Patent ID: 12202086

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG.1shows an automation system10according to the invention. The automation system10comprises an automation unit12according to the invention and an automated guided vehicle14. The automated guided vehicle14transports a stack16of component carriers18which are arranged on a transport trolley20.

The automation unit12has an enclosure22. A front structure24, on which a loading opening26is formed, protrudes from the enclosure22. An intervention area28at the loading opening26is monitored by a safety system30. The automation unit12can have a control cabinet32, which is arranged here on the rear of the enclosure22. An electronic controller (not shown in detail) for the automation unit12can be provided in the control cabinet32.

FIG.2ashows a section of the automation system10fromFIG.1. The enclosure22is shown inFIG.2in partially removed or broken form. A first stacking space34, a second stacking space36, a third stacking space38and a plurality of further stacking spaces39are formed within the enclosure22. A stack16of component carriers18can be arranged on each of the stacking spaces34,36,38,39. The automation unit12has a transfer device40. By means of the transfer device40, component carriers18can be transferred individually or in groups between the stacking spaces34,36,38,39. The transfer device40is designed in this case with a pallet changer.

The automation unit12has a separating device42for the first stacking space34. The first stacking space34can be separated inwardly (from the remainder of the interior44of the enclosure22with the stacking spaces36,38,39) or released by means of the separating device42. In this case, the separating device42comprises a displaceable hood46and a bulkhead wall48. The hood46is displaceable over the stacking spaces34,36,38,39; in particular, the hood46can be arranged over the first stacking space34or the second stacking space36. The bulkhead wall48is fixed between the first stacking space34and the second stacking space36. The hood46is located in this case over the second stacking space36, cf. alsoFIG.2b, so that the separating device42releases the first stacking space34.

It can also be seen inFIG.2bthat the automated guided vehicle14has a lifting device50for driving under and lifting the transport trolley20of the stack16.

The front structure24of the enclosure22has two side panels52and a roof segment54. In the configuration shown inFIGS.2aand2b, the roof segment54is in a covering position. The two side panels52and the roof segment54surround the loading opening26from the side and from above.

The safety system30of the automation unit12is designed for contactless, in this case optical, monitoring of the intervention area28at the loading opening26. The safety system30has two laser scanners56. The laser scanners56can each be arranged in upper corners of the front structure24at the loading opening26.

InFIG.2a, the safety system30is in full monitoring mode. In full monitoring mode, the safety system30monitors the entire intervention area28. In full monitoring mode, the laser scanners56are set up to detect any intervention in the loading opening26. If the safety system30detects an intervention in the intervention area28, the safety system30interrupts operation of the automation unit12and sends the automated guided vehicle14a command that forces it to stop. When the operation of the automation unit12is interrupted, the transfer device40in particular is stopped. If present, a handling device (not shown here) of the automation unit12is also stopped. The handling device serves to handle components that are provided on the component carriers18and are also not shown in detail.

FIGS.2aand2bshow the automation system10in a state at the beginning of an automated loading process. For automated loading, the automation unit12is in automatic loading mode. The automated guided vehicle14has registered the loading process to be carried out with the automation unit12. When the automated guided vehicle14with the stack16has moved directly (e.g. to less than eight centimeters) in front of the loading opening26, the safety system30is switched to partial monitoring mode, which allows the stack16to be infed through the loading opening26to the first stacking space34.

The automation unit12and the automated guided vehicle14can each have redundant communication devices that are not shown in detail. Secure communication can be set up between the automation unit12and the automated guided vehicle10by means of the redundant communication devices. (Secure) communication includes in particular the registration of a loading process by the automated guided vehicle14with the automation unit12and the sending of a stop command from the automation unit12to the automated guided vehicle14if the safety system30is triggered.

FIG.3shows the automation unit12with the safety system30in partial monitoring mode. In partial monitoring mode, the safety system30only monitors a sub-area58of the intervention area28, in this case an outer sub-area. An infeed area60, in this case an inner infeed area, is excluded from monitoring. A distinction can be made between an intervention in the monitored sub-area58and the non-monitored infeed area60in that the safety system30determines a location of an intervention in the intervention area28, with an intervention in the monitored sub-area58leading to the safety system30being triggered, whereas an intervention in the non-monitored infeed area60is tolerated without further reaction. The size, in particular the height and/or width, of the monitored sub-area58or of the non-monitored infeed area60can be matched to the size of the stack16or the automated guided vehicle14.

