM> of the pallet <NUM> when raising the vehicle forks <NUM> into engagement with the pallet <NUM>. For example, the method may include sealing, using a circumferential seal <NUM>, the pallet vacuum cup <NUM> to the transport device vacuum cone <NUM>. The method may include activating the transport device vacuum source <NUM> to generate vacuum pressure at the apertures <NUM> of the mounting surface <NUM> for vacuum coupling the workpiece <NUM> to the workpiece mounting fixture <NUM> when the pallet <NUM> is supported and/or transported by the transport device <NUM>.

Vacuum coupling of the workpiece <NUM> to the mounting surface <NUM> when supporting the pallet <NUM> on the first or second processing station <NUM>, <NUM> may comprise lowering, using the transport device <NUM> (e.g., the vehicle forks <NUM>), the pallet <NUM> onto the first or second processing station <NUM>, <NUM>. As described above, the first and second processing station <NUM>, <NUM> may each have a station frame <NUM> having a station vacuum cone <NUM> fluidly coupled (e.g., via the utilities pit <NUM>) to the factory vacuum pressure source <NUM>. Prior to the pallet vacuum cup <NUM> being lowered onto the station vacuum cone <NUM>, the method may include directing, using a compressed air conduit <NUM> at the station frame <NUM>, a burst of compressed air toward the station vacuum cone <NUM> to remove any debris (e.g., machining dust) that may be on the station vacuum cone <NUM>.

The method may include sealingly engaging, via the circumferential seal <NUM>, the station vacuum cone <NUM> with the pallet vacuum cup <NUM> of the pallet <NUM> when lowering the pallet <NUM> onto the station frame <NUM>. The method may also include activating the factory vacuum pressure source <NUM> by triggering the mechanical vacuum valve <NUM> (<FIG>) to thereby generate vacuum pressure at the apertures <NUM> of the mounting surface <NUM> of the workpiece mounting fixture <NUM> for vacuum coupling the workpiece <NUM> to the workpiece mounting fixture <NUM> at one of the first or second processing station <NUM>, <NUM>. To accommodate the potential loss of vacuum pressure provided by the factory vacuum pressure source <NUM> or by the transport device vacuum source <NUM>, the method may additionally include maintaining vacuum coupling of the workpiece <NUM> to the mounting surface <NUM> using a vacuum reserve tank <NUM> that may be included with the pallet <NUM>.

For examples of the manufacturing cell <NUM> having a subcell <NUM> (e.g., machining subcell <NUM>, inspection subcell <NUM>, etc.) that is at least partially enclosed by a subcell boundary <NUM> (e.g., subcell walls <NUM>, safety fence <NUM>, etc.) as described above, the method may include moving the transport device <NUM> toward an entrance <NUM> of the subcell. As described above, the entrance <NUM> of the subcell <NUM> may include at least one pass-through sensor <NUM>. In addition, the entrance <NUM> may include an entrance barrier <NUM> that is selectively configurable to either prevent or allow passage of the transport device <NUM> through the entrance <NUM>. As described above, the entrance barrier <NUM> may be a physical subcell door <NUM>, as may be included with the machining subcell <NUM>. Alternatively, the entrance barrier <NUM> may be an optical safety curtain (not shown) generated by one or more door laser scanners (not shown), as may be included with the inspection subcell <NUM>.

When a transport device <NUM> approaches the entrance <NUM>, the method may include emitting, using a vehicle signaling device <NUM> (e.g., a transport device laser beacon), a transport device signal such as a laser beam. Alternatively, the vehicle signaling device <NUM> may be a wireless transmitting device (not shown) configured to transmit a wireless signal (i.e., the transport device signal) over a dedicated wifi network. As mentioned above, the wireless signal may include a request for opening the entrance <NUM>. The method may additionally include sensing, using the pass-through sensor <NUM>, the transport device signal when the transport device <NUM> is within a predetermined distance of the entrance <NUM> and is facing toward the entrance <NUM>. For example, the pass-through sensor <NUM> may receive a wireless signal, which may include a request (i.e., to the controller <NUM>) to allow the transport device <NUM> to pass through the entrance <NUM>. The method may also include commanding, using the manufacturing cell <NUM> controller <NUM>, in response to the pass-through sensor <NUM> sensing or receiving the transport device signal, the entrance barrier <NUM> to allow passage of the transport device <NUM> through the entrance <NUM>, such as by opening the subcell door <NUM> of the machining subcell <NUM>, and/or deactivating the door laser scanners of the inspection subcell <NUM>, and/or allowing the transport device <NUM> to pass through the two-dimensional optical curtain generating by the door laser scanners.

In the manufacturing system <NUM> as described herein, the transport device <NUM> may comprise a conveyor system <NUM> having a plurality of conveyor sections <NUM> extending along transport device routes <NUM> between the plurality of pallet stations <NUM>.

