Patent Description:
The present invention relates to a highly automated modular plant for managing products, which can be managed by software.

Highly automated modular production plants managed by software are known. United States patent application <CIT> shows a reconfigurable integrated production system.

This system includes a plurality of production cells, each of which is associated with at least one step of the processing process.

The workpieces are moved inside each cell and are conveyed between one cell and another.

Such systems are often structurally and functionally complicated.

Further, such systems are bulky and for reasons of safety do not allow processing operators to move between the various cells.

One object of the present invention is to improve current production plants and generally automatic plants for managing products, so as to overcome the aforesaid limits of the prior art.

Another object of the present invention is to provide an automatic modular plant for managing products, which is organized in such a manner that excluding one modular work area does not compromise the production flow and introducing a new work area does not involve reconfiguring the plant.

Another object of the present invention is to provide an automatic modular plant for managing products that is reliable and versatile, that is able to adapt to different production needs.

Another object of the present invention is to provide an automatic modular plant for managing products, in particular a plant for processing components either in small batches or as single components (one piece flow).

Another object of the present invention is to provide an automatic modular plant for managing products in which the work of the operators who access the plant is functionally integrated with the automatic production cycle.

Another object of the present invention is to provide an automatic modular plant for managing products in which the safety of the operators who access the automatic modular plant is ensured.

Another object of the present invention is to provide an automatic modular plant for managing products in which it is easy to maintain and repair the machines.

These objects of the invention are achieved by a plant for managing products in accordance with claim <NUM>. Preferred embodiments of the invention are subject-matter of the dependent claims.

In order to better understand the invention, a description is given below of a nonlimiting exemplary embodiment thereof, illustrated in the attached drawings in which:.

With reference to the attached figures, a modular plant <NUM> is now disclosed for managing products, which is visible in <FIG>. The plant <NUM> can work in a completely automated or partially automated manner, in particular an embodiment will be analyzed of a plant <NUM> for processing mechanical components in small batches or as single components (one piece flow) by operations of chip removal from a bar.

The base unit of the modular plant <NUM> consists of a work area <NUM> bounded by perimeter walls <NUM>, at least one of which is provided with at least one access <NUM> for accessing the modular plant <NUM>. In the embodiment of <FIG>, the walls bound a work area <NUM> having a square shape. The possibility is not ruled out of using virtual alternatives such as photoelectric barriers, laser scanners or a combination of physical and virtual boundaries to bound the work area <NUM>.

The plant <NUM> consists of a plurality of work areas <NUM>. In <FIG>, part of the plant <NUM> is shown consisting of four work areas <NUM> assembled near one another. Transit corridors <NUM> are formed between two work areas <NUM>.

Each work area <NUM> contains at least one robotic unit <NUM> for moving and handling mechanical components being processed and objects inherent to processing and communicates with at least one other adjacent work area <NUM> by at least one automated overhead conveying unit <NUM>, arranged above the separating walls <NUM> of the work areas <NUM> and passing above the corridors <NUM> that are featured between two different work areas <NUM>.

Possibly, in the same work area <NUM>, more than one overhead conveying unit <NUM> can be installed to connect a plurality of work areas <NUM> together. For example, in the work area <NUM> shown in <FIG>, there are four overhead conveying units <NUM>, one for each side of the square work area <NUM>, arranged perpendicularly and above the walls <NUM> of the area <NUM>.

With reference to <FIG>, inside the work area <NUM>, there may also be a processing station <NUM> for the mechanical components associated operationally with the robotic unit <NUM>.

Each work area <NUM> is provided with control panels <NUM> for the operation of the electric units in the area <NUM>, like the robotic unit <NUM>, the processing station/s <NUM>, the overhead conveying units <NUM>, etc..

Further, each work area <NUM> is connected to supply lines <NUM> for the supply of energy, air, fluids, and data. In the embodiment of <FIG>, the supply lines <NUM> are arranged above the work area <NUM> and follow the perimeter bounded by the walls <NUM>. Other possible solutions for the position of the supply lines <NUM> are not ruled out.

The work area <NUM> can also contain internally storage units that are not shown in the attached figures, which are suitable for containing products being processed or objects inherent to processing. The area <NUM> can also contain movable guards that are suitable for compartmentalizing the work area <NUM> into different zones. In this manner, the operator accesses the inside of one of the isolated zones of work area <NUM> in total safety, without stopping the production cycle of the other zones in the same work area <NUM>.