It can also be seen inFIG.3that the hood46is located over the first stacking space34so that the separating device42separates the first stacking space34. Because the loading opening26is monitored by the safety system30, however, this separation is not absolutely necessary in automatic loading mode.

FIGS.4aand4bshow the automation system10fromFIG.1during the infeed of the stack16through the loading opening26. In the configuration shown, the stack16has been brought almost completely through the loading opening26by the automated guided vehicle14. The safety system30then adjusted the size of the monitored sub-area58and therefore the size of the infeed area60such that a housing62of the automated guided vehicle14can pass through the loading opening26without the safety system30being triggered.

As the loading process continues, the automated guided vehicle14will move the stack16to the first stacking space34and then move away from the automation unit12again. After the automated guided vehicle14has left the loading opening26, the safety system30is switched back to full monitoring mode.

FIG.5shows the automation unit12fromFIG.1in a state at the beginning of a manual loading process. For manual loading, the automation unit12is switched to manual loading mode. This can be done by an operator64making a corresponding entry on an operator terminal66of the automation unit12.

InFIG.5, the safety system30is in full monitoring mode, so that any intervention in the loading opening26is detected and causes the automation unit12to stop. The hood46of the separating device42can be located above the second stacking space36, so that the first stacking space34is released.

After the operator64has registered the manual loading process, the first stacking space34is initially separated inwardly by means of the separating device42. For this purpose, the hood46is moved over the first stacking space34. The safety system30is then deactivated. This state is shown inFIG.6.

Since the front structure24protrudes from a wall67, which is in this case vertical, of the enclosure22, on the one hand it causes the loading opening26to be at a distance from the first stacking space34, so that in the event of an intervention (with the safety system30activated), there is more time to interrupt the operation of the automation unit12. On the other hand, the roof segment54in particular hinders the operator64when loading the first stacking space34.

In order to simplify loading, after the safety system30has been deactivated, the operator64can bring the roof segment54of the front structure24out of the covering position, cf.FIGS.5and6, into an open position, seeFIG.7. For this purpose, the roof segment54can be pushed inwards (over the first stacking space34). The safety system30may monitor the position of the roof segment54such that when the safety system30is activated, an attempt to open the roof segment54will trigger the safety system30and consequently interrupt the operation of the automation unit12. Opening the roof segment54makes it easier for the operator64to move the stack16to the first stacking space34. In order to push the stack16onto the first stacking space34with the transport trolley20, the operator64can step through the loading opening26to just in front of the first stacking space34when the roof segment54is open. The operator64does not have to bend down or stretch through the loading opening26for this purpose.

The manual or automated loading processes described above with reference toFIGS.2ato7, with the infeed of a stack16of component carriers18through the loading opening26onto the first stacking space34, can also be carried out, with appropriate adjustments, in order to outfeed a stack16of component carriers18from the first stacking space34.

In the automation unit12, the stacking spaces34,36,38,39are arranged one behind the other in a longitudinal direction68, cf. alsoFIG.1. In other words, the stacking spaces34,36,38,39lie on a straight line. The loading, i.e. the infeed and outfeed of a stack16of component carriers18through the loading opening26, takes place along the longitudinal direction68. For this purpose, the loading opening26can be arranged to run transversely to the longitudinal direction68.

FIG.8shows an automation unit70. With the exception of a safety system30, the automation unit70corresponds to the automation unit12fromFIG.1. In this respect, reference is made to the above description.

The safety system30of the automation unit70has a closing device72for a loading opening26. The closing device72is designed here with a roller door74which can be rolled up into a box76arranged on the upper side of the loading opening. InFIG.8, the closing device72is in a closed position; the roller door74closes the loading opening26. The closed position of the closing device72is set up in full monitoring mode of the safety system30. In full monitoring mode, an attempt to open the closing device72leads to the operation of the automation unit70being interrupted and possibly to an automated guided vehicle14of an automation system10with the automation unit70being stopped.

