Patent Description:
<CIT>) discloses an automated method of assembling or processing components using computer numerical controlled drives to decouple the stages of delivering components to a tool, into a series of separately programmable stages, namely, a component loading stage, a component separating stage, an accelerating stage, and a delivery stage, wherein the timing, position, speed, velocity, and acceleration of each component during each stage is selected through programming of the computer numerical controls.

<CIT>) discloses a device, system and method of automated manufacture comprising: delivering a workpiece with a delivery device; receiving the workpiece with a receiving device, the delivering of the workpiece and the receiving of the workpiece being electronically synchronized; processing the workpiece with a processing tool while the workpiece is on the receiving device; transferring the workpiece to a completion device, the ejection of the workpiece and the transferring of the workpiece being electronically synchronized. In particular the workpiece may comprise: a platform with mounts supporting a first component in a selected orientation; and a locating surface, the method comprising: engaging and disengaging the locating surface of the workpiece with releasable connectors on the delivery device, on the receiving device and on the completion device.

<CIT> discloses a method of mass producing different products in an automated production station and corresponding station having a plurality of part-processing devices, wherein workpieces are identified and corresponding control parameters are retrieved for their processing.

The following summary is intended to introduce the reader to various aspects of the applicant's teaching, but not to define any invention.

The various embodiments described herein generally relate to methods (and associated systems) for mass producing different products in an automated production station having a plurality of part-processing devices.

The drawings included herewith are for illustrating various examples of apparatuses, systems, and processes of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:.

Embodiments of the present invention are set out in the appended claims.

It is possible that an apparatus, system, or process described below is not an embodiment.

A production process can involve processing (e.g. transferring, transporting, handling, manipulating, assembling, etc.) parts to produce a product. During the production process, the part requiring further processing (for example, a subcomponent or partially finished product) can be referred to as a workpiece. The workpiece can be moved through a production station among various part-processing devices that perform the various operations on the workpiece(s) in production of the product. In some examples, such production processes can utilize a large number of standard, multi-purpose, re-configurable machines for performing specific operations on the workpiece(s) in production of the product.

To introduce different parts/workpieces and/or produce different products, addition of machines and/or separate processing lines may be required. In some examples, limited space in production facilities may preclude such expansion. Certain machines may also require manual reconfiguration and retooling when switching between different parts and/or products for processing, which may contribute to production overhead and inefficiencies. Furthermore, in some examples, production of certain products may require use of only a subset of part-processing devices in the production station, with the remaining devices remaining idle and resulting in underutilization of available production assets.

According to some aspects of the present disclosure, an automated production station can accommodate different workpieces for producing different end products in a continuous mass production process, without necessarily requiring extensive additions and/or reconfiguration of production station assets when producing different products, and which may facilitate improved utilization of existing production station assets.

According to some aspects, the production station of the present disclosure can operate to distinguish between at least a first workpiece and a second workpiece fed into the production station for processing. The first workpiece can be for producing a first product in the production station and the second workpiece can be for producing a second product in the production station that is different from the first product. In response to identifying the first workpiece as being received in the production station, control parameters associated with the first workpiece are selected, and a plurality of part-processing devices in the production station are electronically synchronized based on the selected control parameters to perform coordinated operations on the first workpiece in production of the first product. In response to identifying the second workpiece as being received in the production station, control parameters associated with the second workpiece are selected, and the part-processing devices in the production station are electronically synchronized based on the selected control parameters to perform coordinated operations on the second workpiece in production of the second product. The identifying, selecting, and synchronizing steps for the first workpiece can be repeated a plurality of times for producing a plurality of the first products, and the identifying, selecting, and synchronizing steps for the second workpiece can be repeated a plurality of times for producing a plurality of the second products interchangeably with the first products in a continuous mass production process of the first and second products.

Referring to <FIG>, an example automated production station <NUM> is shown for producing different products. The production station <NUM> can include one or more part-processing devices <NUM>, a station control system <NUM>, a communication network <NUM>, and a system storage component <NUM>. Although only three part-processing devices 110a, 110b, and 110c are shown in <FIG>, the automated production station <NUM> may include fewer or more part-processing devices <NUM>.

The station control system <NUM> can include control interfaces that allow a user to electronically configure the automated production station <NUM>. The station control system <NUM> can select control parameters for the part-processing device <NUM> to perform coordinated operations. The control parameters can be determined by the station control system <NUM>, or received at the station control system <NUM> as input data. As shown in <FIG>, the station control system <NUM> includes a station storage component <NUM>, a station processor <NUM>, and a station communication component <NUM>.

The station storage component <NUM> can include RAM, ROM, one or more hard drives, one or more flash drives or some other suitable data storage elements such as disk drives. The station storage component <NUM> can include one or more databases for storing data related to the automated production station <NUM>. The station storage component <NUM> can store data in respect of the operation of the automated production station <NUM>, such as data in respect of the part-processing devices <NUM> and the coordinated operations being carried out by the part-processing devices <NUM>.

For example, the station storage component <NUM> can store data received from the part-processing devices <NUM>, data in respect of the coordinated operations delegated by the station control system <NUM>, property data in respect of each of the part-processing devices <NUM>, etc. The station storage component <NUM> can also store computer programs that are executable by the station processor <NUM> to facilitate communication between the station control system <NUM> and the part-processing devices <NUM>, and configuration of the part-processing devices <NUM>.

In some embodiments, the station storage component <NUM> can instead be the system storage component <NUM>, which is accessible via the communication network <NUM>.

In some embodiments, the station storage component <NUM> can store data that is more current based on the operation of the station control system <NUM>, and the system storage component <NUM> can store data that is considered by the station control system <NUM> to unlikely be used in the immediate future. For example, the station storage component <NUM> can store operating data and part-processing property data only for the part-processing devices <NUM> operating during a certain production run or day, whereas the system storage component <NUM> can store the data for all part-processing devices <NUM>, which is typically infrequently changed. In some embodiments, the system storage component <NUM> can be a third party data storage.

The station processor <NUM> can control the operation of the station control system <NUM>. The station processor <NUM> may be implemented any suitable processors, controllers, digital signal processors, graphics processing units, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), microcontrollers, and/or other suitably programmed or programmable logic circuits that can provide sufficient processing power depending on the configuration, purposes and requirements of the station control system <NUM>. In some embodiments, the station processor <NUM> can include more than one processor with each processor being configured to perform different dedicated tasks. The station processor <NUM> together with the processor at the part-processing devices <NUM> contribute to the control of the automated production station <NUM>.

