• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
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    • 专利摘要:
    FLEXIBLE TRANSPORT SYSTEM. The invention relates to a conveyor system that includes a plurality of feed conveyor segments aligned end to end, each having an upward channel and at least one carrier drive member disposed in the channel. At least one carrier is supported for movement along the feed conveyor segments. Each carrier includes at least one drive coupling member that cooperates with at least one carrier drive member to move the carrier along the respective feed conveyor segments. The conveyor system may additionally include a plurality of return conveyor segments separated from the plurality of forward feed conveyor segments.
    公开号:BR112015021155B1
    申请号:R112015021155-0
    申请日:2014-03-14
    公开日:2021-02-17
    发明作者:Kevin J. Laurence；Michael P. Larose
    申请人:Kuka Systems Corporation North America；
    IPC主号:
    专利说明:

    [0001] [001] This application claims priority benefit from Provisional Patent Application No. Serial US 61 / 781,147 filed on March 14, 2013 (pending), and Patent Application No. Serial US 14 / 211,793 filed on March 14, 2013 2014 (pending), and US Patent Application Serial 14 / 211,572 filed on March 14, 2014 (pending), the disclosure of which is hereby incorporated by reference in its entirety for reference. TECHNICAL FIELD
    [0002] [002] The invention relates in general to material handling systems and, more particularly, to transport systems for manufacturing on the assembly line. BACKGROUND
    [0003] [003] Material handling systems for assembly line fabrication are generally designed to facilitate efficient and rapid fabrication of an assembly from a plurality of parts or subassemblies. A particularly suitable area for such material handling systems is automotive production. For example, material handling systems can be used for the assembly of a vehicle blade metal body, transmission system, chassis subassemblies or nibs. Material handling systems can also be used in painting, welding, joining, or other general assembly operations.
    [0004] [004] Generally a carrier, a structure to accumulate the various parts and subassemblies that will eventually be linked to a vehicle body, travels through a plurality of stations. At each station, components can be added and / or joining operations can be carried out (for example, resistance welding, adhesive bonding, pin welding, etc.) by a plurality of robots or workers. The individual components or subassemblies can be supplied to the various stations by a warehouse, which presents the parts to the robots or workers in a consistent orientation and at a frequency sufficient to keep pace with an assembly line. In different stations or in conjunction with other tasks, a plurality of geometric orientation tools ("geometric tools") can be used to manipulate the parts in precise alignment with various antecedent reference points to be linked permanently.
    [0005] [005] Often, the carrier can be transported by a generic transfer frame. The transfer frame can be moved from station to station by a variety of different transfer systems, such as a suspended track system, for example, and can be raised and lowered in relation to the stations.
    [0006] [006] There are several disadvantages to traditional transportation systems. For example, the transfer frame and carriers produce a bulky combined assembly. At the end of the assembly line, each of the transfer frames and carrier assemblies must return to the beginning of the line. This often involves dedicating a return circuit, typically located above the assembly line, for the purpose of returning empty carriers and frames. Unfortunately, this return circuit generally bisects an upper walkway and therefore prevents the maintenance staff on one side from being able to move safely to the other side of the walkway. This greatly delays the location of defects and access to equipment cabinets and overhead installations.
    [0007] [007] Additionally, each of the frames and the carriers can be tied in a communal way to a suspended carrier. Consequently, carriers and frames at one station cannot be moved independently of carriers and frames at other stations. This results in an absence of flexibility, and carriers become unable to pass unnecessary stations quickly. In addition, carriers must be moved through the various stations in constant motion and in a delay pattern. A carrier and the corresponding parts that are subjected to processing at one station, even when processing is completed, cannot move until all other stations have completed their respective tasks. Limit switches, deceleration switches and locking switches control the suspended conveyor as a single collective unit.
    [0008] [008] Therefore, an improved non-suspended transport system with improved flexibility is required. SUMMARY
    [0009] [009] The present invention resolves the aforementioned and other shortcomings and disadvantages of conventional transportation systems known to date for use in transfer components along an assembly line. Although the invention is described in connection with certain modalities, it will be understood that the invention is not limited to those modalities. On the contrary, the invention includes all alternatives, modifications and equivalents, since they can be included within the spirit and scope of the present invention.
    [0010] [0010] According to one aspect of the present invention, a flexible conveyor system includes a plurality of feed conveyor segments and at least one carrier sustained by movement along the feed conveyor segments. Each feed conveyor segment has an upward channel and at least one carrier drive member disposed within the channel. Each carrier includes at least one drive coupling member that cooperates with carrier drive members from the forward feed conveyor segments to move the carrier along the respective conveyor segments. In an exemplary embodiment, the carrier drive member may be a belt that extends within the channel, and the drive coupling member may be a friction rail. In another exemplary embodiment, the carrier drive member may be a motor, and the drive coupling member may be a magnet. The support structure associated with each carrier supports the mounting components above the feed conveyor segments.
    [0011] [0011] Another aspect of the conveyor system may additionally include a plurality of return track segments aligned end to end and separated from the plurality of forward feed track segments. Each return track segment has a channel that extends longitudinally along the return track segment, and at least one carrier drive member disposed within the channel. In an exemplary embodiment, the carrier drive member may be a belt that extends within the channel. In another exemplary embodiment, the carrier drive member may be a linear motor. The carrier drive members of the return conveyor segments that cooperate with the carrier drive coupling members received on the return conveyor segments to move the carriers along the respective return conveyor segments.
    [0012] [0012] The above objectives and other objectives and advantages in accordance with the principles of the present invention will be evident from the accompanying drawings and their description. BRIEF DESCRIPTION OF THE DRAWINGS
    [0013] [0013] The accompanying drawings which are incorporated into this specification and which form part of it illustrate modalities of the invention and, together with the general description provided above and the detailed description provided below, serve to explain the principles of the invention. Similar reference numbers are used to indicate similar features throughout the various figures in the drawings.
    [0014] [0014] Figure 1 is a schematic plan view of an assembly line that includes an exemplary transport system in accordance with the principles of the present invention.
    [0015] [0015] Figure 2 is a schematic elevation view of the exemplary transport system in Figure 1.