In <FIG>, the automated overhead conveying unit <NUM> is shown. Each overhead conveying unit <NUM> is supported by supports <NUM>. In the embodiment shown in the attached figures, the supports <NUM> are fixed to the inner floor of each of the work areas <NUM> that the conveying unit <NUM> puts in communication. The possibility is not ruled out that the supports <NUM> are fixed to the ceiling of the structure that houses the plant <NUM> or to the perimeter walls <NUM> if they are physical.

The overhead conveying unit <NUM> comprises a box-shaped outer casing <NUM>. In the shown embodiment, the outer casing <NUM> is devoid of the summit surface.

According to the invention, on the side surfaces <NUM> and <NUM> that face the work areas <NUM> connected by the overhead conveying unit <NUM>, openings <NUM> and <NUM> are obtained respectively that are necessary for permitting the robotic unit <NUM> to handle the mechanical components and the objects inherent to processing conveyed on the overhead conveying unit <NUM>.

Inside the cavity defined by the box-shaped casing <NUM>, there is a fixed guide <NUM>, which, in the embodiment shown, bounds a circuit having an oval shape. The possibility of using guides <NUM> having a different shape is not ruled out.

A plurality of conveying plates <NUM> circulate along the fixed guide <NUM>: the robotic handling units <NUM> place on the conveying plates <NUM> the objects to be conveyed and pick the objects to be conveyed therefrom once conveyed to the desired work area <NUM>. The conveying plates <NUM> are connected to anchoring systems, which for the sake of simplicity are not shown in the attached figures, and are moved by one or more dragging groups <NUM>.

One embodiment of the conveying plates <NUM> is shown in <FIG>. The upper surface <NUM> of the plate comprises according to the invention coupling elements <NUM>, <NUM>, <NUM> designed for receiving each type of object or product that it is necessary to convey from one work area <NUM> to the other inside the plant <NUM>. The coupling elements <NUM>, <NUM>, <NUM> have to ensure the orientation and stability of the object during the movement step along the fixed guide <NUM>.

The central seat <NUM> is shaped to receive the pallets on which the bar pieces are clamped that will have to be processed at the different work areas <NUM> to provide the final mechanical component. In <FIG>, a coupling between the conveying plate <NUM> and the pallet with a component being processed is shown near the opening <NUM>. The side seats <NUM> are on the other hand shaped for receiving other objects inherent to the processing, like work tools. The pins <NUM> on the other hand perform the task of retaining grippers for robots and boxes containing for example scrap, chips, pieces, etc..

The lower surface <NUM> of the plate <NUM> comprises coupling elements <NUM> for coupling with the fixed guide <NUM> fitted to a support <NUM> fixed on the lower surface <NUM>. In the embodiment shown in <FIG>, there are four coupling elements <NUM> of cylindrical shape on which annular grooves <NUM> are obtained that are suitable for coming into contact with the side portions of the fixed guide <NUM>. Owing to the coupling elements <NUM>, the plate <NUM> is maintained stably in position whilst it is moved by the dragging groups <NUM> along the fixed guide <NUM>, so as to ensure correct conveying of the mechanical components or of the objects inherent to the processing.

The work area <NUM> can possibly provide also one exchange position <NUM> for exchanging objects with the outside, obtained near one of the perimeter walls <NUM>. The work area <NUM> provided with exchange position <NUM> is shown in <FIG>. The exchange position <NUM>, in this particular embodiment, comprises a rotating circular table <NUM>. Other possible embodiments of the exchange position <NUM> are not ruled out, such as for example a linear or loop guide system.

A first half <NUM> of the rotating table <NUM> is located inside the work area <NUM>, whilst the second half <NUM> is located outside the work area <NUM>. The two halves <NUM>, <NUM> are separated by a separating means <NUM>, which can be of a physical or virtual type. In the embodiment of <FIG>, the separating means <NUM> is a plate fixed perpendicularly to the table <NUM> and isolates the outer space from the work area <NUM>. On the table <NUM>, there are the same coupling elements <NUM>, <NUM>, <NUM> obtained on the conveying plate <NUM>, on which objects can be arranged that are to be taken outside or inside the work area <NUM>.

