Patent Description:
The present invention relates generally to wheel/tire assemblies and more specifically to a robotic bead exerciser system for a wheel/tire assembly process.

Machines, assembly lines, and robots are used for tire and wheel manufacturing and assembly. These machines may automate tire assembly processes, increasing efficiencies and lowering costs. In addition to assembling tires, the machines may also perform certain calibrations, tests, and verifications. The document <CIT> describes a tire fitting device that comprises clamping means for clamping a center of a wheel on which a tire is to be mounted. Force applying means apply an external force to a side surface of the tire. The force applying means is located closer to a bead portion of the tire than to a maximum width portion of the tire. The tire fitting device applies an external force to an inner side surface portion of the tire biased toward an edge of the tire.

A bead exerciser system for an automated wheel assembly may include a center lift configured to lift a wheel assembly off of a conveyor belt, a drum roller configured to rotate the wheel assembly, a pair of pinch rollers driven by an actuator and configured to apply force to a tire of the wheel assembly, a feedback component configured to detect a force of the tire against the pinch rollers, and a controller configured to receive the force from the force sensor and generate a command for an alert in response to the force falling outside of a predefined threshold range.

A bead exerciser system for an automated wheel assembly may include a drum roller configured to rotate a wheel assembly; a pair of pinch rollers arranged on an opposite side of the wheel assembly than the drum roller, the pinch rollers driven by a driver and configured to apply force to a tire of the wheel assembly; and a controller configured to determine a force from actuator data received from the driver and generate a command for an alert in response to the force falling outside of a predefined threshold range.

A method for validating a force of a bead exerciser system may include receiving actuator data from a driver configured to vertically move a pair of pinch rollers; determining a force of the pinch rollers based on the actuator data; determining whether the force is within a predefined threshold range; and instructing an alert in response to the force not being within the predefined threshold range.

The embodiments of the present invention are pointed out with particularity in the appended claims. However, other features of the various embodiments will become more apparent and will be best understood by referring to the following detailed description in conjunction with the accompanying drawings in which:.

Disclosed herein is a robotic bead exerciser system included as part of a conveyor system for wheel and tire assembly. The bead exerciser system may be a pre-balance system where the wheel is automatically fed into a bead exerciser station. The station may then simulate a load around the bead of the tire via pinch rollers. A controller may transmit data indicative of a force applied at the tire by the exerciser station. The controller may then determine whether the force is appropriate for the wheel and tire assembly and provide feedback to the operator when appropriate to do so. The controller may also instruct the assembly to cease the process in order to avoid damaging of the parts or the exerciser station.

<FIG> illustrates a back view of a bead exerciser system <NUM>. <FIG> illustrates an isometric view of the bead exerciser system <NUM>. <FIG> illustrates a back zoomed in view of the bead exerciser system <NUM>. During wheel assembly, a wheel and tire assembly (not shown in <FIG>, also referred to herein as wheel assembly <NUM> and shown in <FIG>) may be automatically fed into a bead exerciser station <NUM> via a conveyor <NUM>. The conveyor <NUM> may be a free rolling conveyor, and may include a belt configured to lift the wheel assembly <NUM> off of the free rolling conveyor, or both.

In one example embodiment, at least one centering arm <NUM> may be arranged on either side of the conveyor <NUM>. In the example shown in <FIG>, each centering arm <NUM> includes a pair of centering arms <NUM>. The centering arms <NUM> may, but not necessarily are required to, aid in centering the wheel assembly <NUM> on the conveyor <NUM> and may open and close around the wheel assembly <NUM> in order to center or align the wheel assembly on the conveyor <NUM>. The bead exerciser assembly <NUM> may include a centering station <NUM> configured to center the wheel assembly <NUM> on the conveyor <NUM>.