    [0016] [0016] Figure 3 is a more detailed top plan view of the transport system of Figure 1.
    [0017] [0017] Figure 4 is a top plan view of the transport system of Figure 3, which additionally includes a walkway and a suspended return conveyor.
    [0018] [0018] Figure 5 is a perspective view of an exemplary carrier in accordance with the principles of the present invention.
    [0019] [0019] Figure 6 is a perspective view of an exemplary treadmill segment, in accordance with the principles of the present invention.
    [0020] [0020] Figure 7 is a partial cross-sectional view of the belt segment of Figure 6, taken along line 7-7.
    [0021] [0021] Figure 8 is a partial cross-sectional view of the belt segment of Figure 7, which further illustrates a carrier coupled with the belt segment.
    [0022] [0022] Figure 9 is a detailed view of the surrounding area of Figure 5.
    [0023] [0023] Figure 10 is an end view of the carrier of Figure 5, which further illustrates the configuration of the rollers.
    [0024] [0024] Figure 11 is a perspective view of an exemplary component placement station, in accordance with the principles of the present invention.
    [0025] [0025] Figure 12 is a perspective view of an exemplary geometric tool station, in accordance with the principles of the present invention.
    [0026] [0026] Figure 13 is a top plan view of exemplary geometric tool stations, in accordance with the principles of the present invention.
    [0027] [0027] Figure 14 is a perspective view of an exemplary discharge station, in accordance with the principles of the present invention.
    [0028] [0028] Figure 15 is an end elevation view of the discharge station of Figure 14.
    [0029] [0029] Figure 16 is a side elevation view of the transportation system of Figure 4, which illustrates a suspended return conveyor and a walkway.
    [0030] [0030] Figure 17 is a side elevation view of the suspended return conveyor in Figure 16.
    [0031] [0031] Figure 18 is a cross-sectional view taken along line 18-18 of Figure 16.
    [0032] [0032] Figure 19 is an enlarged detail view of the return conveyor in Figure 18.
    [0033] [0033] Figure 20 is a perspective view of an exemplary adjustable fitting assembly in accordance with the principles of the present invention.
    [0034] [0034] Figure 21 is a perspective view of an exemplary carrier that includes a strip of data matrix in accordance with the principles of the present invention.
    [0035] [0035] Figure 22 is a schematic top plan view of an assembly line that includes another exemplary transport system in accordance with the principles of the present invention.
    [0036] [0036] Figure 23 is a perspective view of an exemplary treadmill segment of the transport system of Figure 22.
    [0037] [0037] Figure 24 is a perspective view of the belt segment of Figure 23, which illustrates another exemplary carrier coupled with the belt segment.
    [0038] [0038] Figure 25 is a partial cross-sectional view of the belt segment of Figure 24.
    [0039] [0039] Figure 26 is a detailed view of another modality of a carrier in accordance with the principles of the present invention and configured for use with the mat segment of Figures 25 and 25. DETAILED DESCRIPTION
    [0040] [0040] Figure 1 is a schematic illustration of an exemplary inverted flexible transport system 10 in accordance with the principles of the present invention. A plurality of stations 12 are configured to process and assemble various components and subcomponents, such as automotive bodies.
    [0041] [0041] System 10 includes a conveyor belt 14 that transports parts between the various stations 12. A carrier 16 (described in more detail below with respect to Figures 5 and 9) cooperates with conveyor belt 14 and serves as a foundation for receiving various parts and subcomponents. Carrier 16 is introduced at the beginning of line 18, and is carried by a plurality of belt segments 20 (described in more detail below with respect to Figures 6 to 8) that are arranged under the belt 14. It has been observed that several configurations of belt 20 can provide acceptable results. Two important design characteristics of the belt 20 include resistance to elongation and the application of sufficient frictional forces between the belt segment 20 and the carrier 16. For example, an embodiment of the invention may use a steel-reinforced nylon belt to resist the elongation while the belt segment 20 is under load while carrying carrier 16. Additionally, certain modalities may use a grooved belt to improve the frictional forces between the belt segment 20 and carrier 16, while other modalities may use a molded urethane coating or other resilient component. In the exemplary system 10, the belt segments 20 can be completely closed by the belt segments 15. It should be noted that, although the belt 14 is illustrated in the drawings as being continuous, the belt actually comprises a plurality of segments, each of which segment is adjacent to adjacent segments. Carrier 16 is guided by the various belt segments 20 towards the end of the line 22.
    [0042] [0042] Still with reference to Figure 1, a possible configuration of the various stations 12 that the carrier 16 passes through the belt segments 15 and the belt segments 20 will be described. After being correlated with the belt segment 15, the carrier 16 first it enters a component placement station 24, which may include a first placement station 24a and a second placement station 24b. A plurality of feed conveyors 40 retain, orient and advance various automotive body components and subassemblies that are positioned close to the conveyor segment 15. Various robots (described in more detail below) can grab the parts from the feed conveyor 40 and placing them in the carrier 16. The carrier 16 thus advances to the next station 12, a geometric tool 28, in which the various components in the carrier 16 are aligned with each other and connected together. Carrier 16 can then proceed to the next station 12, which is a tool for reassembly 30. The tool for reassembly 30 can apply welds that may not be applied to the geometric tool station 28 due to obstructions in the geometric tool 28, or because of time constraints. The carrier 16 can then travel through a plurality of additional stations 12 which can include adhesive bonding, additional geometric tools 28, additional component placement stations 24 or additional reassembly tools 30.
    [0043] [0043] When the carrier 16 enters the geometric tool 28, the belt segment 15 and the belt segment 20 are lowered to the ground. This effectively transfers the weight of the parts or subcomponents on the geometric tool 28 itself, and outside of the carrier 16. When the load of the parts is no longer on the carrier 16, the geometric tool 28 and its various accessories can manipulate the subassembly and place each one among the components in a particular geometric relationship with each other. Although carrier 16 is lowered out of the way, robots are able to more easily access various surfaces of the automotive body in the absence of interference projections from carrier 16. As belt segment 15 is lowered, belt segment 20 is placed in a free-opening configuration, the internal clutch decouples belt segment 20 from a drive. The carrier 16 then has the ability to move back and forth, so that it allows the parts to be fitted by the geometric tool 28.