The safety system30also has two contact protection strips78. The contact protection strips78are arranged laterally next to the loading opening26in this case. The contact protection strips78are triggered when touched. When the contact protection strips78are triggered, the safety system30interrupts operation of the automation unit70and, if necessary, stops the automated guided vehicle14. As a result, an operator64(cf.FIGS.5to7) being trapped between the automation unit70and the automated guided vehicle14can be avoided.

The contact protection strips78can be integrated into side panels52which protrude from a wall67of an enclosure22of the automation unit70, which wall in this case runs vertically. Guiding elements80can be arranged on the side panels52in order to simplify the infeed of a stack16of component carriers18in the loading opening26.

An intervention area28that can be monitored by the safety system30—and is monitored in full monitoring mode—comprises the loading opening26and the region of the contact protection strips78. In partial monitoring mode, a sub-area monitored by the safety system30can comprise the region of the contact protection strips78and—when the closing device72is partially closed—the covered part of the loading opening26.

FIG.9shows the automation unit70in partial monitoring mode of the safety system30. In partial monitoring mode, the automation unit70can be loaded automatically. In this case, the closing device72is open for partial monitoring mode. The roller door74(cf.FIG.8) has been raised and is accommodated in the box76. As a result, the first stacking space34is accessible from the outside. The contact protection strips78are also active in partial monitoring mode and stop the automation unit70and, if necessary, the automated guided vehicle14if they are touched.

The contact protection strips78of the safety system30can be deactivated for manual loading. This avoids (harmless) contact leading to an interruption in the operation of the automation unit70.

In manual loading mode of the automation unit70, the closing device72can only be opened when the first stacking space34has been separated from the remainder of the interior44of the enclosure22by means of a separating device42. For this purpose (as described above), a hood46can be moved over the first stacking space34. In automatic loading mode of the automation unit70, the closing device72can also be opened when the first stacking space34has been released, if the automated guided vehicle14is located directly in front of the loading opening26.

The automation unit70can have an alignment device82at the first stacking space34. A stack16of component carriers18can be precisely aligned by means of the alignment device82after it has been brought to the first stacking space34. This simplifies the transfer of component carriers18by means of a transfer device40. The alignment device82can act on a transport trolley20of the stack16for aligning. The alignment device82can also be provided in the automation unit12fromFIG.1.

FIG.10shows an automation unit84. In the automation unit84, a closing device72and a separating device42have a common separating element86. The separating element86can be arranged either to close a loading opening26or to separate a first stacking space34. The separating element86is part of a sectional door88in this case. A drive90of the sectional door88can be arranged on top of the loading opening26. The closing device72is shown closed inFIG.10. The separating element86closes the loading opening26. When the closing device72is opened, the separating element86is guided over and behind the first stacking space34by means of a rail arrangement92. Partition walls of the separating device42, which partition walls are not shown in more detail and are in particular fixed, can be arranged to the side of the first stacking space34. A bulkhead wall48of the separating device42, which bulkhead wall is in particular fixed, can be arranged between the first stacking space34and the second stacking space36.

Otherwise, the automation unit84corresponds in structure and function to the automation unit70fromFIG.8. In this respect, reference is made to the above description.

FIG.11shows a schematic flowchart of a method100for the manual loading of an automation unit. The method is described here by way of example using the automation unit12fromFIG.1. The method100can also be carried out with the automation unit70fromFIG.8or the automation unit84fromFIG.10.

If the automation unit12is in automatic loading mode at the beginning of the method100, the automation unit12is first switched to manual loading mode in step102.

In step104, the first stacking space34is separated by means of the separating device42. The safety system30is then deactivated in step106. The roof segment54of the front structure24can then be opened. In step108, an operator64can now load the first stacking space34through the loading opening26. The operator64can first outfeed a first stack16of component carriers18with processed components from the first stacking space34through the loading opening26and then bring a second stack16of component carriers18with components to be processed through the loading opening26to the first stacking space34.

The safety system30is then reactivated in step110. If necessary, the roof segment54may be closed beforehand. Then, in step112, the first stacking space34is released by the separating device42.

Further manual loading processes can then be carried out, cf. the dashed arrow inFIG.11. It should be noted that the component carriers18outfed from the first stacking space34in a subsequent process cycle are typically not those component carriers18that were brought to the first stacking space34in the immediately preceding loading process, but rather other component carriers18that were stacked using the transfer device40have reached the first stacking space34. A transport trolley20on the first stacking space34is not restacked as a matter of principle, but outfed again after it has been infed during the next loading process.