The conveyor <NUM> may include at least one conveying apparatus configured to move the wheel assembly <NUM> thereon from the centering station <NUM> to bead exerciser assembly <NUM>. The bead exerciser assembly 120may include a lift cylinder <NUM>. The lift cylinder <NUM> may be arranged proximal to a bead exerciser assembly <NUM> at a distal portion of the conveyor <NUM>. During use, the lift cylinder <NUM> may be configured to move vertically from a first fixed position below the conveyor <NUM> to a second fixed position extending through and above the conveyor. The lift cylinder <NUM> is configured to engage with the wheel assembly <NUM> at the wheel and lift the wheel assembly <NUM> off of the conveyor <NUM>. The cylinder <NUM> may engage with the bore of the wheel. The lift cylinder <NUM> may also center the wheel assembly <NUM> and align the wheel assembly <NUM> relative to the bead exerciser assembly <NUM>.

During operation the wheel assembly <NUM> may proceed along the conveyor <NUM> and once the wheel assembly is arranged at or proximal to the bead exerciser assembly <NUM>, the lift cylinder <NUM> may extend upward from a resting position below the conveyor <NUM> to engage with the wheel and elevate the wheel assembly <NUM> above the conveyor. The system <NUM> may include at least one top roller <NUM> arranged on an upper support <NUM> of the system <NUM>. The lift cylinder <NUM> may raise the wheel assembly <NUM> to abut the at least one top roller <NUM>. In the example shown in the Figures, the top roller <NUM> includes a pair of top rollers <NUM>.

The bead exerciser assembly <NUM> may be arranged at one side of the system <NUM> and include a support <NUM>. The support <NUM> may be configured to house at least one actuator <NUM>. The exerciser assembly <NUM> may include a pair of pinch rollers <NUM>, including a top pinch roller 134a and a bottom pinch roller 134b, each arranged on a respective arm <NUM> and extending perpendicularly outward from the support <NUM>. The pinch rollers <NUM> may be rotatable discs configured to engage the tire beads of the wheel assembly. The arms <NUM> may be attached to the actuator <NUM> and may be movable in the vertical direction in order to 'pinch' the tire.

The actuator <NUM> may be any type of actuator configured to move the arms <NUM> of the bead exerciser assembly <NUM>. The actuator <NUM>, for example, may be a linear actuator, such as an EDRIVE, ball-screw, cylinder. The actuator <NUM> may include a motor, such as a servo motor, to apply torque. The actuator <NUM> may be configured to vertically adjust each of the arms <NUM> holding the pinch rollers <NUM>. The arms <NUM> may adjust the position of the pinch rollers <NUM> and therefore adjust the hold or force applied by the pinch rollers <NUM> to the tire. A top pinch roller 134a may make contact with the top of the tire, while a bottom pinch roller 134b may make contact with the bottom of the tire. In one example, the contact may be approximately <NUM>-<NUM> from the edge of the wheel. The pinch rollers <NUM> may engage the tire and 'pinch' the tire. In one example, the pinch rollers <NUM> may extend into the tire approximately <NUM>. The pinch rollers <NUM> may move in tandem in that each laterally move at the same rate and distance. In another example, one of the pinch rollers <NUM> may move while the other remains stationary.

In the examples described herein, the pinch rollers <NUM> may move together. That is, the pinch rollers <NUM> may be arranged at opposite ends of the same actuator <NUM>. However, each pinch roller <NUM> may also move independent of the other and be arranged on separate actuators.

A drum roller <NUM> may be arranged on an opposite side of the system <NUM> of the bead exerciser assembly <NUM>. The drum roller <NUM> may be configured to move horizontally from a first resting position to a second engage position where the roller <NUM> engaged with the tire of the wheel assembly. The drum roller <NUM> may rotate, and once in contact with the tire, may cause the wheel assembly <NUM> to rotate or spin about the lift cylinder <NUM>, prior to the wheel assembly engaging or coming into contact with the pinch rollers <NUM>. The lift cylinder assembly may include at least one bearing to allow for rotation of the wheel assembly.

The drum roller <NUM> may spin the wheel assembly <NUM> concurrent with the pinch rollers <NUM> applying pressure at or near the tire beads. Air nozzles (not specifically labeled), may blow air onto the wheel assembly, aiding to clean any excessive soap or debris from the assembly.