    [0044] [0044] After completing each of the various processing stations 12, carrier 16 ends at the end of line 22 at an unloading station 32. At unloading station 32, the completed automotive body subassembly is removed from carrier 16. The carrier 16 is decoupled from conveyor 14 and a robot transfers carrier 16 from conveyor 14 to a suspended return conveyor 34 (described in more detail below with reference to Figure 14) which transports carrier 16 back to the beginning of line 18.
    [0045] [0045] Figure 2 is a side elevation view of the exemplary transport system 10 of Figure 1, which includes a suspended return conveyor 34 arranged between conveyor 14 and a footbridge 36. Footbridge 36 can support support equipment 60 , such as motor controllers, robot control cabinets, plant distribution systems, etc., and facilitates maintenance, repair and troubleshooting. It should be noted that this configuration of track 14, return track 34 and walkway 36 allows an unobstructed path for the body of service personnel on walkway 36. By way of counterexample, if the suspended return track 34 is located above the walkway 36, the staff of service personnel will be unable to walk from one side of the walkway 36 to the other side of the walkway 36. The path may be cleared by the suspended return belt 34 and by the carriers 16 which are recycled back to the beginning of the run. line 18. In this view, the geometric tool 28 and the reassembly tool 30 are described as having conveyor segments 15 configured to raise and lower independently of other conveyor segments 15 and independently of other stations 12. It should also be noted that the stations 12 and their corresponding belt segments 20 have the ability to control the linear speed independently of the segments adjacent belt 20. This enables carrier 16 to be advanced by conveyor 14 through it overtaking unused stations 12. Additionally, this allows carrier 16 to be released from a station 12 and placed in a vacant station 12, even before adjacent carrier 16 is released from an adjacent station 12.
    [0046] [0046] Now, in reference to Figure 3, a plan view of the transport system 10 of Figure 1 is illustrated in great detail, however, the walkway 36 and the suspended return track 34 have been omitted for clarity. Beginning at the beginning of line 18, a carrier 16 is located at a component placement station 24a and has been loaded with several large subassemblies of an automotive body. The belt segment 15 and the corresponding belt segment 20 of the station 24a are configured to be static. For the purposes of this discussion, a static mat segment 15 is defined as one that does not have the ability to lift and lower with respect to the assembly line floor. At component placement station 24b, carrier 16 receives additional automotive body components from a plurality of feed conveyors 40. Some embodiments may use feed conveyors 40 in a horizontal configuration, while other embodiments may use conveyors vertical to minimize the consumption of assembly line floor space. As with station 24a, the station at 24b is also configured to be static and has only the linear translation capability of carrier 16. A plurality of robots 42 transfers automotive body components from feed conveyor 40 to carrier 16 which is parked at the component placement station 24b. The parts of the feed conveyor 40 are advanced on the assembly line at a rate sufficient to supply the carrier 16 as it enters the component placement station 24b.
    [0047] [0047] A geometric tool 28 is the first station 12 of the assembly line that is configured with a vertical translation tower 44. The vertical translation towers 44 are configured to move the belt segment 15, and the corresponding belt segment 20 , above and below with respect to the assembly line floor. Since vertical translational towers 44 and robots are a primary physical interface between the system 10 and the facility floor, it is undesirable to hide a majority of plant utilities on it. Therefore, robots 42 and vertical translation towers 44 can include channels or penetrations in the other respective bases, so that electrical power conductors, electrical signal conductors, hydraulic lines, pneumatic lines and the like can travel from the line floor. up to system 10 in a protected and effective manner.
    [0048] [0048] Still with reference to Figure 3, a plurality of geometric tool trays 46a-46c can be positioned under the belt segment 15 and arranged between a pair of vertical translational towers 44. Each one of the geometric tool trays 46a -46c is configured with a plurality of indexing pins, fixing accessories, clamp means and the like that correspond to a particular automotive model and embodiment and combination of automotive body parts. Therefore, the transport system 10, in this particular example, has the ability to accommodate at least three different variations of automotive body frames to be processed on the assembly line.
    [0049] [0049] When carrier 16 is positioned on the appropriate geometric tool tray 46a-46c, an internal clutch mechanism disengages the power from belt segment 20. This essentially places carrier 16 in a configuration that allows for forward movement and back of carrier 16 with respect to geometric tool tray 46a-46c. Therefore, when the belt segment 15 is lowered in contact with the geometric tool tray 46a-46c by the vertical translation towers 44, the carrier 16 has the ability to freely retribute to bring the parts into contact with the appropriate portions of the tray. geometric tool 46a-46c. When lowered, carrier 16 no longer supports the weight of the automotive body components and the weight of said components is now in contact with the various components of the geometric tool tray 46a-46c. A plurality of robots 42 preliminarily hold each of the automotive body components in a desired relationship with the other automotive body components. When the parts are preliminarily attached, the track segment 15 is lifted by the vertical translational towers 44, which puts the automotive components back in contact with the carrier 16. When the track segment 15 is fully raised, the entire weight of the car assembly is on carrier 16, and carrier 16 is ready for movement at the next station 12.
    [0050] [0050] The next station 12 is a tool for reassembly 30. The tool for reassembly 30 is configured to perform additional connection operations that are impractical due to obstructions in the preceding station 12 or due to time limitations in the preceding station 12. A plurality of reassembly tool trays 48a-48c can be positioned under the belt segment 15 in the same way as the plurality of geometric tool trays 46a-46c is positioned on the geometric tool 28. When the carrier 16 is positioned on the tool tray for proper reassembly 48a-48c, a pair of vertical translational towers 44 lower the belt segment 15 in contact with the reassembly tool tray 48a-48c. A plurality of robots 42 provide additional welding for the automotive components that are positioned and supported by the re-pumping tool 30. After the additional welding steps are complete, the pair of vertical translational towers 44 lifts the conveyor segment 15 and cooperates with the carrier 16 vertically with respect to the assembly line floor. The weight of the automotive body components is transferred from the reassembly tool tray 48a48c to the carrier 16. When the belt segment 15 and the cooperation carrier 16 are fully lifted, the carrier 16 is ready to be advanced to the next station 12. It should be noted that these exemplary views describe a truncated version of an entire assembly line. Any combination or number of individual stations 12 can be placed in a sequential order to allow flexibility in the production process. For example, additional operations can be performed at the various stations 12 to include adhesive bonding, pin or fastening, automated or mechanical adjustment of parts, automated or manual application of chips and other accessory components, etc.