The station communication component <NUM> can include any interface that enables the station control system <NUM> to communicate with various devices and other systems. For example, the station communication component <NUM> can facilitate communication with the other components of the automated production station <NUM>, such as the part-processing devices <NUM> and the system storage component <NUM> via the communication network <NUM>.

The station communication component <NUM> can include at least one of a serial port, a parallel port or a USB port, in some embodiments. The station communication component <NUM> may also include an interface to component via one or more of an Internet, Local Area Network (LAN), Ethernet, Firewire, modem, fiber, or digital subscriber line connection. Various combinations of these elements may be incorporated within the station communication component <NUM>. For example, the station communication component <NUM> may receive input from various input devices, such as a mouse, a keyboard, a touch screen, a thumbwheel, a track-pad, a track-ball, a card-reader, voice recognition software and the like depending on the requirements and implementation of the station control system <NUM>.

The communication network <NUM> can include any network capable of carrying data, including the Internet, Ethernet, plain old telephone service (POTS) line, public switch telephone network (PSTN), integrated services digital network (ISDN), digital subscriber line (DSL), coaxial cable, fiber optics, satellite, mobile, wireless (e.g. Wi-Fi, WiMAX), SS7 signaling network, fixed line, local area network, wide area network, and others, including any combination of these, capable of interfacing with, and enabling communication between the station control system <NUM>, the part-processing devices <NUM>, and the system storage component <NUM>.

For example, each part-processing device <NUM> and the station control system <NUM> may be equipped with a wireless communication interface to enable wireless communications according to a Wi-Fi protocol (e.g. IEEE <NUM> protocol or similar).

Similar to the station storage component <NUM>, the system storage component <NUM> can store information about the part-processing devices <NUM>, including operating data, profile data (e.g., servo-motor profile data), motion data with which the part-processing devices <NUM> operate (e.g., tool motion data), data in respect of products that the automated production station can produce, data in respect of parts or workpieces that may be used to produce the products.

Profile data, motion data, product data, part data, and workpiece data can be stored in the system storage component <NUM> for subsequent retrieval by the part-processing devices <NUM>. The part-processing devices <NUM> can download motion data, product data, part data, and workpiece data from the system storage component <NUM> via the communication network <NUM>, for example.

Profile data and motion data can be generated for the part-processing devices <NUM>. For example, tables representing the profile data and motion data of tools of the part-processing devices <NUM> can be imported and form the basis for the profile data and motion data, respectively. In another example, the station control system <NUM> can generate the motion data based on data collected by the part-processing device <NUM>.

In some embodiments, operating data can be stored in the system storage component <NUM>, and the operating data can be retrieved by the station control system <NUM> when needed. The station control system <NUM> can download the operating data from the system storage component <NUM> via the communication network <NUM>. Example operating data can include, but not limited to, a current position of one or more tooling of the part-processing device <NUM>, a current speed of one or more tooling of the part-processing device <NUM>, a current velocity of one or more tooling of the part-processing device <NUM>, and a current acceleration of one or more tooling of the part-processing device <NUM>. In some embodiments, the operating data, or at least some of the operating data, can be stored in the station storage component <NUM>.

In some embodiments, one or more computing devices (not shown in <FIG>) can communicate with the automated production station <NUM> via the communication network <NUM>. A user may electronically configure the automated production station <NUM> using the computing device. The computing device can include any device capable of communication with other devices through a network such as communication network <NUM>. The computing device can include a processor and memory, and may be an electronic tablet device, a personal computer, workstation, server, portable computer, mobile device, personal digital assistant, laptop, smart phone, WAP phone, an interactive television, video display terminals, gaming consoles, and portable electronic devices or any combination of these.

Reference is now made to <FIG>, which shows a block diagram of an example part-processing device <NUM>. The example part-processing device <NUM> can be part-processing devices 110a, 110b, 110c of the automated production station <NUM>. The part-processing device <NUM> includes a part-processing control system <NUM>, a sensor system <NUM>, one or more tooling components <NUM>, and a motion system <NUM>.

The part-processing control system <NUM> can include a processor <NUM>, a storage component (or memory) <NUM>, and a communication component <NUM>. The part-processing control system <NUM> can facilitate the operation of the part-processing device <NUM>. The part-processing control system <NUM> can include control interfaces that allow a user to electronically configure the part-processing device <NUM>. The part-processing control system <NUM> can collect and store motion data of the part-processing device <NUM> in the part-processing storage component <NUM>.

The processor <NUM> can include any suitable processors, controllers, digital signal processors. microcontrollers, and/or other suitably programmed or programmable logic circuits that can provide sufficient processing power depending on the configuration, purposes and requirements of the part-processing device <NUM>. In some embodiments, the processor <NUM> can include more than one processor with each processor being configured to perform different dedicated tasks.

The part-processing storage component <NUM> can store data to be used during the operation of the part-processing device <NUM> and/or to facilitate the operation of the part-processing device <NUM>. Example data can include operating data in respect of its operation, and data in respect of parts, workpieces, or the product etc..

In some embodiments, the part-processing storage component <NUM> can store software applications executable by the processor <NUM>. For example, the software application can facilitate communication with the station control system <NUM> and/or operation of the part-processing device <NUM>, including components thereof such as but not limited to tooling components <NUM>, pneumatic actuators, servo-motors, and others.

The communication component <NUM> can include any component for facilitating communication with the station control system <NUM> via the communication network <NUM>. For example, the communication component <NUM> can include a wireless transceiver for communicating within a wireless communications network.

The sensor system <NUM> can include one or more sensors for collecting data from the environment of the part-processing device <NUM>. For example, the sensor system <NUM> can include a LiDAR device (or other optical/laser, sonar, radar range-finding such as time-of-flight sensors). The sensor system <NUM> can include optical sensors, such as video cameras and systems (e.g., stereo vision).

The sensor system <NUM> can detect workpieces within a detection range. Furthermore, the sensor system <NUM> can detect different properties of the workpieces and generate identification data for the workpieces. The term "workpiece" used herein refers to a part or a partially-finished product. Parts can have different geometric properties, such as but not limited to, different types, shapes, and sizes. The terms "different parts" and/or "different products" used herein refers to parts having such different properties and not merely a plurality of identical parts.

The part-processing device <NUM> can receive control parameters from the station control system <NUM>, a control interface, or an external system. Based on the control parameters, the part-processing control system <NUM> can operate the part-processing device <NUM> to process a workpiece detected by the sensor system <NUM>.

