Patent Description:
The present invention relates generally to automated manufacturing systems and, more particularly, to a system and method for automated assembly of components.

Automation plays an ever-increasing role in the manufacturing and assembly of products. As manufacturing systems become more and more automated, there is a corresponding increased use of robotic manipulators to fabricate, process, and assemble components and sub-assemblies into end products. One example of such automated manufacturing systems can be found in the automotive industry, where automated manufacturing lines assemble completed vehicles from component parts. Many automated manufacturing systems utilize assembly lines having multi-axis robotic manipulators cooperating in a coordinated manner to process and assemble components into a desired end product. Typically, these multi-axis robotic manipulators comprise a plurality of serially arranged links that are moved by motors to perform the processing and assembly functions.

As these manufacturing systems have become more automated, the tolerances between assembled components have become smaller and smaller. While conventional six degree-of-freedom manipulators provide flexibility needed for these highly automated manufacturing systems, the configuration of robotic manipulators with serially arranged links results in looser tolerances in the assembled components, or requires that the robotic manipulators are frequently calibrated to ensure that close tolerances can be achieved and maintained. Accordingly, there is a need for improved automated systems that facilitate quick, efficient, and repeatable assembly of components into end products, and which overcome these and other drawbacks of current automated manufacturing systems. According to <CIT> a hand for parallel link robot includes: a holder configured to extract a workpiece from an extraction portion and hold the workpiece; and a swing-up mechanism portion configured to swing the workpiece held by the holder up centering around a turning axis to change a posture of the workpiece, and a parallel link robot includes: a link mechanism portion; and the hand mounted to the link mechanism portion. According to <CIT> a workpiece conveyor that conveys a workpiece includes chucks that hold a workpiece, and a movable body that supports the chucks and is movable in an X direction along first and second guides, which are disposed in parallel or substantially parallel spaced apart from each other, and the movable body includes a first structure guided by the first guide, a second structure guided by the second guide, and a joint that is provided between the first structure and the second structure, and allows one of the first structure and the second structure to swing with respect to the other about an axis of a swing shaft set parallel or substantially parallel to the X direction. According to <CIT> a device for harvesting mushrooms from a mushroom bed involves a robotic aim configured to interchangeably deploy one of a plurality of different suction grippers, each of the suction grippers having a suction cup having a size and shape profile appropriate for gripping a cap of a mushroom, the cap having a size and shape profile within a predetermined range.

The present invention provides a system and associated method for the automated assembly of components to a workpiece on an assembly line.

In one aspect, an exemplary system for automatically handling components to be assembled onto a product on an assembly line includes a carriage supported on a frame that positions the system adjacent the assembly line. The carriage is movable to and between a first, retracted position spaced a distance away from the assembly line, and a second, work position displaced from the retracted position in a direction toward the assembly line. The carriage supports a multi-axis articulating manipulator that, in turn, supports a component mounting tool configured to receive and support at least one component for assembly to the product. The manipulator may be arranged in a first orientation when the carriage is in the first position, and may be pivoted to a second orientation when the carriage is in the second position such that a component on the component mounting tool is supported in a pose for processing when the carriage is in the first position, and the component is supported in a pose for joining to the product when the carriage is in the second position.

In another aspect, a method of handling components to be assembled to a product on an assembly line includes receiving the component on a component mounting tool at a first, retracted position spaced from the assembly line, and moving the component mounting tool in a direction toward the assembly line to a second, work position. In the first position, the component mounting tool is in a first pose adapted to facilitate receiving or processing the component. In the second position, the component mounting tool is in a second pose adapted to facilitate joining the component to the product.

The accompanying drawings illustrate exemplary embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.

<FIG> depicts an exemplary manufacturing plant <NUM> including an exemplary system <NUM> for automatically handling components to be assembled onto a workpiece <NUM> that is moved along a manufacturing assembly line <NUM> in accordance with the principles of the present disclosure. In the embodiment shown, the manufacturing plant <NUM> comprises a plurality of individual manufacturing cells 18a, 18b, 18c, 18d positioned adjacent the manufacturing assembly line <NUM> and disposed on either side of the assembly line <NUM>. The assembly line <NUM> may include conveying structure (not shown) for automated movement of workpieces <NUM> along the assembly line <NUM> (such as in the direction of arrow <NUM>), whereby the workpieces <NUM> may be positioned adjacent the plurality of manufacturing cells 18a - 18d and automated systems, such as robotic manipulators, assemble components onto the workpieces <NUM> or process the workpieces <NUM> as part of the manufacturing process. In the embodiment shown, the workpieces <NUM> are depicted as automotive vehicles, and the cells 18a - 18d of the manufacturing plant <NUM> are configured to assemble components onto the vehicle body or to perform various processing steps which may be desired. While the exemplary embodiment is shown and described herein as a manufacturing plant <NUM> with cells 18a - 18d adapted to assemble and process vehicles, it will be appreciated that the manufacturing plant <NUM> and cells 18a - 18d may alternatively be configured to produce various other products.