The bead exerciser assembly <NUM> may include a controller <NUM>. The controller <NUM> may be stand-alone controller specific for the bead exerciser assembly <NUM>, or may be a general controller for the general wheel assembly. The controller <NUM> may include one or more processors configured to perform instructions, commands and other routines in support of the processes described herein. Such instructions and other data may be maintained in a non-volatile manner using a variety of types of computer-readable storage medium. The computer-readable medium (also referred to as a processor-readable medium or storage) includes any non-transitory medium (e.g., a tangible medium) that participates in providing instructions or other data that may be read by the controller <NUM> or processor. Computer-executable instructions may be compiled or interpreted from computer programs created using a variety of programming languages and/or technologies, including, without limitation, and either alone or in combination, Java, C, C++, C#, Objective C, Fortran, Pascal, Java Script, Python, Perl, Ladder Logic, and PL/SQL. The system may specifically implement and use a combination of TP programming (Teach Pendant programming) and Karel.

The controller <NUM> may be configured to control operation of the components of the bead exerciser system <NUM>. For example, the controller <NUM> may be configured to provide instructions to the conveyor <NUM>, lift cylinder <NUM>, drum roller <NUM>, pinch rollers <NUM>, actuator <NUM>, etc. The controller <NUM> may be in communication with these components, among others, including display <NUM>. The display <NUM> may be a human machine interface (HMI) configured to receive commands from system operators. The display <NUM> may also be configured to display data relevant to the operation of the system <NUM>. In one example, the display <NUM> may display alerts, provide feedback to the operators, etc. The display <NUM> may be a touchscreen configured to receive input, as well as include other buttons and controls. The display <NUM> may provide images, text, etc., to the operator and may be made of light emitting diodes (LEDs), liquid crystal displays, etc. An example display screen is illustrated in <FIG>.

The actuator <NUM> may be configured to transmit actuator data to the controller <NUM>. The actuator data may include feedback data regarding the state of the driver. This data may include linear position of the driver and arms <NUM>, force data, pressure, current, torque of the driver motor, etc. The controller <NUM> may use this data to determine certain characteristics of the system <NUM>, include status, verifications, etc. Specifically, the controller <NUM> may determine a force being applied at the wheel beads by the pinch rollers <NUM>. The actuator data may include one or more of the above example data metrics. This may especially be the case in the event that multiple sensors are present, or more than one type of sensor.

The controller <NUM> may determine the force based on the data supplied from the actuator <NUM>. In one example, the servo motor torque of the actuator <NUM> may be used to calculate the force. In another example, the actuator <NUM> may supply a force to the controller from a force sensor <NUM>. The force sensor <NUM> may detect a resistive load applied at the pinch rollers <NUM> and output that resistance to the controller <NUM>. The controller <NUM> may determine, based on this resistance and state of the actuator <NUM>, the applied force of the pinch rollers <NUM>. The force sensor <NUM>, may include an electric force sensing resistor, or torque sensor, or any device capable of detecting or determining a force. In the example where a current sensor may measure the current of the servo motor. The current may be used to determine the force. More than one sensor, or type of sensor may be included. For example, the system <NUM> may include both a force sensor <NUM> and the current sensor. The controller <NUM> may determine the force based on data supplied by both sensors. In this example, a first force may be determined from a first set of data received from the force sensor <NUM> and a second force may be determined from a second set of data received from the current sensor. The first and second forces may then be averaged to determine the force.

Upon determining the force, the controller <NUM> may then use the calculated force to verify the tire status based on the exercising of the tire beads. The verification may alert operators of the system <NUM> of potential operating issues with the system <NUM>, or quality issues with the wheel assembly.

The controller <NUM> may interface with memory <NUM> to verify and check the actuator data. For example, the memory <NUM> may maintain a look-up table configured to maintain various thresholds. The thresholds may include the predefined thresholds, such as predefined forces, positions, distances, etc. The thresholds may be specific to a wheel assembly <NUM> size, type, make, model, etc. The thresholds may be applied in response to the specific tire attributes being recognized, or by operator input at the display <NUM>. The thresholds may also be continually updated based on new data, inputs, etc. For example, during a set up phase, the threshold for force may be initially set by an initial actuator data indicating a pinch force of a test tire. This is described in greater detail below with respect to <FIG>.