In some embodiments, the part-processing device <NUM> can be equipped with one or more tooling components <NUM> for engaging with workpieces detected by the sensor system <NUM>. Tooling components <NUM> can be used to present a part or process a part. Example tooling components <NUM> can include screws or end of arm tooling. The operation of the tooling components <NUM> can be controlled by the part-processing control system <NUM> and, in some embodiments, with consideration of the data collected by the sensor system <NUM>.

Part-processing devices <NUM> can be equipped with a motion system <NUM> for facilitating motion of the part-processing devices <NUM> or components thereof, such as sensors <NUM> or tooling components <NUM>. The motion system <NUM> can include one or more pneumatic actuators and/or servo-motors.

Part-processing devices <NUM> can undergo testing or validation. Testing or validation can determine the operation of the part-processing device <NUM> satisfies certain requirements, such as accuracy, reliability, and speed. Specialized testing and validation may also be required when the automated production station <NUM> is configured to produce certain products, such as but not limited to, food or beverage, vehicle, pharmaceutical, and medical products.

Reference is now made to <FIG>, which shows another schematic diagram of part-processing device <NUM> for the automated production station of <FIG>. Part-processing device <NUM> can handle one or more workpieces <NUM>. As shown in <FIG>, part-processing device <NUM> can include tooling components <NUM> such as one or more workpiece presentation tools <NUM>, <NUM> and one or more processing tools <NUM>, <NUM>.

Workpiece presentation tools <NUM>, <NUM> can, for example, be a part of one or more component delivery devices. In some embodiments, workpiece presentation tools <NUM>,<NUM> can include one or more screws for separating a lead component from an adjacent component. Accordingly, workpiece presentation tool <NUM>, <NUM> can be configured to: load one or more workpieces <NUM> at an intake position at a leading end of a stream of like workpieces <NUM>; separate workpiece <NUM> from the like workpieces <NUM>; accelerate workpiece <NUM>; and deliver workpiece <NUM> at a predetermined delivery time, delivery position, delivery speed and moving along a delivery trajectory. Workpiece presentation tool <NUM>, <NUM> can be configured to deliver workpieces <NUM> before loading one or more subsequent workpieces <NUM> at the intake position.

Processing tools <NUM>, <NUM> can, for example, be a part of one or more receiving devices. Processing tool <NUM> can be configured to conduct one or more value-added operation using one or more of workpieces <NUM>. For example, processing tool can be configured to assemble two or more of workpieces <NUM> together. In some embodiments, processing tool <NUM>, <NUM> can include one or more of assembly tools <NUM>, <NUM>. Accordingly, processing tool <NUM>, <NUM> can be configured to: receive one or more workpieces <NUM> while processing tool <NUM>, <NUM> moves along a processing tool trajectory configured to permit transfer of the component(s) <NUM> at the delivery position from workpiece presentation tool <NUM>, <NUM> to processing tool <NUM>, <NUM>; process workpiece <NUM>; and move workpiece <NUM> to an ejection position.

Part-processing device <NUM> can also include one or more part-processing control systems <NUM>. As described above, part-processing control system <NUM> can include one or more processors <NUM> and related accessories that enable control of at least some aspects of performance of workpiece presentation tool <NUM>, <NUM> and/or processing tool <NUM>, <NUM>. Processor <NUM> may, for example, be configured to make decisions regarding the control and operation of part-processing device <NUM> and cause one or more actions to be carried out based on machine-readable instructions including those stored within part-processing control system <NUM> and/or other machine-readable instructions received at part-processing control system <NUM> via wired and/or wireless communication.

Part-processing control system <NUM> can also include storage component <NUM>, such as memory(ies), memory data devices or register(s). Storage component <NUM> can include any storage means (e.g., devices) suitable for retrievably storing machine-readable instructions executable by processor <NUM> of part-processing control system <NUM> and other data. Storage component <NUM> can be non-volatile and can include erasable programmable read only memory (EPROM), flash memory, and/or other electromagnetic media suitable for storing electronic data signals in volatile or non-volatile, non-transient form. Storage component <NUM> can contain machine-readable instructions for execution by processor <NUM> and also other data related to the operation of workpiece presentation tool <NUM>, <NUM> and/or processing tool <NUM>, <NUM>. For example, storage component <NUM> can hold feedback data representative of feedback signals received from one or more sensors (e.g., encoders) associated with workpiece presentation tool <NUM>, <NUM> and/or processing tool <NUM>, <NUM>.

Machine-readable instructions stored in storage component <NUM> can cause part-processing control system <NUM> to cause the execution of various methods disclosed herein including the generation of one or more signals <NUM> (e.g., output data) useful in the operation of the part-processing device <NUM>. Such machine-readable instructions can be incorporated into one or more computer program products which can be stored on suitable medium or media. In some embodiments, the machine-readable instructions can be executable by processor <NUM> and configured to cause processor <NUM> to generate signals <NUM> useful in the synchronization of two or more operations carried out by workpiece presentation tool <NUM>, <NUM> and/or processing tool <NUM>, <NUM>. That is, the machine-readable instructions can be executable by processor <NUM> can cause the processor <NUM> to select control parameters for the operation of workpiece presentation tool <NUM>, <NUM> and/or processing tool <NUM>, <NUM> and generate signals <NUM> representative of the control parameters. For example, the machine-readable instructions can be configured to cause processor <NUM> to generate signals <NUM> useful in the synchronization of the delivery of workpiece <NUM> by workpiece presentation tool <NUM>, <NUM> and the receipt of workpiece <NUM> by component processing tool <NUM>, <NUM>.

The synchronization of two or more operations of workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM> can effectively include electronic camming and/or electronic gearing instead of mechanical cams and/or gears used in some existing applications. In various embodiments, the use of such electronic synchronization can provide more flexibility and improved performance of part-processing device <NUM> in comparison with conventional systems comprising mechanical synchronization means. Accordingly, in various embodiments, storage component <NUM> can hold data representative of one or more cam profiles to be used in the operation of workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM>. For example, such cam profile(s) can be in tabular form and can include corresponding positions representative of synchronized trajectories to be followed by workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM> during operation. In various embodiments, one of workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM> can be operated as a master device and the other of workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM> can be operated as a slave device executing movements based on the execution of movements by the master device in order to substantially maintain synchronization between the slave device and the master device. In some embodiments, part-processing device <NUM> can include one or more master devices and one or more respective slave devices. For example, one or more slave devices can be electronically cammed with a master device.