    [0051] [0051] The last exemplary station 12 illustrated in Figure 3 is a unloading station 32. When carrier 16 is at unloading station 32, a plurality of lifting forks 50 is reciprocated in a position between carrier 16 and the components of automotive body. The vertical travel towers 44 lower the conveyor segment 15 and the carrier 16 by a sufficient distance to transfer the weight of the automotive body components on the lifting forks 50. The lifting forks 50 then retract to their original position far away track 14 and place the partially assembled automotive body in a car or other transport for movement throughout the factory. As will be described in more detail below with reference to Figure 14, a robot 42 transfers carrier 16 from conveyor segment 15 to a suspended return conveyor 34. Suspended return conveyor 34 returns carrier 16 from the end of line 22 back to the beginning of line 18. As will be explained in more detail in the discussion that follows the configuration of the suspended return conveyor, it is such that an unobstructed path on footbridge 36 is maintained.
    [0052] [0052] Figure 4 is a plan view of the transport system 10, similar to Figure 3, but now includes the walkway 36 and the suspended return track 34. The walkway 36 and the corresponding equipment 60 are located directly above the track 14 The suspended return track 34 is located below the walkway 36 in this top view. A plurality of stairs 62a and 62b connect the floor level of the assembly line of the walkway 36. In the absence of a carrier return mat arranged above the walkway 36, a worker can walk up the stairs 62a, through the walkway 36, and down stairs 62b on the opposite side of walkway 36. This configuration provides greatly improved efficiency during troubleshooting and repair procedures. A technician on walkway 36 can move freely from left side 64 to right side 66 of walkway 36. Left side 64 and right side 66 orientation is defined when one is at the beginning of line 18 and looks towards the end of the line 22. Therefore, the performance of the equipment 60 on the left side 64 of the walkway 36 can readily be compared with the performance of the equipment 60 on the right side 66 of the walkway 36 during troubleshooting procedures.
    [0053] [0053] Figure 4 also illustrates an optional repair station 68 positioned at the end of line 22. Damaged portions of carrier 16 can be replaced, adjusted or repacked after being removed from the assembly line and placed on a belt segment 15 of the repair station 68. A partition (not shown) can be arranged between the discharge station 32 and repair station 68, so that carrier 16 can be used in service safely while the main assembly line continues to operate .
    [0054] [0054] Figure 5 shows an exemplary carrier 16 in accordance with the principles of the invention. A friction rail 80 is correlated to a groove rail 82 with a plurality of lifters 84. Carrier 16 includes a friction rail 80 and the groove rail 82 connected with a lifter 84 that uses, for example, threaded fasteners, welding , rivets or other suitable attachment methods. A plurality of transverse supports 86 is engaged in a perpendicular orientation with respect to the plug rail 82. Transverse support 86 ends on a plurality of load-bearing surfaces 88. The load-bearing surfaces 88 are configured to support the various portions and subassemblies of the automotive body as carrier 16 and cooperative automotive body components that travel down the track 14. A plurality of parallel rollers 90 and angled rollers 92 cooperate with the correlation surfaces on track 14 and stabilizes the carrier 16 as it runs down the track 14. The engagement between the parallel rollers 90 and the angle rollers 92 will be shown in detail in the following figures.
    [0055] [0055] Figure 6 shows an exemplary belt segment 15, and illustrates the nested belt segment 20 therein. A belt motor 94 can be operated by a motor controller (not shown) to drive belt segment 20 of a belt segment 15 independently of other belt segments 20. As shown below with respect to Figures 7 to 10, the carrier 16 pilots within a channel 96 defined by a top surface 98, a first rail 100, a second rail 102, and the belt segment 20. The support surfaces of the first rail 100 and the second rail 102 can be manufactured from from SAE 4140 steel in some embodiments of the invention. The friction rail 80, the parallel rollers 90 and the angled rollers 92 of the carrier 16 generally travel below the top surface 98 of the rail 14 while the plug rail 82 and the transverse supports 86 rotate above the top surface 98 of the rail 14.
    [0056] [0056] Referring now to Figures 7 to 10, a coupling of a carrier 16 to a belt segment 15 is described. Figure 7 shows a detailed cross-sectional view of the belt segment 15 The first rail 100 and the second rail 102 are generally symmetrical and the individual features of the first rail 100 apply equally to the second rail 102. The parallel face 110 of the belt segment 15 and a parallel cooperating roller 90 on the carrier 16 generally serve to guide the carrier 16 axially along the conveyor segment 15. An angled face 112 of the conveyor segment 15 and a cooperating angled roller 92 on the carrier 16 serves to intercept the carrier 16 within the channel 94 of the conveyor segment 15. The rollers angled 92 and the cooperating face angled rollers 112 serve to maintain the carrier 16 in constant frictional relationship with the belt segment 20. Under normal operating conditions, the parallel rollers 90 are suspended at above the non-contact face 114 by lifting forces that are exerted on the friction rail 80 by the belt segment 20. In certain portions of the system 10, the first rail 100 and the second rail 102 are maintained in a movable relationship with each other other. This allows the first rail 100 and the second rail 102 to be separated from each other for the purpose of coupling and uncoupling of carrier 16 from conveyor segment 15. Figure 8 shows an end view of the cooperation between carrier 16 and its rollers 90 and 92 and the belt segment 15 and their faces 110 and 112.