With continued reference to <FIG>, an exemplary manufacturing cell 18a may include an exemplary component handling system <NUM> in accordance with the principles of the present disclosure. The component handling system <NUM> may be arranged in the cell 18a adjacent a plurality of robotic manipulators. For example, a first robotic manipulator 22a may be configured to pick one or more components from a supply (not shown) and position the components on or within the component handling system <NUM>. The first robotic manipulator 22a may be situated within the manufacturing cell 18a or, alternatively, may be placed adjacent the manufacturing cell 18a and may be configured to extend within the manufacturing cell 18a in cooperation with the component handling system <NUM>. Additional robotic manipulators 22b, 22c may be positioned within the cell 18a and may be configured to cooperate with the component handling system <NUM> to facilitate the assembly of and/or processing of components that are positioned by the component handling system <NUM> for assembly onto the workpiece <NUM>. While the exemplary manufacturing cell 18a has been shown and described herein as including several robotic manipulators 22a, 22b, 22c which cooperate with the component handling system <NUM>, it will be appreciated that various other configurations of manufacturing cells may alternatively be used.

With continued reference to <FIG>, and referring further to <FIG>, <FIG>, and <FIG>, an exemplary component handling system <NUM> in accordance with the principles of the present disclosure is depicted in more detail. In the embodiment shown, the component handling system <NUM> may be supported on a frame <NUM> for location within a manufacturing cell 18a and adjacent the manufacturing line <NUM>. The exemplary component handling system <NUM> includes a multi-axis articulating manipulator <NUM> supported on the frame <NUM> by a carriage <NUM>. The carriage <NUM> is supported on the frame <NUM> for movement to and between a first, retracted position that is spaced a distance away from the assembly line, as depicted in <FIG>, and a second, work position that is displaced from the retracted position in a direction toward the assembly line <NUM>, as depicted in <FIG>. In the embodiment shown, the carriage <NUM> is selectively moved between the first and second positions by an actuator <NUM> having an extendable rod <NUM>. It will be appreciated, however, that various other mechanisms suitable for moving the carriage <NUM> between the first and second positions may be used.

The exemplary component handling system <NUM> further includes a component mounting tool <NUM> coupled with the multi-axis manipulator <NUM> and configured to receive and support at least one component <NUM> for assembly to the workpiece <NUM>. In the embodiment shown, the component <NUM> is illustrated as a door that is to be mounted to the vehicle body as the vehicle body moves along the assembly line <NUM> and is positioned adjacent the manufacturing cell 18a. While the component <NUM> is shown and described herein as a vehicle door, it will be appreciated that, in other embodiments, various other components may be received on the component mounting tool <NUM> for processing and/or assembly onto a workpiece. As non-limiting examples, automotive components such as body panels, handles, or hinges, or even non-automotive components, may be received and supported on a component mounting tool in accordance with the principles of the present disclosure.

As shown in <FIG>, when the carriage <NUM> is in the first, retracted position, the mounting tool <NUM> is oriented and positioned to receive a component <NUM>, and supports the component <NUM> in a pose that facilitates further processing of the component <NUM>, such as by a robotic manipulator 22a positioned adjacent the component handling system <NUM>. As a non-limiting example of the embodiment shown, the component <NUM>, in the form of a vehicle door, may be supported with an interior side of the door facing up to thereby facilitate the positioning and attachment of sub-components onto the door. Advantageously, the first position of the carriage <NUM> facilitates the loading and processing of components and sub-components while the workpiece <NUM> is moving between the manufacturing cells 18a - 18d of the manufacturing assembly line <NUM>, thereby providing increased efficiencies of throughput. When the carriage <NUM> is then moved to the second, work position as depicted in <FIG>, the mounting tool <NUM> is moved in translation with the carriage <NUM>, and is also moved in a curvilinear manner such that the mounting tool <NUM> supports the component <NUM> in a second pose that facilitates joining the component <NUM> to the workpiece <NUM>. For example, in the embodiment shown, the component <NUM> may be supported in a generally vertical orientation of the door corresponding to how the door will be attached to the vehicle body (workpiece <NUM>).