Accordingly, in various embodiments, the machine-readable instructions can be configured to cause processor <NUM> to generate signals <NUM> useful in causing electronic camming of the delivery of workpiece <NUM> by workpiece presentation tool <NUM>, <NUM> and of the receipt of workpiece <NUM> by processing tool <NUM>, <NUM>. In some embodiments, the machine-readable instructions can be configured to cause processor <NUM> to generate signals <NUM> useful in causing electronic camming of the loading, separation, acceleration and delivery of workpiece <NUM> by workpiece presentation tool <NUM>, <NUM>, and, of the receipt of workpiece <NUM> by processing tool <NUM>, <NUM>.

In various embodiments, the machine-readable instructions can be configured to cause data processor to generate signals <NUM> useful in controlling movement of workpiece <NUM> along the delivery trajectory and controlling movement of processing tool <NUM>, <NUM> along the processing tool trajectory. The delivery trajectory and the processing tool trajectory can be substantially tangential at the delivery position of workpiece <NUM>. Similarly, the machine-readable instructions can be configured to cause processor <NUM> to generate signals <NUM> useful in causing the delivery speed of workpiece <NUM> and a speed of processing tool <NUM>, <NUM> to be substantially the same when workpiece <NUM> is at the delivery position. Accordingly, the transfer of workpiece <NUM> from workpiece presentation tool <NUM>, <NUM> to processing tool <NUM>, <NUM> can be relatively smooth (i.e., substantially free of significant acceleration and/or jerk). The smooth transfer or workpiece <NUM> can also substantially reduce the risk of damaging workpiece <NUM> and can also permit the transfer of relatively delicate workpieces in some applications.

In various embodiments, the machine-readable instructions can be configured to cause processor <NUM> to generate signals <NUM> useful in controlling at least some aspect of the processing of the workpiece <NUM>. For example, such processing can include one or more value-added operations that can be carried out by processing tool <NUM>, <NUM>. Such value-added operation can include the assembly of two or more or workpieces <NUM> together. Such operation or other operations associated with part-processing device <NUM> can also be electronically synchronized with one or more of workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM> and can also operate as a master device or as a slave device depending on the specific application. Accordingly, the machine-readable instructions may, for example, be configured to cause processor <NUM> to generate signals <NUM> useful in causing electronic camming of the processing of workpiece <NUM> and one or more operations associated with workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM>. Alternatively, one or more operations conducted by workpiece presentation tool <NUM>, <NUM> or processing tool <NUM>, <NUM> can be under binary control rather than direct electronic synchronization. However, in some embodiments, the triggering of an operation via a binary control signal can be dependent on the position of the master device and can still be based on the cam profile.

As explained above, part-processing device <NUM> can include one or more servo-motors associated with workpiece presentation tool <NUM>, <NUM> and one or more servo-motors associated with processing tool <NUM>, <NUM>. Accordingly, the machine-readable instructions can be configured to cause processor <NUM> to generate signals useful in controlling the one or more servo-motors associated with workpiece presentation tool <NUM>,<NUM> and the one or more servo-motors associated with processing tool <NUM>, <NUM> according to a predetermined cam profile.

Reference is now made to <FIG>, which shows a flowchart illustrating a method <NUM> for handling workpieces. In some embodiments, method <NUM> can also include the performance of one or more valued-added operations. The devices and tools disclosed herein can be configured for cooperative operation with each other for performing all or part of method <NUM>. In various embodiments, method <NUM> can involve: loading a first workpiece <NUM> at an intake position at a leading end of a stream of like first workpieces <NUM> (see block <NUM>); separating first workpiece <NUM> from like first workpieces (see block <NUM>); accelerating first workpiece <NUM> (see block <NUM>); delivering first workpiece <NUM> at a predetermined delivery time, delivery position, delivery speed and moving along delivery trajectory using first workpiece presentation tool <NUM>, <NUM> (see block <NUM>); receiving first workpiece <NUM> at processing tool <NUM>, <NUM> moving along a processing tool trajectory configured to permit transfer of first workpiece <NUM> at the delivery position from first workpiece presentation tool <NUM>, <NUM> to processing tool <NUM>, <NUM> (see block <NUM>); processing first workpiece <NUM> (see block <NUM>); and moving the first workpiece <NUM> to an ejection position (see block <NUM>). The delivering of first workpiece <NUM> and the receiving of the first workpiece <NUM> can be electronically synchronized. Method <NUM> can also involve delivering workpiece <NUM> before loading a subsequent workpiece at the intake position.

As explained above, the delivery trajectory and the processing tool trajectory can be substantially tangential when first workpiece <NUM> is at the delivery position and the transfer of first workpiece <NUM> between workpiece presentation tool <NUM>, <NUM> and processing tool <NUM>, <NUM> is occurring. Also, the delivery speed of first workpiece <NUM> and a speed of processing tool <NUM>, <NUM> can be substantially the same when first workpiece <NUM> is at the delivery position and the transfer of first workpiece <NUM> is occurring. Method <NUM> can also involve receiving a second workpiece <NUM> at processing tool <NUM>, <NUM>. Method <NUM> can also involve assembling first workpiece <NUM> with second workpiece <NUM>. It should be understood that the first and second workpieces can be different from each other and can be configured for assembly with each other.

The delivering of first workpiece <NUM> can include a first computer numerically controlled operation and the receiving of first workpiece <NUM> can include a second computer numerically controlled operation. The first computer numerically controlled operation and the second computer numerically controlled operation can be electronically synchronized (e.g., cammed, geared) as explained above.

Similarly, the loading, separating, accelerating and delivering of first workpiece <NUM> can include a first computer numerically controlled operation and the receiving of first workpiece <NUM> can includes a second computer numerically controlled operation. The first computer numerically controlled operation and the second computer numerically controlled operation can be electronically synchronized (e.g., cammed, geared).

Instead or in addition, the receiving of first workpiece <NUM> can include a first computer numerically controlled operation and the processing of first workpiece <NUM> can include a second computer numerically controlled operation. The first computer numerically controlled operation and the second computer numerically controlled operation can be electronically synchronized (e.g., cammed, geared).

Reference is now made to <FIG>, which shows a schematic diagram of an example system <NUM> for processing workpieces using asynchronous feeding of workpieces and <FIG> is a schematic diagram of an example system <NUM> for processing workpieces using synchronous feeding of workpieces. Systems <NUM> and <NUM> can have similarities with part-processing device <NUM> explained above. In some embodiments, part-processing device <NUM> can be incorporated in whole or in part into one or both of systems <NUM> and <NUM>. Systems <NUM> and <NUM> can be implemented in automated production station <NUM>.