In one example, the actuator <NUM> may supply the actuator data to the controller <NUM> indicating a force and a driver position. The driver position may indicate the location of the arms <NUM>. The controller <NUM> may evaluate the actuator data by comparing the location of the arms with an expected force. If the received force is not within a range of the expected force, the controller <NUM> may recognize an issue with the tire. For example, if the received force is lower than a lower threshold, than the controller <NUM> may determine that the tire is deflated. If the received force is higher than a higher threshold, than the controller <NUM> may determine that the tire is over inflated. This is just one example of wheel assembly verification. The controller <NUM> may also determine that the wrong wheel assembly <NUM> has been loaded at the conveyor <NUM>.

<FIG> illustrates a block diagram of a portion of the bead exerciser system <NUM> including the actuator <NUM>, controller <NUM> and display <NUM>. The actuator <NUM>, as explained, may include a force sensor <NUM>. The force sensor <NUM> may be configured to detect a 'pinch' force of the pinch rollers <NUM>. The controller <NUM> may receive the actuator data, including driver position and force, from the actuator <NUM> and use the actuator data to verify the current wheel assembly <NUM>. The controller <NUM> may compare the actuator data to expected thresholds, may calculate a force of the pinch rollers <NUM>, and verify that the drive data is a position within a predefined threshold. That is, at a specific pinch roller distance D or position of the pinch rollers, a certain force is expected. If the controller <NUM> detects a discrepancy with the data where the drive data or calculated force falls outside of the predefined threshold for a certain position, the controller <NUM> may transmit a command to the display <NUM> to indicate an alert. For example, the alert could be "force exceeding limit," "force below limit," "cease operation," "low tire pressure," "wrong part", etc..

<FIG> illustrates an example flow chart for the bead exerciser system <NUM>. The process <NUM> begins at block <NUM> where the controller <NUM> receives the actuator data from the actuator <NUM>.

At block <NUM>, the controller <NUM> receives or determines the pinch force. As explained above, the pinch force may be calculated based on a resistance and known position of the arms <NUM>. The pinch force may also be received as part of the actuator data from the force sensor <NUM> within the driver.

At block <NUM>, the controller <NUM> may determine whether the force is within a predefined threshold. As explained above, the predefined threshold may include more than one threshold and may be associated with a specific tire size, assembly type, etc. The thresholds may be predetermined, but updated, via a look up table. If the force falls outsides of the threshold, or threshold range, the process proceeds to block <NUM>. If the force is within the threshold, or threshold range, the process <NUM> proceeds ends.

At block <NUM>, the controller <NUM> may instruct the display <NUM> to indicate an alert. As explained, the alert may be commensurate with the type of issue that the data and force may imply. For example, a low force may indicate a low tire pressure. A high force may indicate that the pinch rollers <NUM> have hit the rim and therefore maybe the wrong parts were used or inputted. Once the alert is issued, the process <NUM> may end.

<FIG> illustrates an example screen presented by the display <NUM>. In this example screen, the operator may enter wheel information, such as style number, dimensions, etc. These inputs may be used to determine the predefined thresholds as discussed earlier.

In addition to using force calculations to determine errors, force readings may also be used by the system <NUM> for iterative assembly learning. For example, certain force calculations may be used to teach offsets for a specific wheel/tire assembly. These offset values may be stored for future use. In one example, the pinch rollers may pinch the wheel/tire assembly until a force threshold is reached. Once the threshold is reached, the value for the distance D between the pinch rollers <NUM> may be saved with respect to the particular wheel/tire assembly. This value may be saved for future use in this system or others. Other force readings may be used as well to create expected distance thresholds between the pinch rollers, excepted forces at certain pinch roller distances, etc..

<FIG> illustrates an example flow chart for the bead exerciser system <NUM> where the system <NUM> is configured to store and recall certain thresholds. The process <NUM> begins at block <NUM> where the controller <NUM> instructs the pinch rollers <NUM> to actuate or pinch the tire. This instruction may come from a command at the display <NUM>. The display <NUM> may also receive an indication of the type or size of wheel assembly. That is, an operator or user may enter certain parameters at the display <NUM>. The controller <NUM> may in turn instruct the pinch rollers <NUM> and any other component of the system <NUM>, to act in response to these commands and inputs.