The plant <NUM>, consisting of a plurality of work areas <NUM> as disclosed, can work automatically. Possibly, if necessary or preferred, it is also possible to use workers to perform certain functions such as for example quality control.

The distance that separates two adjacent work areas has to be such as to create a corridor <NUM> that is wide enough to permit the transit of operators who access the plant <NUM> and of corresponding operating tools, such as for example forklift and scaffoldings.

In the disclosed embodiment, the plant <NUM> is set up to manufacture mechanical components mainly by chip removal techniques. With reference to <FIG>, the bar piece <NUM> to be processed is placed and clamped on a pallet <NUM>, forming the pallet/bar assembly <NUM>. The pallets with bar <NUM> start to circulate from one work area <NUM> to another, where at the processing stations <NUM> of the various work areas <NUM>, the bar piece <NUM> is altered until it takes on the final shape of the component.

In order to centre, place and clamp the bar piece <NUM> on the pallet, a centring and locking device <NUM> is used that is shown in <FIG>. The centring and locking device <NUM> consists of a main body <NUM> to which a head portion <NUM> is fitted. The centring and locking device <NUM> is movable along guides <NUM> and <NUM> that are perpendicular to one another whilst the head portion <NUM> is movable along guides <NUM> fitted to the main body <NUM>.

Initially, a robotic unit <NUM> deposits the pallet <NUM> on the end of the head portion <NUM>. The centring and locking device <NUM> approaches a sawing machine <NUM> where the bar is arranged from which the bar piece <NUM> will be cut to be clamped on the pallet <NUM>. Through coordinated movements along the guides <NUM>, <NUM>, the head portion <NUM> is arranged on an axis with the bar from which the bar piece <NUM> will be cut. Subsequently, the centring and locking device <NUM> moves along the guide <NUM> so as to bring the head portion <NUM> to the bar from which the bar piece <NUM> will be cut. Once the bar and the pallet <NUM> are in contact, a screwing system <NUM> locks the bar and the pallet <NUM>. After locking, the sawing machine <NUM> cuts part of the bar <NUM>, on the basis of the type of processing that it will undergo inside the plant <NUM>. Once the cutting has been completed, the centring and locking device <NUM> moves away from the sawing machine <NUM> along the guide <NUM>. Lastly, a robotic unit <NUM> picks the pallet with bar <NUM>, which is sent to the work areas <NUM> or is placed at a processing station <NUM> or at an exchange position <NUM> of the same area.

The main advantage of the centring and locking device <NUM> is being able to perform cutting actions when the bar piece <NUM> is already placed and clamped on the pallet <NUM>.

The pallets with bar <NUM>, the tools and the objects inherent to the processing are handled by the robotic units <NUM> in each work area <NUM>.

Once the general object has been picked, it can be placed at the processing station <NUM>, at the exchange position <NUM> (if featured), in warehouses (if featured) or can be placed on the only or on one of the overhead conveying units <NUM> so that it can be moved to a subsequent work area <NUM>.

The height of the overhead conveying unit <NUM> has to be such as to be easily reached by the robotic unit <NUM> featured in the work areas <NUM> and to enable operators and instruments to transit with facility through the corridors <NUM> between the various work areas <NUM>.

The side surfaces <NUM> of the overhead conveying unit <NUM>, facing the corridor <NUM> featured between two adjacent work areas <NUM> and connected by the overhead conveying unit <NUM>, have a height that is such as not to permit the accidental fall of moving objects onto the overhead conveying unit <NUM> in the corridor <NUM> below, so as to avoid possible accidents to the operators moving along the corridors <NUM> of the plant <NUM>.

The motion of the conveying plates <NUM> along the fixed guide <NUM> is synchronized with the movement of the departure robotic unit <NUM>, in such a way that there is a conveying plate <NUM> near the opening <NUM> or <NUM> ready to receive the object to be conveyed. Once the object is secured in the relative coupling element <NUM>, <NUM>, <NUM>, the conveying plate <NUM> starts to move along the fixed guide <NUM> to the opposite end of the overhead conveying unit <NUM>. The plate <NUM> stops near the opening <NUM>, <NUM> opposite the opening where the object has been loaded. Subsequently the object is picked from the robotic unit <NUM> of the destination work area <NUM>.