Systems <NUM> and <NUM> can be configured to carry out steps from or entire methods disclosed herein. Systems <NUM>, <NUM> can receive workpieces <NUM> and/or other raw materials as inputs; progressively add value to them via one or more processing tools <NUM>, <NUM>; and finally discharges them either as discrete finished products, as unfinished products or as rejected scrap (i.e., defective products).

Accordingly, systems <NUM> and <NUM> can receive raw materials and/or workpieces <NUM> from one or more feeders <NUM>. One or more feeders can be a track, or other devices configured to deliver its raw materials or workpieces <NUM> to one or more workpiece presentation tools <NUM>, <NUM>. The delivery from the feeders <NUM> can be done directly or via a respective buffer <NUM>. Each workpiece presentation tools <NUM>, <NUM> or a workpiece transfer device <NUM> can be numerically controlled and configured to deliver raw materials or workpieces to one or more processing tools <NUM>, <NUM>. Each processing tool <NUM>, <NUM> can add value to a workpiece <NUM> (i.e., part, component or work-in-progress) via one or more programmable process steps <NUM>. A given processing tool <NUM>, <NUM> can operate in parallel to and/or in series with one or more other processing tools <NUM>, <NUM>. Once the workpiece <NUM> passes through a final processing tool <NUM>, <NUM>, it can be discharged either as a successfully completed and validated finished product, as an unfinished product or as rejected scrap. Human interaction with systems <NUM> and <NUM> can be done via operator interface <NUM>.

The various elements described above can be controlled at least in part by software resources known as base software backplane. The backplane can be configured to permit various elements of system to carry out various control functions including: management of inputs and outputs; management of local control tasks, including programmable process steps <NUM> within processing tools <NUM>, <NUM> and local inspection tasks within validation stations <NUM>; communications between different elements in system <NUM>, <NUM> and communication with a human user via operator interface <NUM>.

In system <NUM> of <FIG>, feeders <NUM> may not be electronically synchronized with any other element or operation of system <NUM> and can be controlled by software backplane and the operation of feeders <NUM> can still be in harmony with other elements of system <NUM>. Accordingly, feeders <NUM> can supply workpieces <NUM> to workpiece presentation tools <NUM>, <NUM> via buffers <NUM> (e.g., asynchronous feeding) and feeders <NUM> can be operated to keep a sufficient supply of workpieces <NUM> in respective buffers <NUM>. Alternatively, in system <NUM> of <FIG>, feeders <NUM> can be electronically synchronized with one or more element or operation of system <NUM> and can under the control of a master device for example in order to provide synchronous feeding of workpieces <NUM> directly (i.e., without buffers) to workpiece presentation tools <NUM>, <NUM>.

At least part of part-processing device <NUM> and systems <NUM>, <NUM> can include a numerically synchronized control architecture. In various embodiments, workpiece transfer devices <NUM>, workpiece presentation tools <NUM>, <NUM> and processing tools <NUM>, <NUM> can be numerically controlled. Accordingly, movements of workpieces <NUM> such as raw materials and work-in-process through systems <NUM> and <NUM> can occur along programmable axes of motion, which can be either rotary or linear. Movement of tooling associated with programmable process steps <NUM> of processing tools <NUM>, <NUM> can also take place along programmable linear and/or rotary axes of motion.

Reference is now made to <FIG>, which shows a schematic diagram of example workpiece transfer devices <NUM> including validation stations <NUM>. Validation stations <NUM> can located at one or more feeders <NUM>, workpiece presentation tools <NUM>, <NUM>, workpiece transfer devices <NUM> and/or processing tools <NUM>, <NUM>. Validation stations <NUM> can include devices configured to conduct inspections, checks, or tests on one or more of workpieces <NUM> such as raw materials or work-in-process. At these points, such workpieces <NUM> can be eliminated from system <NUM>, <NUM> as scrap if they do not meet one or more predetermined inspection criteria. Validation station <NUM> can be configured to conduct an inspection operation on one or more of workpieces <NUM>. The inspection operation can be electronically synchronized with a master device of part-processing device <NUM>, and/or systems <NUM>, <NUM>.

Reference is now made to <FIG>, which shows an example automated production station for mass producing a plurality of different products. The automated production station <NUM> includes one or more part-processing devices <NUM>, a station control system <NUM>, and a station power system <NUM>, and one or more tracks <NUM>.

The production station <NUM> can be any type of production station for manufacturing any type of product. For example, the production station <NUM> can be configured to manufacture food or beverage, textile, computer or electronic, vehicle, chemical, pharmaceutical, medical, cosmetic, or other products. The production station <NUM> can perform discrete manufacturing processes to produce discrete products or perform process manufacturing processes to produce bulk or undifferentiated products. The particular arrangement and configuration of the production station <NUM> can depend on the type of the product being manufactured.

Station control system <NUM> is an example of station control system <NUM>. Station power system <NUM> can provide a common electrical power supply for the part-processing devices <NUM>, the one or more tracks <NUM>, and the station control system <NUM>. Station power system <NUM> can include but is not limited to power supplies, converters, inverters, and energy storage components.

Each of the one or more part-processing devices <NUM> is an example of a part-processing device <NUM>. The part-processing devices <NUM> can be configured to perform a specific processing task on a workpiece. For example, the one or more part-processing devices <NUM> can include one or more indexing devices that receive and index workpieces and one or more workpiece transfer devices that transfers the workpieces from the indexing devices to another part-processing device <NUM> for further processing.

The one or more part-processing devices <NUM> can include one or more transport tracks that move one or more workpieces among the part-processing devices <NUM>. The transport tracks can move the workpieces along the production station <NUM> for the part-processing devices <NUM> to successively process the workpieces. The transport tracks can include a plurality of carriages mounted to the track. Each carriage can receive and transport a plurality of the workpieces.

In some embodiments, the carriages are shaped to receive the workpieces. If the workpieces have different shapes, part-processing devices <NUM> may selectively transfer workpieces to carriages shaped to receive the workpieces. If the workpieces have a similar shape, the carriage can be common for different workpieces and part-processing devices <NUM> can transfer workpieces to the carriages indiscriminately.

In some embodiments, the workpieces can be transferred among the part-processing devices <NUM> without a transport track. That is, the part-processing devices <NUM> can transfer one or more workpieces to other part-processing devices <NUM> directly, without the transport track. Similarly, the part-processing devices <NUM> can receive one or more workpieces from other part-processing devices <NUM> directly.

During operation of the production station <NUM>, a workpiece can travel among the part-processing devices <NUM>. For example, a workpiece can travel from a part-processing device, such as part-processing device 110a, to a downstream part-processing device, such as part-processing device 110b. Each part-processing device <NUM> can progressively process the workpiece until a product is complete.