In the manufacturing system <NUM> as described herein, the locating cones <NUM>, <NUM> may each have a generally conical outer surface <NUM>; and two of the locating cups <NUM>, <NUM> may comprise, respectively, a circular tapered hole <NUM>, and a slotted tapered hole <NUM>.

In the manufacturing system <NUM> as described herein, the subcell <NUM> may comprise at least one of the following: a machining subcell <NUM> for machining workpieces <NUM>; an inspection subcell <NUM> for inspecting workpieces <NUM>; and a cleaning subcell <NUM> for cleaning workpieces <NUM>.

Also disclosed but not claimed herein is a manufacturing cell <NUM> for processing workpieces <NUM>, comprising: a robotic device <NUM> configured to operate on a workpiece <NUM> supported on any one of a plurality of pallets <NUM>, each of the pallets <NUM> configured to be transported by a transport device <NUM>; a first processing station <NUM> and a second processing station <NUM> located within reach of the robotic device <NUM> and each configured to support any one of the pallets <NUM> in fixed position relative to the robotic device <NUM>; and a controller <NUM> configured to coordinate the operation of the manufacturing cell <NUM> in a manner allowing the robotic device <NUM> to continuously operate on a workpiece <NUM> supported by one of the plurality of pallets <NUM> at the first processing station <NUM> while another one of the plurality of pallets <NUM> is transferred to or from the second processing station <NUM>.

In the method of processing workpieces as described herein, transporting the pallets <NUM> may comprise: transporting the pallets <NUM> using a conveyor system <NUM> having a plurality of conveyor sections <NUM> extending along transport device routes <NUM> between the plurality of pallet stations <NUM>.

The method of processing workpieces as described herein may further comprise: coupling, using a locating system <NUM>, any one of the pallets <NUM> to either one of the first and second processing stations <NUM>, <NUM> in a precise and repeatable location and orientation relative to the robotic device <NUM>.

In the method of processing workpieces as described herein, coupling any one of the pallets <NUM> to either one of the first and second processing stations <NUM>, <NUM> may comprise: coupling, using at least one three-point locating system <NUM>, any one of the pallets <NUM> to either one of the first and second processing stations <NUM>, <NUM>.

In the method of processing workpieces as described herein, coupling any one of the pallets <NUM> to either one of the first and second processing stations <NUM>, <NUM> may comprise: coupling a cup system <NUM>, included with each of the pallets <NUM>, to a cone system <NUM>, included with each of the first and second processing stations <NUM>, <NUM>; wherein: the cone system <NUM> has locating cones <NUM>, <NUM>; and the cup system <NUM> has locating cups <NUM>, <NUM> configured to engage respectively with the locating cones <NUM>, <NUM>.

In the method of processing workpieces as described herein, vacuum coupling the workpiece <NUM> to the mounting surface <NUM> when supporting the pallet <NUM> at the first or second processing station <NUM>, <NUM> may comprise: placing, using the transport device <NUM>, the pallet <NUM> at the first processing station <NUM> and/or the second processing station <NUM>, each having a station vacuum connector <NUM> fluidly coupled to a factory vacuum pressure source <NUM>; sealingly engaging the station vacuum connector <NUM> with a pallet vacuum connector <NUM> of the pallet <NUM> when placing the pallet <NUM> at the first processing station <NUM> and/or the second processing station <NUM>; and activating the factory vacuum pressure source <NUM> to thereby generate vacuum pressure at the apertures <NUM> of the mounting surface <NUM> for vacuum coupling the workpiece <NUM> to the workpiece mounting fixture <NUM> at the first and/or second processing stations <NUM>, <NUM>.

Claim 1:
A manufacturing system (<NUM>) for processing workpieces (<NUM>), comprising:
a manufacturing cell (<NUM>);
a plurality of pallets (<NUM>) each configured to support one or more workpieces (<NUM>);
at least one robotic device (<NUM>) mounted in the manufacturing cell (<NUM>) and configured to operate on the one or more workpieces (<NUM>);
at least two processing stations (<NUM>, <NUM>), including a first processing station (<NUM>) and a second processing station (<NUM>), each located in the manufacturing cell (<NUM>) within reach of the robotic device (<NUM>) and each configured to support any one of the plurality of pallets (<NUM>) in fixed position relative to the robotic device (<NUM>);
a transport device (<NUM>) configured to transport any one of the plurality of pallets (<NUM>) to and from each of the first processing station (<NUM>) and the second processing station (<NUM>); and
a controller (<NUM>) configured to coordinate the operation of the manufacturing cell (<NUM>) in a manner allowing the robotic device (<NUM>) to continuously operate on a workpiece (<NUM>) supported by one of the plurality of pallets (<NUM>) at the first processing station (<NUM>) while another one of the plurality of pallets (<NUM>) is transferred to or from the second processing station (<NUM>).