At block <NUM>, the controller <NUM> may determine whether the tire type is recognized. That is, is the type of tire stored in the memory <NUM>. The tire type may have been stored in the memory <NUM> previously by user input, a previous operation, etc. The look up tables within the memory may identify the tires by size, type, make, model, etc. If the tire type is recognized, the process proceeds to block <NUM>, if not, the process proceeds to block <NUM>.

At block <NUM>, the controller <NUM> may determine whether each of the predefined thresholds have been saved with respect to the specific tire. As explained above, the look-up table may be configured to maintain various thresholds. The thresholds may include the predefined thresholds, such as predefined forces, positions, distances, etc. In one example, the tire type may be associated with a force threshold, but not a position threshold. In another example, the tire type may be associated with each of the possible thresholds. That is, the controller <NUM> may determine whether additional threshold values should be stored with respect to the tire type. If a threshold value is already stored for each of the various thresholds, the process <NUM> proceeds to block <NUM>. If not, the process proceeds to block <NUM>.

At block <NUM>, the controller <NUM> may proceed to calibrate and verify the wheel assembly <NUM> similar to block <NUM> of <FIG>.

At block <NUM>, the controller <NUM> may receive feedback data such as the linear position of the driver and arms <NUM>, force data, pressure, current, torque of the driver motor, etc..

At block <NUM>, the controller <NUM> may update the lookup table within the memory <NUM> with threshold values derived from the feedback data. That is, any missing threshold value may be `filled in' during the verification of a wheel assembly <NUM> in order to provide a continuously updated database. Furthermore, the controller <NUM> may recognize trends in the feedback data where the feedback data of a certain tire type reflects a trend that may require one of the stored thresholds be adjusted.

Thus, the thresholds may also be continually updated based on new data, inputs, etc. For example, during a set up phase, the threshold for force may be initially set by an initial actuator data indicating a pinch force of a test tire.

The embodiments of the present disclosure generally provide for a plurality of circuits, electrical devices, and at least one controller. All references to the circuits, the at least one controller, and other electrical devices and the functionality provided by each, are not intended to be limited to encompassing only what is illustrated and described herein. While particular labels may be assigned to the various circuit(s), controller(s) and other electrical devices disclosed, such labels are not intended to limit the scope of operation for the various circuit(s), controller(s) and other electrical devices. Such circuit(s), controller(s) and other electrical devices may be combined with each other and/or separated in any manner based on the particular type of electrical implementation that is desired.

It is recognized that any controller as disclosed herein may include any number of microprocessors, integrated circuits, memory devices (e.g., FLASH, random access memory (RAM), read only memory (ROM), electrically programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), or other suitable variants thereof) and software which co-act with one another to perform operation(s) disclosed herein. In addition, any controller as disclosed utilizes any one or more microprocessors to execute a computer-program that is embodied in a non-transitory computer readable medium that is programmed to perform any number of the functions as disclosed. Further, any controller as provided herein includes a housing and the various number of microprocessors, integrated circuits, and memory devices ((e.g., FLASH, random access memory (RAM), read only memory (ROM), electrically programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM)) positioned within the housing. The controller(s) as disclosed also include hardware based inputs and outputs for receiving and transmitting data, respectively from and to other hardware based devices as discussed herein.

With regard to the processes, systems, methods, heuristics, etc., described herein, it should be understood that, although the steps of such processes, etc., have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes herein are provided for the purpose of illustrating certain embodiments, and should in no way be construed so as to limit the claims.

Claim 1:
A bead exerciser system (<NUM>) for an automated wheel assembly (<NUM>) comprising
a pair of pinch rollers (<NUM>) driven by a driver and configured to apply a force to a tire of a wheel assembly (<NUM>); the system being characterized by
a center lift configured to lift a wheel assembly (<NUM>) off of a conveyor belt;
a drum roller (<NUM>) configured to rotate the wheel assembly (<NUM>); and
a feedback component configured to detect a force of the tire against the pinch rollers; and
a controller (<NUM>) configured to receive the force from the feedback component and generate a command for an alert in response to the force falling outside of a predefined threshold range.