In some embodiments, the part-processing devices <NUM> can be configured to process a plurality of workpieces in parallel. That is, a part-processing device <NUM> can receive a plurality of workpieces, process the plurality of workpieces in parallel, and transfer the plurality of workpieces to another part-processing device <NUM> for further processing.

Each part-processing device <NUM> can include one or more tooling components <NUM> for processing a workpiece. The processing tasks performed by the tooling components <NUM> of a particular part-processing device <NUM> can be related to each other. For example, the tooling components <NUM> of a particular part-processing device <NUM> can perform sub-steps or sub-processes in the overall processing task accomplished by the part-processing device <NUM>. The tooling components <NUM> for a particular part-processing device <NUM> can, in some embodiments, be physically located proximate to each other. For example, the tooling components <NUM> for a particular part-processing device <NUM> may be housed within a common chassis or share a common power supply.

In some embodiments, the production station <NUM> can include one or more tracks <NUM>. As shown in <FIG>, one or more tracks <NUM> extend from the production station <NUM>. Each of the one or more tracks <NUM> can include a conveyor. In some embodiments, a track <NUM> can transport a plurality of different workpieces. The plurality of different workpieces on a track <NUM> can have any arrangement and orientation. For example, a track <NUM> can receive different workpieces in series or in parallel.

In some embodiments, a track <NUM> can be configured as an in-feed track to transport workpieces into the production station <NUM> for processing. In some embodiments, a track <NUM> can be configured as an out-feed track to transport workpieces or products from the production station <NUM>. Products may be transported out of the production station <NUM> after completion. Workpieces may be transported out of the production station <NUM> if they are surplus, not a component used in the products being produced, or have been identified as being defective. A workpiece may be identified as being defective if detected properties of the workpiece do not correspond to expected properties, as defined by part data for that type of part. In some embodiments, at least one of the one or more tracks <NUM> can be operable as both an in-feed track and an out-feed track.

Different configurations for the in-feed tracks and out-feed tracks are possible. For example, automated production station <NUM> can be configured to produce four different products, each product being output on one of four out-feed tracks. In another example, different products can be output on the same out-feed track.

Continuing with the example of four different products, each product can be assembled with two parts (e.g., a lid and a container body) and there can be different types of each part. For example, the lid can be round or square and the container body can be straight or curved. In some embodiments, both types of container bodies can be received at a first in-feed track and both types of lids can be received a second in-feed track. In other embodiments, a first type of lid and a first type of container body can be received at a first in-feed track and a second type of lid and a second type of container body can be received at a second in-feed track.

Reference is now made to <FIG>, which is a flowchart of an example method <NUM> of mass producing a plurality of different products using an automated production station like that of <FIG>. The method <NUM> can be implemented by an automated production station, such as automated production station <NUM>, having a plurality of part-processing devices, such as part-processing devices <NUM>.

Method <NUM> can begin at <NUM>, when a first workpiece is received in the production station <NUM> and identified. The first workpiece can be received at a part-processing device <NUM>. The identification of the first workpiece can involve determining the geometry of the first workpiece. The geometry of the first workpiece can be used to determine what the first workpiece is - whether the first workpiece is a part or a partially-assembled workpiece. Furthermore, parts can have different geometric properties, such as but not limited to, different types, shapes, and sizes.

In some embodiments, the sensor system <NUM> of the part-processing device <NUM> can include a scanner that can be used to scan the workpiece and generate identification data. For example, a part-processing device <NUM> can have an optical scanner that generates image data as identification data.

The processor <NUM> can receive the identification data and determine whether to further process the first workpiece. For example, the part-processing device <NUM> can determine that a part does not correspond to profile data for that part. For example, a cap may have a deformation, possibly due to a defect or damage. The part-processing device <NUM> can determine that the part should not be processed and divert the part out of the production station <NUM>.

In another example, the part-processing device <NUM> can be configured to produce a bottle with a square cap/closure. However, the part-processing device <NUM> can identify a round cap and determine that the round cap is not a component of the current product being produced. As such, the part-processing device <NUM> can determine that the round cap should not be processed. In some embodiments, a downstream part-processing device <NUM> in the production station <NUM> can process the round cap. In other embodiments, the part-processing device <NUM> can divert the round cap out of the production station <NUM>.

In another example, the part-processing device <NUM> can identify the part as being a component of a product currently being produced. However, the part may not be processed because the capacity of the production station <NUM> is at a pre-determined capacity. The capacity of the production station <NUM> can be based on a capacity of one or more part-processing devices <NUM> in the production station <NUM>, a productivity rate of the one or more part-processing devices <NUM>, or the supply of other components used for the product currently being produced. If it is determined that the part cannot be processed, the part-processing device <NUM> can divert the part out of the production station <NUM>. In other embodiments, the part-processing device <NUM> can hold the part and process the part when capacity becomes available.

At <NUM>, the method can involve selecting control parameters associated with the first workpiece identified in <NUM>. Processor <NUM> can be configured to receive the identification data from the scanner and analyze the identification data. For example, a processor can receive the image data from the optical scanner and select the control parameters based on the image data received.

At <NUM>, the part-processing devices <NUM> can be electronically synchronized based on the control parameters selected in <NUM> to perform coordinated operations on the first workpiece for producing a first product. For example, a part-processing device <NUM> can use one or more tooling components <NUM> to engage the first workpiece to adjust its orientation, transfer the first workpiece, or mate a part to the first workpiece, etc..

At <NUM>, a second workpiece is received in the production station <NUM> and identified. The second workpiece is a different type from the first workpiece. Similar to <NUM>, the identification of the second workpiece can involve determining what the second workpiece is.

In some embodiments, the second workpiece can be received at a different part-processing device <NUM> from the first workpiece. For example, the first workpiece can be received and identified at part-processing device 110a and the second workpiece can be received and identified at part-processing device 110b.

In some embodiments, the second workpiece can be received at a common part-processing device <NUM> as the first workpiece. For example, both the first workpiece and the second workpiece can be received and identified at part-processing device 110a.

In some embodiments, the first workpiece and the second workpiece are fed into the production station <NUM> on a common in-feed track. The common part-processing device <NUM> can receive both the first workpiece and the second workpiece from the common in-feed track. In other embodiments, a first part-processing device 110a can identify and retrieve the first workpiece from the common in-feed track and a second part-processing device 110b can identify and retrieve the second workpiece from the common in-feed track. The first part-processing device 110a can identify the second workpiece on the common in-feed track and leave (i.e., not retrieve) the second workpiece on the common in-feed track. Similarly, the second part-processing device 110b can identify the first workpiece on the common in-feed track and leave (i.e., not retrieve) the first workpiece on the common in-feed track.