    [0057] [0057] With reference to Figures 9 and 10, the angled rollers 92 of the carrier 16 are related to the lifter 84 and are arranged such that the contact surfaces of the angled rollers 92 form, substantially, an angle of forty-five degrees with respect to the friction rail 80 and snap rail 82. The center lines of rotation of the angled rollers 92 form right angles to each other. It will be appreciated that several other angular orientations can produce acceptable results, considering that surfaces coupled to the mat 14 are appropriately dimensioned. Parallel rollers 90 are coupled to the slide rail 82 to reduce the side clearance between carrier 16 and belt 14.
    [0058] [0058] Figure 11 illustrates an exemplary component placement station 24 with a belt segment 15 and carrier 16 located therein. This configuration is achieved by using a start transfer robot 122 to transfer an empty carrier 16 from suspended return belt 34 to component placement station mat segment 15. A similar final transfer robot 124 depicted in Figure 14) is located at the end of line 22 and is configured to pick up the empty carrier 16 from the unloading station 32 and place the carrier 16 on the suspended return conveyor 34. Once the carrier 16 is placed on the belt segment 15, the belt segment 20 is decoupled from the belt motor 94 (not shown), thereby placing the belt segment 20 in a free-running configuration. A positioning pin package (not shown) locks carrier 16 in the appropriate location along conveyor segment 15. This stabilizes carrier 16 in preparation for receiving automotive body parts. Once the empty carrier 16 has been spatially oriented at the component placement station 24, a robot 42 places the first body component 120 into the carrier 16. The first body component 120 is fed into the component placement system by the conveyor of food 40. Robot 42 repeatedly transfers a first new body component 120 from food carrier 40 through each empty carrier 16 that enters component placement station 24. Once the appropriate number of automotive body components is added to the carrier 16, the positioning pin package (not shown) retracts, the belt segment 20 is re-coupled to the belt motor 94 (not shown) and the carrier 16 is advanced to the next station 12.
    [0059] [0059] Figure 12 depicts an exemplary geometric tool, in accordance with the principles of the invention; the geometric tool trays 46a to 46c are positioned under the conveyor segment 15. In this embodiment, the geometric tool tray 46b is selected to interact with the carrier 16. A pair of vertical translational towers 44 suspends the conveyor segment 15 above geometric tool tray 46b. Once the belt motor 94 has positioned the carrier 16 in a generally acceptable linear position above the geometric tool tray 46b, the belt motor 94 is decoupled from the belt segment 20 allowing the carrier 16 to move freely , back and forth. As the vertical translational towers 44 lower the belt segment 15 towards the geometric tool tray 46b the carrier 16 is guided to the final alignment with the geometric tool tray 46b by angled surfaces of a fork130. This final direction is carried out with very little opposition since the belt motor 94 has been decoupled from the belt segment 20 as described previously. Once the carrier 16 has been lowered to the fork 130, the various accessories and gripping components of the geometric tool tray 46b grasp the automotive body parts. Preliminary welding is completed and carrier 16 and conveyor segment 15 are lifted by vertical translational towers 44 in preparation to move carrier 16 to the next station 12.
    [0060] [0060] Figure 13 is a plan view of the geometric tool shown in Figure 12, and further illustrates a tool for re-skirting 30 and a plurality of robots 42. The geometric tool 28 and the re-skirting tool 30 are virtually identical in this view however, the two stations 12 are distinguished by their respective functions. As described above, the geometric tool 28 is reported, primarily, with the orientation of the automotive body parts in relation to each other and temporarily secured with them by welds. Similarly, the reassembly tool 30 is reported to provide additional structural welding to complete the assembly of various components oriented by the geometric tool 28.
    [0061] [0061] Figure 14 depicts an exemplary unloading station 32 in accordance with the principles of the invention. In the present context, the lifting forks 50 have been positioned between the automotive body and the carrier 16. The vertical translational towers 44 will lower the conveyor segment 15 so that the weight of the automotive body components is removed from the carrier 16 and placed by means of the transfer forks 50. The transfer forks 50 will then withdraw away from the belt segment 15 and the carrier 16 will then be free of automotive body parts. A final transfer robot 124 will remove carrier 16 from conveyor segment 15. Final transfer robot 124 (not shown) will invert carrier 16 so that the friction rail 80 faces upwards. The carrier 16 will then be coupled to the suspended return track 34 and the carrier 16 will travel from one end of the line 22 back to the beginning of the line 18 using friction rollers, drive belts or other means known in the technical.
    [0062] [0062] Figure 15 depicts an end view of the discharge station 32. The belt segment 15 is shown in two possible configurations. In a first configuration 140, illustrated in solid lines, the conveyor segment 15 engages the carrier 16. In a second configuration 142, illustrated in phantom lines, the conveyor segment 15 is unlocked or disengaged from the carrier 16. In this second condition 142, the first track 100 and the second track 102 were pivoted away from the carrier 16 by a belt manipulator 144 shown in more detail in Figure 19. In the second condition 142, the parallel rollers 90 and angled rollers 92 are removed from contact with their surfaces corresponding on the first conveyor 100 and the second conveyor 102. This allows the carrier 16 to be lifted freely from the conveyor segment 15 by the lifting forks 50. This same configuration can be used to couple and uncouple the carrier 16 to the suspended return conveyor. 34 at the beginning of line 18 and at the end of line 22. Similarly, this configuration can be used to couple carrier 16 to the first conveyor segment 15 at the beginning of line 18.
    [0063] [0063] Figure 16 depicts a more detailed side elevation view of the transport system 10. Starting at the beginning of line 18 and progressing to the end of line 22, a pair of component placement stations 24a and 24b are shown. A geometric tool 28, reassembly tool 30 and discharge station 32 complete the assembly line. A repair station 68 follows discharge station 32, but is not considered a part of the assembly line thereon. A plurality of carriers 16 is shown attached to the suspended return conveyor 34. The suspended return conveyor 34 is arranged between conveyor 14 and footbridge 36, and staircase 62b provides user access to footbridge 36. Since the conveyor belt return 34 does not collide through the floor space of the walkway 36, a user is free to serve the various pieces of equipment 60 across all areas of the walkway 36.