FIG.12shows a schematic flowchart of a method200for the automated loading of an automation system10. The method is described here by way of example using the automation system10with the automation unit12fromFIG.1. The method200can also be carried out with an automation system with the automation unit70fromFIG.8or with the automation unit84fromFIG.10.

If the automation unit12is in manual loading mode at the beginning of the method200, the automation unit12is first switched to automatic loading mode in step202.

In full monitoring mode of the safety system30, the entire intervention area28at the loading opening26is initially monitored in step204. During full monitoring operation, an automated loading process is registered with the automation unit12in step206, in particular by the automated guided vehicle14.

If the automated guided vehicle14is located directly in front of the loading opening26, the safety system30is switched to partial monitoring mode, so that in step208, a sub-area58of the intervention area28is monitored. During the monitoring of the sub-area58in partial monitoring mode, the first stacking space34is automatically loaded in step210. First, a first stack16of component carriers18can be outfed from the first stacking space34through the loading opening26by means of the automated guided vehicle14. A second stack16of component carriers18can then be brought through the loading opening26to the first stacking space34by means of the same or another automated guided vehicle14. A size of the monitored sub-area58can be adapted to the respective stack16for infeeding or outfeeding the stack16. The size of the monitored sub-area58can also be changed while the stack16is being guided through the loading opening26, for example if a housing62of the automated guided vehicle14is to pass through the loading opening26.

Finally, in step212, the safety system30is switched back to full monitoring mode so that the entire intervention area28is monitored. Further automated loading processes can then be carried out, cf. the dashed arrow inFIG.12.

FIG.13shows a schematic flowchart of an operating method300for an automation system10. The automation system10can be configured, for example, with the automation unit12fromFIG.1, the automation unit70fromFIG.8or the automation unit84fromFIG.10.

First, one cycle or a plurality of cycles of the manual loading method100according toFIG.11are carried out. Then one cycle or a plurality of cycles of the automated loading method200according toFIG.12are carried out. Subsequently, cycles of the manual loading process100can be carried out again, and so on.

FIG.14shows a schematic flowchart of an operating method400for an automation system10. The automation system10can be configured, for example, with the automation unit12fromFIG.1, the automation unit70fromFIG.8or the automation unit84fromFIG.10.

As part of an automated loading method200, cf.FIG.12, the automation unit12is operated in step402and the automated guided vehicle14is automatically moved in step404in the area surrounding the automation unit12. Meanwhile, at least a sub-area58or the entire intervention area28at the loading opening26is monitored by the safety system30. In step406, the safety system30is triggered by an intervention in the intervention area28or the monitored sub-area58. In step408, the operation of the automation unit12is then interrupted by the safety system30and in step410, the automated guided vehicle14is stopped at the command of the safety system30.

LIST OF REFERENCE SIGNS

Automation system10Automation unit12,70,84Automated guided vehicle14Stack16Component carrier18Transport trolley20Enclosure22Front structure24Loading opening26Intervention area28Safety system30Control cabinet32First stacking space34Second stacking space36Third stacking space38Further stacking spaces39Transfer device40Separating device42Interior44Hood46Bulkhead wall48Lifting device50Side panels52Roof segment54Laser scanner56Sub-area58Infeed area60Housing62Operator64Operator terminal66Wall67Longitudinal direction68Closing device72Roller door74Box76Contact protection strips78Guiding elements80Alignment device82Separating element86Sectional door88Drive90Rail arrangement92Method100for manual loadingSwitching102to manual loading modeSeparating104the first stacking space34Deactivating106the safety system30Manually infeeding and/or outfeeding108a stack16Activating110the safety system30Releasing112the first stacking space34Method200for automated loadingSwitching202to automatic loading modeMonitoring204the entire intervention area28Registering206an automated loading processMonitoring208a sub-area58Automatically infeeding and/or outfeeding210a stack16Monitoring212the entire intervention area28Operating method300with manual and automated loadingOperating method400with triggering of the safety system30Operating402the automation unit12,70,84Moving404the automated guided vehicle14Triggering406of the safety system30Interrupting408the operation of the automation unit12,70,84Stopping410the automated guided vehicle14