The processor <NUM> can receive the identification data and determine whether to further process the second workpiece. Determining whether to further process the second workpiece can be similar to determining whether to further process the first workpiece at <NUM>. For example, the part-processing device <NUM> can determine that a part does not correspond to profile data for that part, a part is not a component of the product currently produced, or that a part cannot be processed.

At <NUM>, the method can involve selecting control parameters associated with the second workpiece identified in <NUM>. Similar to selecting control parameters associated with the first workpiece at <NUM>, processor <NUM> can be configured to receive the identification data for the second workpiece from the scanner and analyze the identification data.

At <NUM>, the part-processing devices <NUM> can be electronically synchronized based on the control parameters selected in <NUM> to perform coordinated operations on the second workpiece for producing a second product. Electronically synchronizing the part-processing devices <NUM> based on the control parameters selected in <NUM> can be similar to synchronizing the part-processing devices <NUM> based on the control parameters selected in <NUM>.

The method can continue repeating <NUM> to <NUM> a plurality of times for producing a plurality of the first products and repeating <NUM> to <NUM> a plurality of times for producing a plurality of the second products interchangeably with the first products.

Reference is now made to <FIG>, which shows a perspective view of an example part-processing devices for an automated production station <NUM>, including example indexing device 810a and an example workpiece transfer device <NUM>0b. Automated production station <NUM> is an example of an automated production station <NUM>. Furthermore, indexing device 810a and workpiece transfer device 810b are examples of part-processing devices <NUM>. Although only two part-processing devices 810a, 810b are shown in <FIG>, production station <NUM> can include fewer or more part-processing devices <NUM>.

The indexing device 810a can include a rotary indexing table <NUM> rotatable about a table axis. As can be seen in <FIG>, the rotary indexing table <NUM> can have a plurality of interchangeable sector plates 808a, 808b, 808c, and 808d.

The indexing device 810a also includes a plurality of first platforms 812a, 812b, 812d 012e (not shown in <FIG>), and 812d spaced apart from each other about the axis, and a plurality of second platforms 814a, 814b, 814c, and 814d spaced apart from each other and the first platforms <NUM> about the axis. Although indexing device 810a is shown as having four first platforms <NUM> and four second platforms <NUM> in <FIG>, it will be understood that fewer or more platforms is possible.

The rotary indexing table <NUM> has a plurality of retaining features for removably mounting the first and second platforms <NUM>, <NUM>. For example, the retaining feature can be an opening in a periphery of the table. Each sector plate can include at least one of retaining features. Each first and second platform <NUM>, <NUM> is removably mountable in any one of the retaining features. In some embodiments, the openings are specific to the first and second platforms - that is, the first platforms are only mountable to a first set of openings and the second platforms are only mountable to a second set of openings. In some embodiments, the first and second platforms can be affixed to the rotary indexing table <NUM>.

As shown in <FIG>, the workpieces <NUM>, <NUM>, and <NUM> can be shaped differently from each other. Each first platform <NUM> can have a first mount shaped for holding a first workpiece <NUM> in a selected orientation. First workpieces 802a, 802c can be received on corresponding first platforms 812a, 812c for indexing. Each second platform <NUM> can have a second mount shaped for holding a second workpiece <NUM> in a selected orientation, the second mount shaped differently from the first mount. Second workpieces 804a, 804b, 804c, and 804d can be received on corresponding second platforms 814a, 814b, 814c, and 814d for indexing.

In other embodiments, the platforms are not shaped for holding specific workpieces. Instead, each platform can have a mount shaped for holding any one of a plurality of the workpieces. That is, the shape of the workpieces may be sufficiently similar so that the workpieces can be held by the same mount. For example, the first mount can also be shaped for holding the third workpiece <NUM> in a selected orientation. Third workpieces 806b, 806d (not shown in <FIG>) can be received on first platforms 812b, 812d (not shown in <FIG>) for indexing. That is, the first platform <NUM> can be common to the first workpieces <NUM> and the third workpieces <NUM>.

Reference is now made to <FIG>, which show the example workpiece transfer device 810b transferring a first workpiece 802c from the indexing device 810a for further processing, and <FIG>, which illustrate the example workpiece transfer device 810b transferring a third workpiece 806b from the indexing device 810a for further processing. The workpiece transfer device 810b can include one or more tooling components <NUM>, such as example tooling component <NUM>, for processing different workpieces <NUM>, <NUM>, <NUM> at <NUM> and <NUM>.

Workpieces <NUM>, <NUM>, <NUM> have different shapes that can require different tooling components <NUM>. In some embodiments, the workpiece transfer device 810b can have a first tooling for transferring the first workpieces <NUM> and a second tooling for transferring the second workpieces <NUM>. The workpiece transfer device 810b can automatically switch between the first tooling and the second tooling for performing operations on the first workpieces <NUM> and the second workpieces <NUM>, respectively.

In some embodiments, the workpiece transfer device 810b can use a common tooling component <NUM> for processing the different workpieces <NUM>, <NUM>, <NUM> at <NUM> and <NUM>. As shown in <FIG>, although workpieces <NUM>, <NUM>, <NUM> have different shapes, tooling component <NUM> can transfer each of the first workpieces <NUM>, the second workpieces <NUM>, and third workpieces <NUM>.

As shown in <FIG>, tooling <NUM> directly engages with the workpieces <NUM>, <NUM>, <NUM>. In some embodiments, the workpiece transfer device 810b can transfer workpieces <NUM>, <NUM>, <NUM> mounted in the first and second platforms <NUM>, <NUM>. That is, the workpiece transfer device 810b can use tooling to engage with the first and second platforms <NUM>, <NUM>. Furthermore, the workpiece transfer device 810b can use common tooling to engage either of the first and second platforms <NUM>, <NUM>. In other embodiments, a first tooling can directly engage the first platform <NUM> and a second tooling can directly engage the second platform <NUM>. The workpiece transfer device 810b can automatically switch between the first tooling and the second tooling, and vice versa.

In some embodiments, a workpiece transfer device 810b can mate a first workpiece <NUM> with a second workpiece <NUM> to assemble the first product and a third workpiece <NUM> with a second workpiece <NUM> to assemble the second product. In other embodiments, a first workpiece transfer device 810b can mate a first workpiece <NUM> with a second workpiece <NUM> to assemble the first product and a second workpiece transfer device 810b can mate a third workpiece <NUM> with a second workpiece <NUM> to assemble a second product.