    [0064] [0064] Figure 17 is a detailed side elevation view of the suspended return conveyor 34. A carrier 16 is coupled with the suspended return conveyor 34 and is mounted on top of a plurality of robots 42. The walkway 36 supports a variety of equipment 60. In one embodiment, a friction roller 150 is in intermittent contact with the friction rail 80 of carrier 16 and serves to propel carrier 16 from the end of line 22 to the beginning of line 18.
    [0065] [0065] Figure 18 is an end elevation view of the transport system 10 taken along the line 18 to 18 of Figure 16, looking along the belt 14. The suspended return belt 34 and related carrier 16 do not obstruct the catwalk 36 in any way. A worker who heads upwards on the left side 64 using the ladder 62a has the ability to move freely around the walkway 36 and down the opposite ladder 62b on the right side 66.
    [0066] [0066] Figure 19 is a detailed view of the suspended return conveyor 34 and the carrier 16. In this view, the suspended return conveyor 34 is shown in the second configuration 142, in which the first rail 100 and the second rail 102 are decoupled from carrier 16. The track manipulator 144 has been activated to separate the first track 100 from the second track 102 and thereby allows carrier 16 to be decoupled from the suspended return track 34.
    [0067] [0067] Figure 20 shows an adjustable precision fitting assembly 160 used to connect vertical translational towers 44 to the belt segment 15. System 10 requires a high degree of alignment accuracy between belt segments 15 and then , a highly accurate and robust alignment adjustment method of belt segments 15 is required. A first plate 162 is attached to the vertical translation tower 44. Similarly, a second plate 164 is related to the conveyor segment 15 by a load distribution assembly 166. In one embodiment, the load distribution assembly 166 includes two or more projections 168 and cooperating receivers 170. The interfaces between projections 168 and receivers 170 are configured to provide marked rigidity to the interface between the second plate 164 and the conveyor segment 15. This also assists in preventing twisting of the conveyor segment. conveyor 15 when under non-symmetrical loads created by the carrier 16.
    [0068] [0068] A plurality of screw jacks 172 and lock nuts 174 are arranged between the first plate 162 and the second plate 164. The screw jacks 162 are received in a plurality of threaded holes 176 in the first plate 162. Opposite sides of the screw jacks 172 are seated in cooperation pockets (not shown) of the second plate 164. Rotating the screw jacks in a counterclockwise direction (when configured with threads on the right) causes the second plate 164 to be driven from the first plate 162 in a location centered on the actuated screw jack 172. By adjusting the plurality of screw jacks 172, the spacing, the pivot on the axis and the lamination of the belt segment 15 can be adjusted. A plurality of loading pins 178 bear most of the weight applied to the precision adjustable socket assembly 160. Since the plurality of screw jacks 172 is adjusted to the appropriate position, the lock nuts 174 are tightened to ensure orientation of the screw jacks 172. In addition, a plurality of loading pin nuts 180 are tightened to keep the first plate 162 and the second plate 164 pulled in a fixed relationship with each other and to keep the screw jacks 172 seated inside the pockets (not shown). To provide a high degree of articulation, the load pins 178 are arranged in load pin holes 182 which are slightly larger than the load pins 178. This allows the second plate 164 to be rolled, moved away and rotate on the axis in conjunction with your cooperating belt segment 15 during adjustment.
    [0069] [0069] Figure 21 depicts an optional additional feature of the transport system 10 that provides additional movement control of the carrier 16 as it progresses through the conveyor segments 15. In this embodiment, a data matrix 190 can be affixed to one side of the slot rail 82. The data matrix 190 contains unique two-dimensional clues that are able to uniquely identify each carrier 16 and its relative position via system 10. Since each belt segment 20 of system 10 is driven individually, by their respective belt motor 94, each carrier 16 can be independently moved, stopped, accelerated, decelerated, reversed, positioned, etc. via system 10. Data matrix 190, in conjunction with at least one cooperative camera reader (not shown) provides system 10 with enhanced quality control tracking, diagnostic characteristics and speed result. Instead of relying on limit switches to include lockout switches and deceleration switches, data matrix 190 allows system 110 to readjust a particular carrier 16 even while adjacent carriers 16 are stationary. A carrier 16 can be progressed quickly through inactive or vacant stations 12 using data matrix 190 in conjunction with independently controlled belt motors 94. In addition to enhanced motion control, productivity, quality control and solution accentuated problems are obtained by uniquely identifying each carrier 16 as it progresses through system 10. System 10 using data matrix 190 can identify and track only a defective carrier 16 or a carrier 16 that , otherwise, it causes downtime in the production process or in the production of defective finished products.
    [0070] [0070] Referring now to Figures 22 to 26, another exemplary embodiment of a flexible transport system 200 in accordance with the principles of the present invention will be described. The transport system 200 of this embodiment is similar in many respects to the transport system 10 described above with respect to Figures 1-21. Consequently, only the differences between the systems will be described, additionally, below. Figure 22 depicts a schematic illustration of a conveyor system 200 similar to conveyor system 10 discussed above in relation to Figure 3. However, instead of a suspended return line, conveyor system 200 includes an optional return line 202 which is separated laterally from the feed line 204 and, in this mode, generally extends parallel to the feed line 204 for return carriers 206 to the beginning 208 of the feed line 204. Various other aspects of the transport system 200 are similar to the transport system 10 described above, which includes the various stations 210 for loading and unloading components for a carrier 206, vertical translational towers 212 for raising and lowering carriers 206 in relation to the assembly line, component food conveyor 214, geometric tool trays 216 and robotic manipulators 218 to perform assembly operations.
    [0071] [0071] As shown in Figure 22, a storage area 220 can be provided adjacent to the discharge station 222 at the end of the feed line 204, for storage carriers 206 that have been removed from the feed line 204 by a robot. A repair station 224 can also be provided adjacent to storage area 220, to repair or adjust carriers 206 as generally described above.