The component handling system <NUM> may additionally be provided with various sensors for monitoring and facilitating the operation of the component handling system <NUM>. In the embodiment shown, the system <NUM> may further include one or more optical sensors, or cameras <NUM> positioned at various suitable locations on or near the manipulator <NUM>, the carriage <NUM>, and/or the component mounting tool <NUM>. The optical sensors <NUM> may be supported on a separate support frame <NUM>, for example, or may be coupled with the frame <NUM> or other structure as may be desired. Other sensors may include, as a non-limiting examples, one or more non-contact proximity sensors <NUM> positioned on or near the component handling system <NUM> and configured to sense the presence of a workpiece <NUM> adjacent the component handling system <NUM>. Other sensors may be used to confirm the presence and/or pose of a component supported on the component mounting tool <NUM>. Signals or data obtained from the sensors <NUM>, <NUM> may be provided to a controller or other suitable computer and used to control and/or monitor operation of the component handling system <NUM>.

With continued reference to <FIG>, <FIG>, and <FIG>, and referring further to <FIG>, the exemplary multi-axis articulating manipulator <NUM> will be described in more detail. In the embodiment shown, the manipulator <NUM> includes a base assembly <NUM> coupling the manipulator <NUM> to the carriage <NUM> for movement with the carriage <NUM> between the first and second positions on the frame <NUM>. A plurality of linkages <NUM> are coupled with a base plate <NUM> of the base assembly <NUM> and are configured to support a tool mounting plate <NUM> on their opposite ends for coupling with the component mounting tool <NUM>. In the embodiment shown, the manipulator <NUM> includes three fixed-length linkages <NUM> coupled at their first ends <NUM> to the base plate <NUM>, and the second ends <NUM> of the linkages <NUM> are coupled with the tool mounting plate <NUM>. The first ends <NUM> of the linkages <NUM> are coupled to the base plate <NUM> by respective pivot joints <NUM> and at least one actuator configured to move the second ends <NUM> of the linkages <NUM> in a controllable manner. Through coordinated movement of the second ends <NUM> of the linkages <NUM>, the pose (position and orientation) of the tool mounting plate <NUM> may be precisely controlled. In the embodiment shown, the first end <NUM> of each linkage <NUM> is coupled to the base plate <NUM> by a pair of linear actuators 66a, 66b that are aligned to control movement of the first ends <NUM> of the linkages <NUM> in respective first and second directions <NUM>, <NUM> arranged orthogonal to one another. The second ends <NUM> of the linkages <NUM> are coupled to the tool mounting plate <NUM> by respective swivel joints <NUM> such that the pose of the tool mounting plate <NUM> may be controlled by selective positioning of the linear actuators 66a, 66b coupled with the respective linkages <NUM>. In use, the multi-axis manipulator <NUM> facilitates precise positioning of a component <NUM> supported by the component mounting tool <NUM> that is coupled with the tool mounting plate <NUM> when the carriage <NUM> is in the second position.

When the carriage <NUM> is in the first position as shown in <FIG>, the base plate <NUM> of the multi-axis manipulator <NUM> is oriented such that the component mounting tool <NUM> coupled with tool mounting plate <NUM> is in the pose described above for receiving and supporting a component <NUM>. As the carriage is moved from the first position to the second position, the base plate <NUM> pivots to an orientation such that the component mounting tool <NUM> coupled with tool mounting plate <NUM> is moved to the pose described above for joining the component <NUM> to the workpiece <NUM>, as depicted in <FIG> and <FIG>.

While the multi-axis manipulator <NUM> has been shown and described herein as including three, fixed-length linkages <NUM>, and linear actuators 66a, 66b coupling the linkages <NUM> to the manipulator base plate <NUM>, it will be appreciated that various other arrangements of linkages and actuators, including variable length linkages, may alternatively be used to facilitate positioning the tool mounting plate <NUM> at a desired pose for mounting a component <NUM> to a workpiece <NUM>.

With continued reference to <FIG>, <FIG>, and <FIG>, and referring further to <FIG> and <FIG>, an exemplary component mounting tool <NUM> in accordance with the principles of the present disclosure will be described. In the embodiment shown, the component mounting tool <NUM> includes a tool frame <NUM> configured to be coupled with the tool mounting plate <NUM> of the multi-axis manipulator <NUM>. One or more shaft assemblies 82a, 82b are supported on the tool frame <NUM> and, in turn, support gripping members <NUM> configured to engage and support components <NUM> to be installed to the workpiece <NUM>. In the embodiment shown, the mounting tool <NUM> includes first and second shaft assemblies 82a, 82b supported on the tool frame <NUM>. Each shaft assembly 82a, 82b includes a shaft 86a, 86b supported for rotation relative to the tool frame <NUM> by respective trunnion mounts <NUM>. Each shaft 86a, 86b may further include a plurality of gripping members <NUM> positioned at spaced-apart circumferential positions around the shaft <NUM>. Advantageously, each gripping member <NUM> may be configured to engage components having different geometries, whereby certain ones of the gripping members <NUM> may be selectively positioned for engagement with components <NUM> to be assembled to the workpiece <NUM> by rotating the shafts <NUM> about their respective longitudinal axes 90a, 90b relative to the frame <NUM>.