In some embodiments, the common workpiece transfer device 810b that mates each of a first workpiece <NUM> and a third workpiece <NUM> with a respective second workpiece <NUM> can also divert the first product to an out-feed track that is different from the second product. That is, the common part-processing device 810b can divert the first product to a first out-feed track and the second product to a second out-feed track. In some embodiments, both the first product and the second product are transferred to a common out-feed track.

In some embodiments, the workpiece transfer device 810b can also mate a first workpiece <NUM> with a fourth workpiece received in the production station <NUM> instead of a second workpiece <NUM> to assemble a third product and a third workpiece <NUM> with a respective fourth workpiece to assemble a fourth product. A first workpiece transfer device 810b can mate a first workpiece <NUM> with a fourth workpiece and a second workpiece transfer device 810b can mate a third workpiece <NUM> with a fourth workpiece. Alternatively, a common workpiece transfer device 810b can mate each of a first workpiece <NUM> and a third workpiece <NUM> with a respective fourth workpiece.

In some embodiments, the common workpiece transfer device 810b that mates each of a first workpiece <NUM> and a third workpiece <NUM> with a fourth workpiece can also divert the third product to an out-feed track that is different from the fourth product. That is, the common part-processing device can divert the third product to a third out-feed track and the fourth product to a fourth out-feed track. In some embodiments, both the third product and the fourth product are transferred to a common out-feed track. Alternatives are possible. For example, each of the third product or the fourth product can be transferred to the first out-feed track for the first product, the second out-feed track for the second product, or the common out-feed track for the first and second products.

In illustration <NUM> of <FIG>, the workpiece transfer device 810b can move towards first workpiece 802c on the indexing device 810a. The indexing device 810a can rotate about its table axis so that the first workpiece 802c is proximate to the transport track 810c having carriage 842a. Second workpiece 804c is held in carriage 842a.

In illustration <NUM> of <FIG>, the workpiece transfer device 810b uses tooling <NUM> to engage the first workpiece 802c. In illustration <NUM> of <FIG>, the workpiece transfer device 810b moves the first workpiece 802c to carriage 842a. Although not shown, the workpiece transfer device 810b can release the first workpiece 802c to be mated with the second workpiece 804c in the carriage 842a. The transport track 810c can move carriage 842a to another part-processing device for further processing. The transport track <NUM>0c can move another carriage 842b to be positioned proximate to the indexing device 810a.

The indexing device 810a can rotate about its table axis so that the third workpiece 806b is positioned proximate to the transport track 810c, as shown in illustration <NUM> of <FIG>. Similar to illustrations <NUM>, <NUM>, and <NUM>, in illustrations <NUM>, <NUM>, and <NUM>, the workpiece transfer device 810b can move toward the third workpiece 806b on the indexing device 810a, engage the third workpiece 806b, and move the third workpiece 806b to carriage 842b.

Although only one workpiece is shown in carriage <NUM>, carriage <NUM> can receive and transport a plurality of workpieces. For example, carriage <NUM> can receive and transport a plurality of a first product, a plurality of a second product, or one of each of the first product and the second product.

It should be noted that terms of degree such as "substantially", "about" and "approximately" when used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of the modified term if this deviation would not negate the meaning of the term it modifies.

In addition, as used herein, the wording "and/or" is intended to represent an inclusive-or. That is, "X and/or Y" is intended to mean X or Y or both, for example. As a further example, "X, Y, and/or Z" is intended to mean X or Y or Z or any combination thereof.

It should be noted that the term "coupled" used herein indicates that two elements can be directly coupled to one another or coupled to one another through one or more intermediate elements.

The embodiments of the systems and methods described herein may be implemented in hardware or software, or a combination of both. These embodiments may be implemented in computer programs executing on programmable computers, each computer including at least one processor, a data storage system (including volatile memory or non-volatile memory or other data storage elements or a combination thereof), and at least one communication interface. For example and without limitation, the programmable computers (referred to below as computing devices) may be a server, network appliance, embedded device, computer expansion module, a personal computer, laptop, personal data assistant, cellular telephone, smart-phone device, tablet computer, a wireless device or any other computing device capable of being configured to carry out the methods described herein.

In some embodiments, the communication interface may be a network communication interface. In embodiments in which elements are combined, the communication interface may be a software communication interface, such as those for inter-process communication (IPC). In still other embodiments, there may be a combination of communication interfaces implemented as hardware, software, and combination thereof.

Program code may be applied to input data to perform the functions described herein and to generate output information. The output information is applied to one or more output devices, in known fashion.

Each program may be implemented in a high level procedural or object oriented programming and/or scripting language, or both, to communicate with a computer system. However, the programs may be implemented in assembly or machine language, if desired. Each such computer program may be stored on a storage media or a device (e.g. ROM, magnetic disk, optical disc) readable by a general or special purpose programmable computer, for configuring and operating the computer when the storage media or device is read by the computer to perform the procedures described herein. Embodiments of the system may also be considered to be implemented as a non-transitory computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner to perform the functions described herein.

Furthermore, the system, processes and methods of the described embodiments are capable of being distributed in a computer program product comprising a computer readable medium that bears computer usable instructions for one or more processors. The medium may be provided in various forms, including one or more diskettes, compact disks, tapes, chips, wireline transmissions, satellite transmissions, internet transmission or downloadings, magnetic and electronic storage media, digital and analog signals, and the like. The computer useable instructions may also be in various forms, including compiled and non-compiled code.

Claim 1:
A method of mass producing different products in an automated production station (<NUM>) having a plurality of part-processing devices (<NUM>), comprising:
a) identifying a first workpiece (<NUM>) received in the production station;
b) selecting control parameters associated with the first workpiece identified in (a);
c) electronically synchronizing the part-processing devices based on the control parameters selected in (b) to perform coordinated operations on the first workpiece for producing a first product, the operations including mating the first workpiece with a respective second workpiece (<NUM>) received in the production station for assembly of the first product;
d) identifying a third workpiece (<NUM>) received in the production station, the third workpiece shaped differently from the first workpiece;
e) selecting control parameters associated with the third workpiece identified in (d);
f) electronically synchronizing the part-processing devices based on the control parameters selected in (e) to perform coordinated operations on the third workpiece for producing a second product, the operations including mating the third workpiece with another respective second workpiece received in the production station for assembly of the second product, each second workpiece having a common shape different from that of the first and third workpieces; and
g) repeating (a) to (c) to produce a plurality of the first products and repeating (d) to (f) to produce a plurality of the second products interchangeably with the first products in a continuous mass production process.