    [0072] [0072] Figure 23 depicts an exemplary track segment 230 used in both forward and return feed lines 202, 204. Track segment 230 includes an elongated track housing 232 that has an open top side that defines a upwardly facing channel 234 extending longitudinally along belt segment 230. At least one linear motor 236 is disposed within channel 234 of each belt segment 230 to control the movement of carriers 206 along belt segments 230. In the embodiment shown, three linear motors 236 are arranged in channel 234 of the belt segment 230. It will be appreciated, however, that each belt segment 230 may alternatively include only a single linear motor 236 or several other numbers of linear motors 236 arranged on channel 234 as desired. An exemplary 236 linear motor that can be used in the 230 treadmill segments is the Quickstick HT2 available from MagneMotion, Inc., of Devens, Massachusetts, USA.
    [0073] [0073] A controller 238 in communication with each linear motor 236 controls the operation of each linear motor 236 to move carriers 206 along conveyor segments 230 with high precision and independently of other carriers 206 held in the plurality of conveyor segments 230. Although a single controller 238 is illustrated in communication with linear motors 236, it will be appreciated that each linear motor 236 may alternatively be in communication with a dedicated controller that controls the operation of that particular linear motor 236, in cooperation with other features of the 200 transport system.
    [0074] [0074] Figures 24 and 25 depict an exemplary carrier 206 in accordance with this embodiment, supported on a conveyor segment 230. In this embodiment, carrier 206 comprises an elongated snap rail 240 for which a plurality of wheel assemblies 242 is coupled. A plurality of lifters 244 are secured to an upper surface of the slide rail 240, in a manner generally similar to the carriers 206 described above with respect to Figures 1 to 21. Lifters 244 are, in turn, coupled to the transverse supports 246 that have load-bearing surfaces 248 and appropriate accessories 250 for supporting mounting components therein. As seen in Figure 25, track housing 232 comprises first and second side walls opposed to 252, 254 and a bottom wall 256, which defines channel 234 of track housing 232. Carrier wheel assemblies 242 206 are configured so that the wheels 258 engage the upper surfaces 260, 262 of the first and second side walls 252, 254 to provide lamination movement of the carrier 206 along the belt segment 230. At least one permanent magnet 264 is secured to a bottom surface of the slot rail 240, generally opposite the lifters 244. The permanent magnets 264 are supported on the slot tracks 240 of the carriers 206 in a fixed space of the linear motors 236.
    [0075] [0075] Figure 26 depicts another exemplary embodiment of a carrier 206a that can be used with the conveyor segment 230 described in relation to Figures 24 to 25. In this embodiment, the wheels 258a of the wheel assemblies 240a include a circumferential flap that radially extends outwardly 266 which cooperates with the side walls 252, 254 of the track housing 232 to facilitate alignment of the carrier 206a on the track segments 230.
    [0076] [0076] In use, linear motors 236 are actuated to create magnetic fields that cooperate with permanent magnet 264 on carrier 206 to provide driving force to move carriers 206 along the plurality of conveyor segments 230 and to precisely position carriers 206 along conveyor segments 230. Advantageously, the conveyor system 200 described in this document provides a fast and efficient method for transferring assembly components along an assembly line, with real-time control of each carrier 206 independently of other carriers 206 that move along the assembly line. In addition, linear motors 236 cooperate with permanent magnets to provide significant holding force that aids in the stability of carriers 206 held on conveyor segments 230. As carriers 206 are moved along conveyor segments 230 of the power line advance 204, parts can be added and assembly operations can be carried out at several stations 210 generally, as described above in relation to the transport system 10 of Figures 1 to 21. Although vertical translational towers 212 can be used to locate Mounting components supported on carriers 206 on a geometric tool tray 216 as described above, linear motors 236 provide such precision of positioning of carriers 206 on conveyor segments 230 that the use of vertical translational towers 212 to lower components into one tool tray 216 may not be required.
    [0077] [0077] At the end of the feed line 204, complete assemblies can be removed from carriers 206 by one or more robots 218. Unloaded carriers 206 can then be removed from conveyor segments 230 and placed in a storage area 220, sent to the repair station 224 or moved to the return line 202 to be transferred back to the start 208 of the advance feed line 204. In this embodiment, the return belt segments 230 are similar in construction to the segments advance feed belt 230 discussed above in relation to Figures 23 to 26. The storage area facilitates the addition and removal of carriers 206 of the advance feed line 204 and return line 202 in various orders as may be desired , so carriers 206 can be provided at the start 208 of the advance feed line 204 to accommodate changes in mounting requirements.
    [0078] [0078] Although the present invention has been illustrated by describing one or more modalities thereof and although the modalities have been described in considerable detail, they are not intended to restrict, or in any way, limit the scope of the appended claims to such detail. The various features shown and described in this document can be used alone or in any combination. Additional advantages and modifications will be readily apparent to those skilled in the art. The invention in its broadest aspects is therefore not limited to specific details, representative apparatus and illustrative methods and examples shown and described. Consequently, deviations can be made from such details without deviating from the scope or spirit of the general inventive concept of the Order.
    权利要求:
    Claims (15)
    [0001]
    Flexible transport system (200) for assembly line manufacturing, comprising: a belt (14) that carries parts; a carrier drive member in the form of a linear motor (236); at least one carrier (206) including at least one actuating coupling member in the form of a magnet (264) cooperating with the linear motor (236); characterized by the fact that the belt (14) carries the parts between several stations (12) of an assembly line; and the belt (14) comprises a plurality of feed conveyor segments (230) aligned end to end; and each feed conveyor segment (230) having an open upper side defining an upward channel (234) extending longitudinally along the feed infeed segment and having an associated carrier drive member disposed within the channel (234); and at least one carrier (206) being supported for movement along the plurality of feed conveyor segments (230), each carrier (206) including at least one actuating coupling member in the form of a magnet (264) which cooperates with the linear motors (236) of the feed conveyor segments (230) so that the linear motors (236) move the carrier (206) along the respective conveyor segments (230) independently of other carriers supported on the plurality of feed conveyor segments (230); and the linear motors (236) being driven to provide the driving force to move the carriers (206) along the plurality of creeping segments (230) and precisely positioning the carriers (206) in desired locations along the conveyor segments (230 ).
    [0002]
    Flexible transport system, according to claim 1, characterized by the fact that the three linear motors (236) are arranged in the channel (234) of the belt segment.