Another function that can be performed by the overhead conveying unit <NUM> is temporary parking of objects inherent to processing, such as tools, grippers, pallets with bars <NUM>, boxes for collecting chips, scrap etc..

The walls <NUM> of the work area mainly perform two functions. The first function consists of separating and functionally circumscribing different work areas <NUM> having different functions, i.e. provided with different processing stations <NUM>. The second function consists of protecting operators who access the plant <NUM>, to avoid possible workplace health hazards for operators.

Owing to the walls <NUM>, if they are physical barriers, any malfunction that may harm the health of an operator working at the plant <NUM> remains, at least initially, circumscribed inside the work area <NUM>. If on the other hand the separating walls are of virtual type, as soon as the operator traverses the separating walls that are of virtual type, the automatic function of the area <NUM> is interrupted, preventing possible hazards.

Access <NUM> to each work area <NUM> remains shut during the operating step of the robotic unit <NUM> and can be crossed only when the robotic unit <NUM> is disabled. The functions performed by the machines inside the work area <NUM> are automated, thus the operator enters through the point of access <NUM> only during the maintenance step or repair in the event of a machine malfunction. The maintenance operator gains access in total safety, once automatic operation of the machines is disabled and there is certainty that there are no severe health hazards for the operator inside.

The operator can interact with the component being processed, picking other tools and other objects inherent to the processing featured in the work areas <NUM> by the exchange position <NUM>. Alternatively, the operator can place tools and other objects inherent to the processing inside the work area <NUM>.

The robotic unit <NUM> of the work area <NUM> concerned inserts the pallet with the component being processed <NUM>, which has to be subjected to manual work operations by the operator, or other objects inherent to the processing, that have to be picked by the operator, in the appropriate coupling elements <NUM>, <NUM>, <NUM> of the inner half <NUM> of the rotating table <NUM>.

Through a command of the operator, the table <NUM> rotates by half a revolution, exposing the inner half <NUM>, with the pallets <NUM> or other objects inserted, outside the work area <NUM>, whereas the outer half <NUM> faces inside the work area <NUM>.

Alternatively, the operator can insert inside the appropriate coupling elements <NUM>,<NUM>,<NUM>, featured on the outer half <NUM>, pallets with bars <NUM> or other objects inherent to the processing to be sent inside the work area <NUM>, then rotate by half a revolution the table <NUM> so as to face the outer half <NUM> inside the work area <NUM>.

There are no limitations to the shape and dimensions of the work areas provided that they are functionally integrated inside the plant and ensure safety and convenience for the operator if provided inside the plant.

The expansion of the work areas depends on multiple factors, such as the dimensions of the building in which the plant is assembled and the number of machines featured inside the work area.

The possibility is not ruled out of associating with the same work area multiple processing stations, which are operationally associated with multiple robot units.

Owing to the plant as disclosed, the limits of the prior art have been overcome. The modular nature of the work areas enables automatic and at the same time flexible processing plants to be devised that are thus adaptable to the quantity of processing tasks necessary for obtaining the final mechanical component.

The functional subdivision into work areas and the presence of overhead conveying units results in the presence of a network of corridors that run between the work areas. The operators are able to move safely between the corridors, which are separated by the work zones separated by the walls of the work areas. Further, maintenance of the various machines of the plant is simplified and easy to perform.

Claim 1:
Plant (<NUM>) for managing products, comprising a plurality of work areas (<NUM>), each bounded by perimeter walls (<NUM>), each work area (<NUM>) comprising at least one robotic unit (<NUM>) for moving and handling the products, and wherein the work areas (<NUM>) are connected together by at least one overhead conveying unit (<NUM>) for conveying products from one work area (<NUM>) to another, characterized in that the overhead conveying unit (<NUM>) comprises an outer casing (<NUM>), provided with openings (<NUM>, <NUM>) obtained on the side surfaces (<NUM>, <NUM>) facing the work areas (<NUM>) and provided with a fixed guide (<NUM>) fitted in the cavity formed by the outer casing (<NUM>) on which a plurality of conveying plates (<NUM>) move, wherein on the upper surface (<NUM>) of the conveying plate (<NUM>) coupling elements (<NUM><NUM>, <NUM>) are obtained that are suitable for receiving pallets (<NUM>) with components being processed and other objects inherent to processing that it is necessary to convey from one work area (<NUM>) to the other inside the processing plant (<NUM>).