As best seen in <FIG>, the component mounting tool <NUM> may further include a locking assembly <NUM> cooperating with the one or more of the shaft assemblies 82a, 82b to lock the shafts 86a, 86b at desired rotational positions so that selected gripping members <NUM> may be positioned for engagement with a component <NUM>. In the embodiment shown, the locking assembly <NUM> includes an actuator <NUM> having an extendable rod <NUM> that engages an associated shaft assembly 82a, 82b to thereby lock the respective shaft 86a, 86b in a desired rotational position. For this purpose, each shaft assembly 82a, 82b further includes a registration block <NUM> supported on the shaft 86a, 86b and having registration features configured to cooperate with the rod <NUM> of the locking assembly actuator <NUM>. In the embodiment shown, the distal end <NUM> of the rod <NUM> has a wedge-shaped tip, and the registration features on the registration block comprise correspondingly shaped notches <NUM> disposed at selected angular positions around the shaft 86a, 86b. In use, when a desired gripping member <NUM> is in position for engagement with a component <NUM>, the rod <NUM> of the locking assembly actuator <NUM> may be extended to engage the corresponding notch <NUM> provided on the registration block <NUM>, thereby preventing further rotation of the shaft 86a, 86b.

While the component mounting tool <NUM> has been shown and described herein as comprising two shaft assemblies 82a, 82b, each having a plurality of gripping members <NUM> disposed at spaced-apart circumferential positions, it will be appreciated that a component mounting tool in accordance with the present disclosure may alternatively comprise only a single shaft assembly, or may include more than two shaft assemblies. Moreover, when only a single type of component will be handled by the component mounting tool <NUM>, or when the components have sufficiently uniform geometries, the component mounting tool <NUM> may not require a plurality of different gripping members <NUM> disposed circumferentially around the shaft assemblies 82a, 82b.

In the embodiment shown, the gripping members <NUM> of the component mounting tool <NUM> are configured as air handlers adapted to sealingly engage a component when vacuum pressure is supplied to the air handlers. As best shown in <FIG>, each air handler includes a housing <NUM> supported on the respective shaft 86a, 86b by a bracket assembly <NUM>. The air handler is provided with a suction face <NUM> having one or more sealing members <NUM> configured to sealingly engage the component <NUM>, and a vacuum bore <NUM> formed in the housing <NUM> communicates with the suction face <NUM> to provide vacuum pressure sufficient to engage and support a component <NUM>. The vacuum bores <NUM> of the respective air handlers may be coupled with a source of vacuum pressure (not shown) which may be controlled to selectively grip and release components <NUM>.

Claim 1:
A system (<NUM>) for automatically handling components (<NUM>) to be assembled onto a product on an assembly line (<NUM>), the system (<NUM>) comprising:
a frame (<NUM>) locatable adjacent the assembly line (<NUM>);
a carriage (<NUM>) supported on the frame (<NUM>) for movement to and between a first retracted position spaced a distance away from the assembly line (<NUM>), and a second, work position displaced from the retracted position in a direction toward the assembly line (<NUM>);
a multi-axis articulating manipulator (<NUM>) supported on the carriage (<NUM>), the manipulator (<NUM>) including a base (<NUM>) coupled with the carriage (<NUM>) and a tool mounting plate (<NUM>) controllably movable relative to the base in at least three degrees of freedom;
the manipulator base (<NUM>) arranged in a first orientation when the carriage (<NUM>) is in the first position, and pivoted to a second orientation when the carriage (<NUM>) is in the second position; and
a component mounting tool (<NUM>) coupled with the tool mounting plate (<NUM>) of the manipulator (<NUM>), the component mounting tool (<NUM>) configured to receive and support at least one component (<NUM>) for assembly to the product;
wherein a component (<NUM>) on the component mounting tool (<NUM>) is supported in a pose for loading and/or processing when the carriage (<NUM>) is in the first position, and the component (<NUM>) is supported in a pose for joining to the product when the carriage (<NUM>) is in the second position.