    [0003]
    Flexible transport system according to claim 1 or 2, characterized by the fact that a controller (238) in communication with each linear motor (236) controls the operation of each linear motor (236) to move carriers along the segments conveyor belt (236) independently of other carriers (206) supported on the plurality of conveyor segments (230).
    [0004]
    Flexible transport system according to any one of claims 1 to 3, characterized by the fact that each linear motor (236) is in communication with a dedicated controller that controls the operation of that particular linear motor (236).
    [0005]
    Flexible transport system according to any one of claims 1 to 4, characterized in that the at least one carrier (206) includes a support structure configured to support mounting components above the feed conveyor segments ( 236).
    [0006]
    Flexible transport system according to claim 5, characterized in that the at least one carrier (206) comprises a mounting rail (240) and a plurality of wheel mounts (242) coupled with the mounting rail ( 240), in particular where each feed conveyor segment (230) comprises first and second opposite side walls (252, 254) defining the channel (234), and where the wheel assemblies (242) of at least a carrier (206) engages the first and second carrier side walls (206) along the conveyor segment (230).
    [0007]
    Flexible transport system according to any one of claims 1 to 6, characterized by the fact that it still comprises a plurality of return conveyor segments (230) aligned end to end and spaced from the plurality of forward feed sterilization segments , in which each return track segment (230) has an open upper side defining an upward channel (234) extending longitudinally along the return track segment, and having an associated carrier drive member in the form of a linear motor (236) disposed within the channel (234).
    [0008]
    Flexible transport system, according to claim 1, characterized by the fact that it still comprises: at least one pair of vertical translational towers (44) supporting one of the plurality of feed conveyor segments (230); the vertical translational towers (44) adjustable between a first configuration (140) in which the sustained feed belt segment (130) is longitudinally aligned with the adjacent feed belt segments and a second configuration (142) wherein the sustained feed belt segment (230) is lowered relative to the adjacent feed belt segments.
    [0009]
    Flexible transport system according to claim 8, characterized by the fact that the pair of vertical translational towers is designed to raise and lower carriers (206) in relation to the assembly line and / or in which the pair of towers Vertical translation (44) is located at or within a station (12) of the assembly line.
    [0010]
    Flexible transport system, according to claim 8 or 9, characterized by the fact that it still comprises: at least one tool tray (46a - 46c, 48a - 48c, 216) associated with the vertical translation towers (44); at least one tool tray (46a - 46c, 48a - 48c, 216) that can be engaged with a carrier (206) on the sustained feed belt segment (230) when the vertical translational towers (44) are adjusted to the second configuration (142) and the sustained feed belt segment (230) is lowered.
    [0011]
    Flexible transport system, according to claim 10, characterized by the fact that it still comprises: a fork (130) cooperating with the tool tray (46a - 46c, 48a - 48c, 216) to align components supported on the carrier (206) with the tool tray (46a - 46c, 48a - 48c, 216) when the segment of the infeed conveyor (230) is lowered by the vertical translational towers (44).
    [0012]
    Flexible transport system according to any one of claims 1 to 11, characterized by the fact that it still comprises: at least one robot (42) adjacent to at least one feed conveyor segment (230), the at least one robot (42) adapted to perform at least one of: placing parts on a carrier (206) received in the channel (234) of the adjacent feed conveyor segment (230), or perform work on a supported part on a carrier (206) received in the channel (234) of the adjacent feed conveyor segment (230).
    [0013]
    Method of assembling components characterized by the fact that it uses a flexible conveyor system (200) that includes a conveyor belt (14) that carries parts, a plurality of feed conveyor belt segments (230) comprised in the conveyor belt (14) and at at least one carrier (206) adapted to be transported along the plurality of feed belt segments (230) each feed belt segment (230) including at least one carrier drive member in the form of a motor linear (236), said at least one carrier (206) including at least one actuating coupling member in the form of a magnet (264) cooperating with the linear motor (236), the method comprising: holding at least one carrier (206) in one of the plurality of feed conveyor segments (230); actuate at least one linear motor (236) to move the carrier along the feed conveyor segments, in which movement of the carrier (206) driving the linear motor (236) is carried out independently of other carriers supported in the plurality of segments forward feed belt (230); stop the movement of the carrier (206) and position the carrier (206) at a selected station using at least one linear motor (206); and perform at least one assembly operation using a robotic manipulator (42).
    [0014]
    Method according to claim 13, characterized in that the at least one assembly operation comprises at least one of placing a component in the carrier, removing a component from the carrier or connecting at least two components together.
    [0015]
    Method, according to claim 14, characterized by the fact that it still comprises: removing an empty carrier (206) from one of the plurality of feed conveyor segments (230); placing the removed carrier (206) on a return line (202) comprising a plurality of return conveyor segments (230), each return conveyor segment (230) including at least one carrier drive member in the form of a linear motor (236); and actuating at least one linear motor (236) to move the carrier (206) along the return conveyor segments (230) in one direction to a starting point of the plurality of the forward feed conveyor segments (230).
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    同族专利:
    公开号 | 公开日
    US20140262681A1|2014-09-18|
    KR20160023636A|2016-03-03|
    US9045183B2|2015-06-02|
    CA2901633A1|2014-09-25|
    WO2014153045A1|2014-09-25|
    JP2020028972A|2020-02-27|
    JP6666239B2|2020-03-13|
    JP2016517377A|2016-06-16|
    MX344531B|2016-12-19|
    MX2015012652A|2016-02-16|
    ZA201506141B|2016-07-27|
    CA2901633C|2020-12-01|
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    法律状态:
    2018-11-13| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-11-19| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-12-01| B09A| Decision: intention to grant|
    2021-02-17| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201361781147P| true| 2013-03-14|2013-03-14|
    US61/781,147|2013-03-14|
    US14/211,793|US9045183B2|2013-03-14|2014-03-14|Flexible conveyance system|
    US14/211,572|2014-03-14|
    US14/211,572|US20140262680A1|2013-03-14|2014-03-14|Flexible Conveyance System|
    US14/211,793|2014-03-14|
    PCT/US2014/028819|WO2014153045A1|2013-03-14|2014-03-14|Flexible conveyance system|
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